Mustang Rebuild

Here I’ve cut a large section of rust out of the inner rocker panel.  This repair is pretty simple.  Drill out the spot welds, use the cut off wheel to cut the metal and the replacement metal is flat and recangular.  It’s doesn’t gett any easier to fabricate a replacement patch.  All I have to do it get the dimensions right and drill a hole for the courtesy light harness.  My car didn’t have the lights, but I think I will install them when the time comes.

Here’s the panel with the patch welded into place and the welds ground down smooth.

This is the area of the dash below the glove box.  It’s riddled with rust holes and where there is metal its paper thin.  There’s no patch panel for this area so I have to fabricate the replacement or find a donor.

I ended up cutting out all of the metal from the bottom of the glove box door down to the very bottom. Additionally from the ash tray to the passenger door.  I rolled a piece of sheet metal over a 2″ PVC pipe until I got the shape I needed and welded in the patch I made. After a ton of ginding, welding, griding welds, and re welding I finally got the lines right, the pin holes filled and it looks pretty good. 

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