skl

All that damn foam they put in the sail panel and elsewhere is a major PITA!!!!

bkrantz

And part of the rust promotion system.

bkrantz

After another couple of quality hours I got 99% of the foam out of the trunk lid rear rib. Fortunately, the foam (at least on this lid) did not fill the entire length of the rib. But even to reach the other "end" I had to make a tool:



The bore scope showed a pretty clear cavity.

bkrantz

Still working on the trunk lid, cutting the patch and welding that and some other spots.



Here's the patch, with a double-recurve profile. A little lumpy.



Fit in place.



Tack-welded.



And fully welded.

bkrantz

I also welded a crack in the rib on the right side.



And 2 holes in the skin, probably from a luggage rack.

bkrantz

I finished up the metal work on the trunk lid today, grinding down all the welds from yesterday.

bkrantz

Now I have to work on reshaping the lid. I set it back in place, roughly aligned.



The biggest problem is still the rear edge, which has been bent down. My guess is that it got set down hard (off the car) on the trailing edge, which bent it inward.

bkrantz

Meanwhile, I finished the right rear fender. Again, the spots sanded on the scratch coat make it look worse that it is, with no more than about 1 or 2 mm difference at most.

bkrantz

More work on straightening the trunk lid today. I managed to lift the trailing edge a bit, with a combination of a new "lifting" tool and a soft face hammer.



Not perfect, but the bottom of the trailing edge is close to flat, and equally distant from the rear panel.

bkrantz

Got to work on dents in the trunk lid today, using the Eastwood pointless dent remover kit. This includes a hot glue gun, glue-on pulling tabs, and hand operated pry thing, and a small slide hammer (not shown).



First up, a shallow dent along the leading edge. The inner reinforcing rib blocks access from the inside.



Glue the tab, and use the puller to bring the dent back even.



Not bad.

bkrantz

I then tried the same kit on the dents in the inner reinforcing ribs.



But the glue is not strong enough, and the tabs kept popping off.



So I got out my weld-on studs, that are the right size for my big slide hammer.



The first dent pulled out nicely.



And the second dent was looking good, until I pulled too hard. Gotta weld that up tomorrow.

bkrantz

Got the trunk lid done today.

I welded the hole I tore yesterday, and also the old hole in the PO repair.



I continued with my technique, and pulled out the last two significant dents. What is left I will correct with filler.

bkrantz

While the welder was out, I also reattached the trunk lock mount on the inside of the rear panel.

bkrantz

Getting close to clearing the list!

skl

I don't see "buy a 2.4 911 engine for a six conversion..."