Priya's SX/4 project

[priya]

Well, my Sweety decided we needed one so he bought a sheet metal brake.  $300 from Princess auto.  We have two other vehicles that need rust repairs so it should see a fair bit of use.  Here's the first item we made with it, the front half of the inner rocker panel which as you can see from the picture has since been welded into place.

[jim]

I just tossed an egg your way for the good pictures, saving Eagles, working with Sweety (your Sweety!), etc,, etc.

[IowaEagle]

You needed another egg too.  When you get good at this (not that that one is not good) I will keep watching my front door step for a set for me.   

[80SpiritGT]

 


Nice work Priya!

[priya]

Thanks guys, I was pretty disappointed when I saw the rust was more extensive than I thought but I'm feeling a lot more confident now.  I've gotten into the swing of it and its going slow but steady.

[priya]

We got the outer rocker formed and I welded it on save for a couple of minor spots.



I cut out about a foot of the rear portion of the outer rocker today and its going to be a bit more of a challenge.  That portion of the inner rocker is bad as well except now I have to work around the mounts for the rear leaf spring.  Part of the wheel well ahead of the rear wheel will need to be replaced so after I have it all cut out there be no reference points so I'll have to be careful working out the proper dimensions of the inner and outer rear rockers and wheel well.  A surprising amount of dirt somehow found its into both the front and rear portions of the rocker even though the cheesy metal had no actual holes to the outside.

[IowaEagle]

Looking better and better.  So, when are you coming to my house?

[priya]

After the Eagle, a 280ZX and a Dodge van are done.

[priya]

Here's the next section I'm working on after I cut out the rusty areas, this is going to be a challenge.  Just below where the blue and white paint meets you can see a 2X6 we had to use to keep the floor in place after key parts of the structure were cut out.



Here's the first panel to go in, still to come, outer rocker, wheel well, and a  small piece of the floorboards.

[IowaEagle]

Are you going to beef up the area where the front of the spring bolts up?

[priya]

Hadn't planned on it, just replacing the stock sheet metal as it was.  I'm open to suggestions as to how to do that, though.

[IowaEagle]

I don't know.  Thought you might.  Just seems to be a critical area for reinforcement.

[bigdog56e]

   If possible I would use double the orignal metal thickness.
                                                                     Eddie

[priya]

Although some of the car is built with galvanized the inner and outer rockers aren't galvanized.  I discussed it with my sweety who's worked for body shops for several years and he didn't think it was necessary or advisable.  He says the factory layout was designed to have a certain amount of flex in it and if we stiffen this area that could result in extra flex elsewhere that could cause other portions of the unibody to fail prematurely.  As well the car was designed to have a certain rate of crush of structures and a change like that could affect this in a possibly negative way.  I'm going to trust that the factory design was adequate and reproduce that as well as I can.  Thanks for the suggestions though.

[priya]

I got the inner rocker welded in today.  It was a bit of a fight as things had shifted around after all that stuff was cut out.  Things gradually came together as I pushed, hammered, clamped, prodded and welded.