92ehatch

Really missing my truck. Mini vans pretty much suck no matter how you look at it. I've had lowered civics perform better.

92ehatch

Tried this method. May work for some people but my clutch let's loose first. Tried hammering on the bar as well and still no go. The bar was actually bending from the pressure.

I'm gonna cut the flange off and replace the bolt.

92ehatch

I love my grinder.

Yes i have to buy a new bolt but it took the relief cuts and the jack method to work.

rustED

iTrader: (2)

Man you're really tearing into this project, I like it! Glad you were able to get the crankshaft pulley bolt out finally, that got to be a relief. What's your plan for the core support/inner fender, are you going to replace it from a donor truck? Nice work so far!

92ehatch

I am going to make the inner fender myself. I decided not to do the afm and battery swap. All i have to do is weld in a flat space for the battery and fill in the edges with metal.

On the core support i just cut a small section out. I'll use rust converter and paint to seal up the surface rust inside and then patch over it.

For strength i will use angle iron against the core support and probably add a cross piece so it will hold the battery up. The inner fender doesn't need to be shaped perfectly imo,just functional as a battery holder.

rustED

iTrader: (2)

Sounds like you have a good plan to fix the inner fender/battery holder area. I lucked out there, mine isn't rusted out. Mine has alot of the other issues that you've already addressed, I need to replace the driverside window regulator, remove the inner trim panels that the seat belts go through, mine are falling apart too. I need to fix some rust in the passenger side rear wheel well.

Mine ran hot the other night on my way home from work, I didn't even realize my heater was blowing cold till I was almost home. My thermostat must have got stuck, it didn't boil over, no evidence (yet) of a blown headgasket, I'm hoping I got lucky!

92ehatch

A stuck thermostat won't cause a no heat issue as far as i know. I would check the coolant for oil contamination or other nasty build up.

The nice thing about our trucks is the interior panels and exterior paint match so well that we can remove the cracking plastic and boom. Instant color match

92ehatch

So i finished the mock up on the transformer stick welder.

I don't have my multimeter to check amp reading but i couldn't help but test it.

I took some scrap metal and with no welding helmet or anything just turned my head and struck it a few times. Ill advised, kids don't try this at home.

Other than burning some holes in the sheet metal it works.

Yall can laugh at the welds if you want to. I'm a first timer and was not even looking at the piece haha.

92ehatch

Well crap. Welder runs at around 90 amps which is ok.

However my 120v supply is drawing 44amps. The circuit breaker will not like that.

I could get wire and run a 240v supply in the garage and rewire my diy welder. Orrrrrr. Just buy a cheap welder and call this one a success and a failure. Success because it works failure because i ain't spending more money on it.

Back to the mechanics for now, I'll figure the patch panels out later

92ehatch

No updates as of late really. Weather and getting sick hampered some

Decided to rebuild the bottom end since I'm this far into it.

I picked up a welder and am trying to teach myself. The home made sick welder works, but i decided buying one was best




My first time ever welding. 1.2mm metal with .030 flux core.



Getting better already

92ehatch

Progress finally.

Work was hell this week but i did manage to get ahold of some panels from a ge dryer and washer to make patch panels out of.

My first was the hole in the radiator support. I think i did more grinding than welding. The metal was so thin i had alot of burn through and a really hard time dialing in what i was doing.





Here is my first panel test fitting




The donor. Freebies from work



And started stitching it in and shaping it.

Gevo

I commend your patience. Good stuff!

92ehatch

Today went well. I'm almost done with the inner fender. The last part has taken some thinking and a little help with basic shapes told me to use triangles to make the last section.





Angle for strength on the core support





In place





Almost finished


Meanwhile earlier in the day this guy got caught in the track on my garage door when it was closing. Didn't turn out well for him

rustED

iTrader: (2)

Nice work on the patch/ metal repair work. Dang that's a big bat, the ones around here just look like mice with wings, lol!

SwVa_1stGen

Nice build 92, where did you find the rear regulator and window if you dont mind me asking, I need the same.
The PO's grandson broke the rear glass and then gutted the gate.
So i need a few more items that what you got

92ehatch

I got them from charlies junk in hendersonville nc.

I don't know where you live but if you are in this area you can have my old rear glass. Is scratched but functional

92ehatch

Could someone measure how far their battery is from the fender to center and from firewall to center so i can get an idea of where mine should sit.

Would appreciate it

92ehatch

Finished the patch work. Now to grind it down, fix my battery holder, reinforce and paint



I think it follows the factory lines well





Need a dremel or die grinder to get the back left corner smoothed out





The back side still needs stitching up and smoothed out before undercoating

rustED

iTrader: (2)

I got about 25-1/2" from firewall to center and 7" from fender to center (measuring from the lip where the hood and fender meet if that makes sense, lol.) I can post pics if you need them for a better reference.

92ehatch

I just needed center measurements to get close enough. I know the battery hangs over slightly and just needed close enough for making my mount. I appreciate the help.