January 2009

I started on the driver's headlight bucket. As you can see, the front section is bent and the bucket itself is very rusty.

Here's another shot of the bent section in front of the headlight.

As you can see, the complete bottom section is rusted out, it will need to be replaced.

Here's the bottom section cut out.

I drilled out all of the spot welds that held the headlight bucket and removed it.

Another shot underneath showing the drain tube of the headlight bucket removed when the top section was removed.

Next was removal of the front support on the driver's side. I had to remove this to get to the spot welds on the side brace.

Here you can see the bent side brace.

I drilled out all of the spot welds and removed the side brace.

I positioned the replacement piece to check for alignment.

I cleaned up this area and began installing the replacement pieces. This shows the bottom section welded in.

A shot of the side brace welded in.

This shows the front support welded back in.

A side shot of the headlight bucket welded back in.

Here's a shot of some of the clamps I used to hold the headlight bucket in.

More clamps.

More clamps.

All of the clamps.

Front shot of the headlight bucket welded in.

Piece in front of the bucket welded back in.

Another shot.

Ground down and primered.

The PO had removed the section in front of the passenger's headlight bucket.

I cut the front section from the donor car, cut, fitted and welded it back in.

Ground down and primered.

The floor of the front trunk also had a couple of rusted out sections.

Here's a shot of the replacement pieces I created.

I put (2) beads of 3M seam sealer on the inside and outside of the circles, then took a damp wash cloth and patted it down so the beads merged together. If you use a very tectured cloth it will give a better original look.

Evidently this car had ran up on something and bent in the bottom. I tried to beat it out, but I was unsuccessful, therfore, I decided to replace it.

Here's the new section positioned into place.

The piece welded in place.

Here's the paint removed, showing the factory seam sealer around the bolt holes.

Grounded down and primered.

This shows where I cut out the rusted channel section.

Another shot.

The new pieces welded in.

Another shot.

This shows the (3) coats of 2K primer. The front trunk and headlight buckets are finished, until I finally add the color coats.

Another shot.

Another shot.

Another shot.

Another shot.

Another shot.

Another shot.