Got the rear bushings pushed in...that's when that insertion tool really shines. No dramatics at all. Then put a final coat of POR on everything. This afternoon it's clean-up and re-starting the bodywork. I've got to get the drivers rear 1/4 finished then I can get the thing sealed and ready for undercoating.

Tomorrow I should get the rear suspension back in if the undercoating goes well - it may wait until the weekend.

Decided to wait on the undercoating and get the exterior welding done first. Glad to be done with suspension parts for now. Here's what I came up with for boxing plates.



That's about all I think they need. Note the new Noltech bushings - just like a factory bushing, but made of a polyester resin.

I got both quarter panel areas sorted out today. Just some finish work on the passenger side.

I also had to rebuild the fender lip. More surface rust to kill in here.


I "rolled" the lips after test fitting the wheels. I'm not proud to say that I've got a 4 lb ball pein hammer - but it sure came in useful for that task (it also revealed where the lips were not solid). Finished with my urethane hammers to take out the bigger bumps.

Here's the drivers side work. The inner fender had to be completely rebuild and I bridged and saved the butt cheek section. I didn't have as much sheet metal to replace on this side - so the repair is significantly smaller. Welds look good on the inside as well.


I've still got a few hours of rust busting to get rid of the surface rust, but then it will be all sorted and time to get it sanded and in a coat of primer. I can't wait for that stage of the process.

you should cut out the butt cheeks and make it look sexy

And put my spare tire where? I like them and they are solid, so they stay.

Dale gave me a hand pulling the engine yesterday - found a newish clutch (could still see the swirl marks on the flywheel!). So that's good. The grease is pretty thick. I've got to get the engine bay painted this week and get the engine finished and put together. I've only got a couple of weeks and I'm getting a little worried - but enough 12 hour days and I'll get it done. I'll be taking a few weeks off to make sure this gets done.

Back out to the garage.

Today's game plan - get the rocker trim holes welded up, get the engine bay cleaned out and prepped for paint.

Will your winter beater be done before winter is over?

Yes

Did the transmission swap today - didn't want to chance the welded threads holding, so I stripped the needed parts out of the old OD and swapped them into the new OD. Gasket sealant is wicked stuff - had to beat the OD apart to get the parts changed. More cleaning as I get the underhood area ready for paint.

There are still a hundred or so little jobs to do, but I almost think I'm hitting the apex of this project. I got the M46 assembled - rebuilt the OD again just to be sure I had the best of all the parts.

Hmm - which one goes back in the car, right or left?


Koni Red's got treated to a fresh coat of red paint.


I spent the afternoon at the machine shop assembling the 405 head for the last time. All valves got 0.158" - 0.160" shims...that should work. Clearance was 0.016" cold.

Then there was a few days of outside rust treatment including spot sand blasting all the little rust areas. Worked really well. Then in some areas I had to strip out the seam sealer to get at the rust under there.


I don't need no stinking trim up top. Hole welded up.


I don't want any rocker trim either...take that rocker trim.


Then I half assed masked it up an got some epoxy primer on it - two coats to make sure it is going to be protected, especially the wheel wells.


Starting to look like a car again (oh I had to rip the masking to get at the inside of the door where I prepped it - oops). I'll wait a day or so before I seam seal the thing and get the wheel wells painted prior to undercoat. the outside just needs sanding now to be finished - there are days of that ahead. Then a coat of primer and some serious blocking. It only needs a touch of filler on the repairs.


There - a rust free 242.

Nice work Craig! I'm very excited to see more progress.
Was there much rust under those rocker panels? I don't really remember.

It was pretty funny really (if rust can be considered funny) - every time I see the old grinder mark from the previous "body guy" I clean the white paint off it and there's the ugly rust spot. Made finding the rust pretty easy. With the spot blaster, I would line up on a previous repair and blast it clean.

The rockers only had a little surface on the drivers side right under the door. The rest was clean - this really is a less rusty car than it looked. I still have to get the under hood area painted, but at least I've got the head back so I can get the engine work done whenever it makes sense to do it (probably after I've got it painted).

Spent a little time today getting a few more things done. The list is getting shorter (at least I think it is). I painted the very inside of the rolled fender lips where the spray gun wouldn't reach with POR-15...while that was setting up, I cleaned up the splash pan and made a rather half-hearted attempt at straitening the piece. Then an hour or so with cleaner to get it perfectly clean, and a shot of black (the gloss is just about a perfect match). No point in getting it perfect.


Then I had to get the Virgo's cleaned up. They are in terrible cosmetic condition, so a quick coat of paint will do for now while I'm waiting for tires for the Tethys.

From half-assed (anything maked with duct tape is, by definition, half-assed)...


To first class.



Only have one problem on a single spoke - wrinkly paint...someone must have shot them before. It will get sanded and fixed tonight.

Dark wheels...

Those Virgos look awesome. Perfect color choice!

Looking forward to the painting of the body next...

The silver was too bright and it was the only other colour. These are not the forever wheels, relax.