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Project Orange Krate - Aftermath
The dust settles (for now) on Project Orange Krate
Sep 1, 2011
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Project Orange Krate - Aftermath
26. Nothing was finer than getting Orange Krate to the point where its body repairs were completed and it was coated in Sherwin-Williams DTM primer. Stay tuned as we’ll address the firewall revisions next!
Once back from media blasting at D&T Powder Coating in Pembroke, Massachusetts, there were a number of problem areas uncovered, like this ugly corrosion in the driver side A-pillar and dash area.
Inside, the car was pretty solid except for this area under the driver’s seat where corrosion had started to work its way through the floorpan.
A close inspection of the driver-side rear quarter panel revealed that rust had crept its way into a number of areas including the inner rear window channels and the bottom of the panel due to water leaks over the years.
To get started on the A-pillar and dash repair, Peter Newell of Competition Specialties in Walpole, Massachusetts, used a standard screwdriver to remove old urethane and body sealer from the area.
Due to the crawl of corrosion into the panel, Newell used a cutoff wheel to remove the damaged area. Note how heavy the corrosion was that was uncovered.
After wire brushing the area to remove any loose rust, a 3-inch air-driven grinder topped with a 36-grit disc was used to clean up the metal.
After the area was refreshed, a good coating of SEM self-etching black primer was applied to protect the metal from any future issues.
Newell fabricated a patch panel from 18-gauge steel and used a hammer and dolly to create the proper contour for the piece. Once the repair panel was MIG-welded in place, a 3-inch grinder topped with a 36-grit disc was used to grind all the welds smooth, creating a factory-looking appearance.
To address the repairs required to the driver-side rear floorpan, a call was made to Classic Industries for one of their steel replacement sections.
With the area to be removed marked, Newell used a Sawzall to cut away the damaged floor, a section at a time, then used a 3-inch cutoff wheel for final finessing to the opening.
The new floorpan was first marked for its needed section and then placed on a stand to cut the area out with a Sawzall.
A set of tin snips was used to get the new panel to the exact size of the opening in the floorpan.
Here, the final installation of the pan mirrors the factory stamping. The welds were then ground smooth using a 3-inch grinder topped with a 36-grit disc.
It was a snap calling Classic Industries for one of their original equipment replacement rear quarter panels featuring every component found on the original factory panel including the correct door jamb and sail panel areas.
With the door mounted in place to establish the door line to the quarter panel, Newell began the removal of the panel, starting with a Snap-On air hammer topped with a chisel cutting tip.
Once the majority of the panel was removed, it was obvious there was more corrosion to the inner structure due to water seepage over the years. This close-up lets you see just how corroded the lower inner rear quarter panel was due to all of the water sitting in the area. This section will be removed and replaced with a fresh patch panel.
After all the spot-welds from the original quarter panel were removed, a hammer and dolly were used to get the inner structure back into shape.
To remove some of the surface corrosion to the inner sail panel area, a DA sander topped with an 80-grit disc did the trick.
With the inner quarter panel structure cleaned of any surface corrosion, a coating of SEM self-etching primer was applied to give it plenty of long-lasting protection.
Newell made sure the new quarter panel was in proper alignment with the body and the door then proceeded to weld it into place with his Lincoln Electric Power MIG 216 MIG welder.
Our pal Ray Williams at our local Sherwin-Williams Automotive Finishes store in Medford, Massachusetts, set us up with the right stuff to seal the surface of Orange Krate. This included Sherwin Williams’ NP75 Squeegee Prime DTM HS Primer and NH77 Ultra-Fill HS DTM HS Hardener spray.
Nothing was finer than getting Orange Krate to the point where its body repairs were completed and it was coated in Sherwin-Williams DTM primer. Stay tuned as we’ll address the firewall revisions next!
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