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1992 VR4 #71/1000

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Just wanted to warn you before you got too much deeper into the build thread and lost all the pictures, it's already happened to a few of the guys and they are none too pleased.

I really appreciate that, it would be drag to have to redo all the photos... Do you know of any alternative hosting websites aside from photobucket?
 
Google photos works well. If they start charging for minimal server space and 3rd party hosting, the world is probably ending...So...
 
I use Imgur for my build photos (though its worth mentioning I have them all in google photos as well). As far as I know there are no limits, they even give you quick URLs for HTML, BBCode, Markdown, or direct links.
 
I got things back up and going with google photos (see previous page for the steering column stuff)... Photobucket has gone hawkish with old photos. My old posts still seem to retain the images, but I plan on removing all the old photos from photobucket and placing on google just in case.
 
Left Side Kicker Panel Replacement

This was tough. The rig I had to set up to get the shape right using the tools at had at hand was silly. If you have access to a break, this sort of bodywork shouldn't be nearly as bad as it was for me. I also learned from the moonroof the value of doing spot welds and then sealing with body sealant or bondo, depending on the location.

Finally finished up one kicker panel. Quick little recap of where I started:
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Did the initial cutout in two steps. I had to remove the pinch weld once I saw how bad it was:
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Got busy with the bead blaster (sand is still falling out of my ears several weeks later). This is a partially done pic:
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Also cut out some additional gusset metal and the primed everything to seal it off from future rust:
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The pinch weld had to be replaced so I cut, bent, and tacked in some 20 gage, being sure to prime inside surfaces as I went:
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Since tac welding 20 gage is the only real way to join such thin material without extreme warping, you have to seal joints somehow. I found a good seam sealer on Amazon and applied it to the appropriate surfaces:
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With the pinch weld replaced, it was time to start on the exterior piece. I started with some CAD (cardboard aided design... any engineers out there??) to cutout and bend up my first piece. I had an elaborate home made brake setup, but I forgot to photograph it:
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Since the old gusset had to be removed, I devised a way to provide some support for the panel with rods:
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After the initial tac welding, I cut, plug welded, and ground the rods flush:
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(definitely not my prettiest welding job):
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Then the rest gets tacked into place:
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Finally, some primer is laid down, and voila!:
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Moonroof Delete (part 2)

I was also unhappy with the way the moonroof joint looked, so I went back to work on that. BTW, it was a huge mistake to try to seam weld that joint to avoid using bondo. The metal is way too thin. If you do this, save yourself the trouble of having to salvage a badly warped piece. Just tac weld it and use bondo. Anyway... pictures. Step 1 was fixing the severe warpage with a combination of hammering and yielding with a rig inside the car:
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Not perfect, but much better. Then onto the much despised bondo. Apply then sand (I'm not willing to admit how many times I applied and then sanded):
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Finished product, ready for painting. I'm much happier with this than my intial work... feather edging truly is akin to artwork, and I'm no artist. You can still see the seam now, but you have to look for it:
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Right Side Kicker Panel Replacement

Last update for now; the passenger side kicker repair is well underway. Since I pretty much did the step by step writeup on the driver's side, passenger side will be all pictures. I'll update this post once more when its completely done. Again, starting from the beginning:
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(There was sandblasting before the priming... lots and lots of sandblasting, I just didn't take any pictures)
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First repair weldment for kicker panels:
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Got the passenger side finished up this evening:
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Right Side Kicker Panel Box-off

Finished up the passenger side fender to kicker panel section this evening. The starting point:
mAeHOvtgq2OfpQcJvQUXW0GBRH03dqoxSTkL66yYnViAD-3E2ljuE82mBkNxm1RBTAKmvhSzF53wrKGcX7E=w1000-no-tmp.jpg


Piece 1:
wHwSYMEiiK7z89J8umKfaC6_MCIvF_DzUnxuIQ7dkBdIFxEFHqd1nyecyiE7qg1mR4Li-Ns8zG-j6IO8SKS=w1000-no-tmp.jpg

ETXrW0OnnrPCM2sG_uISn1yNCwTEG7comWDMo3HuPlvQ2-ift4cAnYeITyhG74RGQWNSS2xNSnVUqkcv1RI=w1000-no-tmp.jpg


Piece 2:
TQ89czZFJJyMjbDmfBmnqfN4iMDtbsNQq-KY8L4ufXQvSZd6W0uWffECXy-SICzekHs71X5bZjrH1-W337N=w1000-no-tmp.jpg

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Stopped welding to prime the inside:
DVGm6nFnSc5C6sqO8jljWstyyOm6pRcnk5MWd5NwcHgc2pmqUYbPY-z0_z59M0hS-WRRucWtNkxEbjajetg=w1000-no-tmp.jpg


