just a little off the back and sides please

[eldubb440]

keep cuttin'...... lmao

seriously.... look at the early pictures in this thread

i like to grind my spot welds if i can, rather than use a drill......... i use the edge of a cutoff wheel on a die grinder

yes......... replace the rear crossmember

i would get the tail light panel off first and set it aside, beware, there are a LOT of spot welds holding it to the gutter on each side up top....... you need to drill those, or better yet use a spot weld cutter; but it is very easy to make that area swiss cheese. it may be easier to just replace the swiss cheese, but you ain't there yet .......... yours will have rust in that seam and you will be able to address it. did I mention "keep cuttin'"?

you may need a section of frame rail from a donor car..... guys here have that stuff...... you got this

 

[eldubb440]

Third question (related to the second): eldubb440 removed the tail panel (actually, he removed EVERYTHING!) Is that what I need to do?

View attachment 1162924 View attachment 1162925

yes! it will also enable you to "get in there" and do what you gotta do

 

[TT from NH]

see below

 

[TT from NH]

Thanks, eldub440! Exactly the guidance I was looking for. You said, "i like to grind my spot welds if i can, rather than use a drill......... i use the edge of a cutoff wheel on a die grinder" and then you said, "better yet use a spot weld cutter"

I take it that you mean for me to use a spot weld cutter on the tail light panel, correct? I'm heading to Harborfreight tools tomorrow to pick up a couple spot weld cutters.

A buddy suggested that I simply use a 3/8" drill bit. Can you tell me the benefits of 1) grinding the spot weld with the edge of a cutoff wheel on a die grinder, versus 2) using a spot weld cutter, versus 3) using a 3/8" drill bit?

 

[eldubb440]

Thanks, eldub440! Exactly the guidance I was looking for. You said, "i like to grind my spot welds if i can, rather than use a drill......... i use the edge of a cutoff wheel on a die grinder" and then you said, "better yet use a spot weld cutter"

I take it that you mean for me to use a spot weld cutter on the tail light panel, correct? I'm heading to Harborfreight tools tomorrow to pick up a couple spot weld cutters.

A buddy suggested that I simply use a 3/8" drill bit. Can you tell me the benefits of 1) grinding the spot weld with the edge of a cutoff wheel on a die grinder, versus 2) using a spot weld cutter, versus 3) using a 3/8" drill bit?

yeah.....let me clarify......

if im separatin 2 layers of metal, and one layer is trash.........i grind the weld on the trash piece if i can. this leaves no holes on the good piece......the grinder is obviously destructive, but perfect for removing old trunk pan from rails and wheelhouses for example........ if my only option is drilling on the good piece, i just use a drill bit


if i need to save both pieces, I use the spot weld cutter........ using the cutter for every weld on a job this size will result is several broken cutters, so i just grind or drill where i can and save the cutter for where it is really needed

the 3/8 bit will leave you with a huge holes to weld........i try to avoid too many big holes, they suck

 

[eldubb440]

you may want to replace the right and left trunk gutters, especially if you're doing full quarters........ that makes those areas on the tail light panel easier to deal with, also less work where they meet the dutchman panel.......i would venture to say you have rust issues there anyway

 

[TT from NH]

yeah.....let me clarify......

if im separatin 2 layers of metal, and one layer is trash.........i grind the weld on the trash piece if i can. this leaves no holes on the good piece......the grinder is obviously destructive, but perfect for removing old trunk pan from rails and wheelhouses for example........ if my only option is drilling on the good piece, i just use a drill bit


if i need to save both pieces, I use the spot weld cutter........ using the cutter for every weld on a job this size will result is several broken cutters, so i just grind or drill where i can and save the cutter for where it is really needed

the 3/8 bit will leave you with a huge holes to weld........i try to avoid too many big holes, they suck

Sensei! Thank you.

 

[TT from NH]

i would get the tail light panel off first and set it aside, beware, there are a LOT of spot welds holding it to the gutter on each side up top....... you need to drill those, or better yet use a spot weld cutter; but it is very easy to make that area swiss cheese.

