Project Evil HX

[EDDO 77]

After removing the windscreen, the first signs of rust became apparent. A portion of the top recess has rusted away completely.
[IMG] windows screenshot program[/IMG]

After a quick cleanup the extent of the damage is exposed.
[IMG] print screen windows[/IMG]

The rusted metal has been cut out and removed with the aid of the trusty angle grinder and cutting disk. This is the closest I will ever get to being a surgeon.
[IMG] upload[/IMG]

The corrosion has affected both the outer and inner skin. Metal patch pieces will need to be formed to replace the missing sections.
[IMG] image hosting without registration[/IMG]

The inner patch piece has been formed from 1.2mm sheet steel and is ready to be fusion welded into the existing fabric.
[IMG] how to make screen shot[/IMG]

Time for senior to step in. As a plumber my father has many years of experience with oxy acetylene welding. He makes it look easy, I think he was probably born with a torch in his hand.
[IMG] windows screen capture[/IMG]

The inner patch piece welded, trimmed and ground back. Good as new.
[IMG] windows print screen[/IMG]

Outer patch piece welded and ground back. That’s the first metal repair completed, ready for a light coat of body filler and shaping.
[IMG] jpg images[/IMG]

Body filler flushed and ready for sealing.
[IMG] click image upload[/IMG]

The repair and lower apron have been sprayed with KBS rust seal. On to the next repair.
[IMG] screen shot windows[/IMG]