Piece 3:
krzSsvWxkedDs6kiA6qZSwZUMFmEUvUPziFrBqZB7d9bYCzNmAz1nTMyHphqvApb3zV4PID-qxcEXD5sUSg=w1000-no-tmp.jpg

(primed the inside)
UQHccKNzmSZQfC-jxKE1kgkrolNdjCKYPFGz-r8diSBx5y63q_UVKYCfzbbQGOmlMuAx7s-ix0fAoDTWbkw=w1000-no-tmp.jpg

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Finishing touches with some cutting and priming:
NRAk1TdJeit-96Wp3cHRRmgber-TOtcRIiKlis1WGmTsCaWGRPRzeGsqfP7WTyTwCkQNnDXJTdo54hJHxiF=w1000-no-tmp.jpg

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Right Rear 1/4 Panel Rust Repair

I keep finding more sections of bodywork to replace. Luckily, I'm starting to get pretty good at this, so it doesn't take nearly as long as it did when I started... Both rear quarters need to be redone. I was able to finish up the passenger side this evening. It started out like this:
hOrATwN7CsFA1Tsy7x5A9b7TmLN11E7crHPOo5xL2qnv_i24I10FZaa7drsFJqiDSPUC48zBEIuRT-VNalN=w1000-no-tmp.jpg

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Did some cutting and gave it some wire wheel attention:
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Added a new rust treatment tool to the arsenal to deal with areas that are really hard to reach, and where sand blasting would make a mess:
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Applied and dried. When it turns black it has done it's job:
lpYBZyGhKMYXUDyhMw_NCQt6co-4iH35PJuc3RI19MCPr37GKEbvDANFv0CJSrPlx-sAsEvdJbyAPkAhQzA=w1000-no-tmp.jpg

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On to the familiar panel fabrication process:
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I gotta be honest, I probably would have scrapped this after uncovering all that you've repaired. I can definitely respect the time and effort you've put into this. Keep the updates coming.
 
Man I'm doing the same thing but not that deep. I'm doing just enough to keep the moulding in in my 91 talon. Long term she'll be just fine props man for saving her.
 
I gotta be honest, I probably would have scrapped this after uncovering all that you've repaired. I can definitely respect the time and effort you've put into this. Keep the updates coming.

The thought did cross my mind. At this point I'm treating all this work as a good learning experience. Also, due to the rather poor initial condition of the car, hopefully the GVR4 community will forgive me when I chop the wheel wells and add fender flares to stuff in some 275 hoosiers for DSP.

As of now there are only two more major patch sections, including the one I've already started on. Then it's off the the races with my anti-rust arsenal, sanding tools, and a can of primer before painting the car. I'll definitely keep the updates coming.
 
Man I'm doing the same thing but not that deep. I'm doing just enough to keep the moulding in in my 91 talon. Long term she'll be just fine props man for saving her.

The repair on FUBAR definitely snowballed. Initially I was just going to do about what you're planning, but I got to work and one thing just led to another. I'll actually respect your repairs if you're able to control yourself and limit the scope of your work; it's difficult not to go to town when you see rust.
 
The thought did cross my mind. At this point I'm treating all this work as a good learning experience. Also, due to the rather poor initial condition of the car, hopefully the GVR4 community will forgive me when I chop the wheel wells and add fender flares to stuff in some 275 hoosiers for DSP.

As of now there are only two more major patch sections, including the one I've already started on. Then it's off the the races with my anti-rust arsenal, sanding tools, and a can of primer before painting the car. I'll definitely keep the updates coming.

Hell yeah. Chop it up. No offense, but nobody looking for a clean Galant shell will ever be in the market to buy this thing ROFL

I say tube it up. Chop off the front clip and start going baller status. Galants don't have the best weight distribution, so here's your chance to fix that. I'd also consider fuel cells, or any of the other mods that make for a nice race car, but typically aren't done because people don't want to cut up the car.

On one hand, it sucks this thing is such a rusty turd. But on the other hand, you get to chop it up any way you like with no f***s given. Not many Galant owners have that luxury, so why not take full advantage?

Keep up the good work. I definitely ain't judging you :thumb:
 
Hell yeah. Chop it up. No offense, but nobody looking for a clean Galant shell will ever be in the market to buy this thing ROFL

I say tube it up. Chop off the front clip and start going baller status. Galants don't have the best weight distribution, so here's your chance to fix that. I'd also consider fuel cells, or any of the other mods that make for a nice race car, but typically aren't done because people don't want to cut up the car.

On one hand, it sucks this thing is such a rusty turd. But on the other hand, you get to chop it up any way you like with no f***s given. Not many Galant owners have that luxury, so why not take full advantage?