Before I continue down the wrong path, eldubb440, give me some more advice on drilling out the spot welds. I tried a spot weld bit and dulled two without cutting through the first sheet of metal. I've had better luck in drilling a small pilot hole and then using a larger bit (1/4") to drill the weld. Am I doing something wrong with the spot weld bit or do I just have a cheap one (I paid $5 at Harborfreight)? As you can see, I'm making Swiss cheese but you said that was likely to happen. Advice? Thanks! Terry

 

[eldubb440]

thats why i dont use the cutters unless i have to.....along the bottom of the tail light panel, just run a drill bit through it, you need to replace that cross member anyway........ in other areas, sometimes you gotta do what ya gotta do........

 

[eldubb440]

Before I continue down the wrong path, eldubb440, give me some more advice on drilling out the spot welds. I tried a spot weld bit and dulled two without cutting through the first sheet of metal. I've had better luck in drilling a small pilot hole and then using a larger bit (1/4") to drill the weld. Am I doing something wrong with the spot weld bit or do I just have a cheap one (I paid $5 at Harborfreight)? As you can see, I'm making Swiss cheese but you said that was likely to happen. Advice? Thanks! Terry

View attachment 1163435 View attachment 1163436 View attachment 1163437 View attachment 1163438

sometimes its easier to cut the "swiss cheese" away and replace it......

 

[TT from NH]

thats why i dont use the cutters unless i have to.....along the bottom of the tail light panel, just run a drill bit through it, you need to replace that cross member anyway........ in other areas, sometimes you gotta do what ya gotta do........

Thanks eldubb440. That's what I was hoping you'd say. Hypothetically, let's say I DIDN'T replace the cross member which now has holes in it. Would I fill those holes first with a weld, grind the welds down flush, and then weld the tail light panel back on? (Remember, I do not know how to weld although be the end of this project I hope to be more proficient.) Terry

 

[eldubb440]

Thanks eldubb440. That's what I was hoping you'd say. Hypothetically, let's say I DIDN'T replace the cross member which now has holes in it. Would I fill those holes first with a weld, grind the welds down flush, and then weld the tail light panel back on? (Remember, I do not know how to weld although be the end of this project I hope to be more proficient.) Terry

yes..... but you should replace that piece in my opinion.....not only do I know it's rusty, but it will also allow you to slide a seat in the trunk area to sit on while you prep the hard to reach areas toward the front

 

[TT from NH]

yes..... but you should replace that piece in my opinion.....not only do I know it's rusty, but it will also allow you to slide a seat in the trunk area to sit on while you prep the hard to reach areas toward the front

No worries; I'm replacing the piece. I just wanted to know what one would do.

 

[TT from NH]

Okay, continuing with the tail light panel removal. THOUGHT #1: First, since I'm replacing the cross member, I decided to cut along the inside and not bother with drilling out the welds. I plan on using the cutting wheel to cut through and grind the welds on the back of the tail light panel. Reaction?

 

[eldubb440]

Okay, continuing with the tail light panel removal. THOUGHT #1: First, since I'm replacing the cross member, I decided to cut along the inside and not bother with drilling out the welds. I plan on using the cutting wheel to cut through and grind the welds on the back of the tail light panel. Reaction?

View attachment 1163842

yes Grasshopper, figuring out shortcuts.... you will be an expert by the time you are done......

 

[TT from NH]

THOUGHT #2: How is the tail light panel attached to the quarter panel and trunk gutter corner? And since I'm replacing the the trunk gutter corners, can I cut through the corners and then grind them off from inside the light tail panel once I have the tail light panel removed? The spot welds are extremely difficult to see.

 

[TT from NH]

THOUGHT #3 (final thought for the day): There's brazing where the quarter panel, trunk gutter corner, and tail light panel join. Is this done at the factory or was it done later in the car's life? How do you remove a brazed weld? (While the picture below is of the driver's side, the passenger side is the same.) Thanks!!!!

 

[eldubb440]

same concept......if you are replacing the gutters, you can destroy them........ what year is that car anyway?

 

[TT from NH]

yes Grasshopper, figuring out shortcuts.... you will be an expert by the time you are done......

 

[eldubb440]

grind the braze...... someone did that, not the factory