Keep up the good work. I definitely ain't judging you :thumb:

I appreciate the GVR4 "right to chop" blessing from a senior member of the community :)
 
Finished up the driver's side rear 1/4 weldment:
2751kA4kYF9kbQEaBpgPjLiC-nPAoKatVpFfIiOaD_n1yZfEmQ1Y770WXnx6G3gK38H8ZvQmJOw7qONMQVP=w1000-no-tmp.jpg

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Now I'm eyeing up the final major body repair, which is not only rusted, but is also bent up:
muiFg74qhlB_wNAu94KRMAY18hcV69_Pm_PpD8CvNw-xuiRBaaNHW6w9rcqmy-veEiZg-metJFPZoHTFUOD=w1000-no-tmp.jpg


It's supposed to look like this (straight):
upload_2017-8-24_23-17-16.png


I started in on it by cutting the spot welds on the back, then had to call it a night:
E9q3hyZk0YtFhkbhwLqprm6rFA2sKaU33wWXrwO8JBOJ_B5BAQ2xuacj8U_pW5lG9qRttJWYc6NYQQHWu8z=w1000-no-tmp.jpg
 
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Rear Fuel Tank Support Replacement

Picking up where I left off. Got the rear section out:
GqhhDTIAQA2y1MUMOgX7YREX6ENRvua8yHEpjckIj70ifZnzV1p28q_vYdUIqKoGDDWm4iURajPF-5sgyP7=w1000-no-tmp.jpg


Cleaned it up:
jYwEmp8iWsnDH-EJ4TAwX2YJ9IAjcjwr3hojbm3PccCreb7d3rpT3blE46LMcFBzImeJMOZomdnMb65wqLG=w1000-no-tmp.jpg

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Welded in some studs and some patch sections and got it straightened out:
okKV6mQw4D4zQK6W1MC6yr3vR8IVAVyYd25LQBVvtZIug-WyTYGb5D2T02RDTB1C8_ksaPN5ZxM4tQgw75l=w1000-no-tmp.jpg


Primed and welded up into place:
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Also had some time to start on a section of the underbody. Although sandblasting is faster on the front end, I've found the cleanup afterward to be just as time consuming as more labor intensive methods. So as long as you can reach a given area, whire wheel & corroseal:
M7ZyjhxADx67wSUIJ2CII0a1HAE7fLSB4fFCPcXTQtRt_UrXoDzBkT3Q2MVjhXeH7ouqukipJtOfxRtH2jT=w1000-no-tmp.jpg
 
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Completed rear tank support patches:
JzJVgM4sr62DPWMEB-nng6LYaUh4DJRCBrExeOckd5Vltp5dlObdEgKaLwJ3smJ46-P7H19V3EAl067IlAg=w1000-no-tmp.jpg

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Finished up the plug welds for the rear tank support on the inside of the trunk:
LI7kjSJdBOA7DaDPiV9jwgouVC5zh_dG7ChEonW5pGIOCuOAish-g8NDx4L_qRhkWXq3wrHHJCRNvGUk410=w1000-no-tmp.jpg


Got about 1/2 way done with driver's side rear fender well patch job:
kufc4eo2sUeZRNEAtoZiKYjQ3jlS02AGEJs4bxGEzDh0-xtlmh04bMws2L98iLvDF1q44EPTaSnIAgE8fir=w1000-no-tmp.jpg


Got about 1/2 the trunk wire wheeled and corrosealed:
haiHmia2Abtyu0IF7BYte_HoKtWkhLQ6FIaS9hnMKaT4Y-MP0qnLb3r-8pkxNw26_kBycvttdECzsvta7lc=w1000-no-tmp.jpg

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Also got the underbody wire wheeled and corrosealed in preparation for the front tank support weldments that will have to be done from scratch:
ASEKKo77astt4qp6gqXKdh2evHK6y2UqvO6cIC_0tE2JfBg5HM_2-HtwyrtIDlwfvo4MoXIXfqyk4BCg0N_=w1000-no-tmp.jpg

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Front Fuel Tank Support Replacement

This is a picture heavy update so I'm gonna have to break it up a bit. Pretty much finished the rear section of the car this weekend :). Let's start with the front fuel tank weldments. Even though I'll be going with an aftermarket fuel cell, this setup will allow me to use a stock tank if I need to:
kV9ah-xUCCmGJIUNw6viSNg_P5Qi_IG0PTCVR0RC_gY-lxPbmCRDZh5pGOXrHwxmIQoVKUGL2e0EWTzq17g=w1000-no-tmp.jpg

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Got the rear section thoroughly wire wheeled and corrosealed:
88uZoJsZdZHPE6InflX9ZGDIx485TTws8zjAWuIExwm8NwMm7CxYj5qAVyWLvVHFpQ5ehntrrBHCHi_IGAA=w1000-no-tmp.jpg

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