Restoration: 1978 Honda Civic (1200) Part 2

[Randy]

Here is a short video of the work since last week. Check out the mini sander/polisher that’s great for getting into small places. I wish I had received it before finishing the ending bay.

I would have got a lot more done but wasted the whole day yesterday getting home after a tire blow out on the highway after hitting a pot hole, then my spare went flat. LOL

I will post the pictures of the mini sander later.

[Randy]

Checking out the next step, I will be fixing the floor up front first, I need to replace sections of the inner rocker. I would like to replace the whole thing as it would involve a lot less welding.
I scrapped off a lot of under coating in preparation of welding and to get a better look at the hidden rot.

[Randy]

I have a piece made up from a former patch I started years ago and never got finished, it can be seen in the upcoming next episodes on YouTube.
I only have a drop of gas for the MIG welder so tonight I used the TIG welder. It a whole lot cleaner and easy to clean up the welds after. For sure it’s a lot slower for me as I am not used to this new machine yet.
Many years ago when I took car restoration in school we used gas only. Mig welders we’re just coming out and we only had one in the class. So I just used a torch and a filler rod, coat hanger for any blow through holes. I worked on some old Chevrolet and Oldsmobile’s.
I did practice on my 76 Civic when I had a spare fender, so I filled in where the side marker light goes.

I will need to make a die to press the sheet metal to take the form of the floor. Where the panel is welded I will be using a 3/8 flange lap and spot welding the seam with the TIG welder. I have tested the TIG for spot welding and it does a nice clean job, I just have to crank the amps up and make a quick weld.

[Randy]

Hello, I have been busy doing the spring thing getting the water back on outside, putting furniture out of hiding. Best of all using my skills to repair our old Gas BBQ. I welded the big hole in the bottom where a propane tank would go to keep the mice and chipmunks out. I hate the smell of fried rodent hair. Modified and welded in supports for better grilling grates. When it gets warmer I will be taking one side panel off to mend in a new section due to rot. Other than that it starts great now with new ignition and battery and gauges to see if it runs too hot.

Onto the car now……. I have been experimenting with how I will make the end pieces of the floor ribs. I was thinking of making a form and press but I think that is overkill. I just opened the jaws of the vice for the correct width and started hammering with the ball of the hammer and a round die for the rounded end. It looks ok to me and it’s going to be covered with gue and carpet anyway. The under side will be sporting undercoating so there is noting to see.

[Randy]

I have the bit above tack welded in as the welder is running on fumes and I just want to keep going.
The dimple dies did a really nice job and was way easier than last time, an the punch I did not have to drill pilot holes. I just drew circles for the holes and put the cutting die on it and a 2x6 piece of lumber underneath the sheet metal and just put it in the press and out came the hole for the dimple die. I did a short video for YouTube to be uploaded later.
So I cut a chunk out of the outer rocker to get access to the inner. Then I was able to spot weld it to the new section of floor and to the back of the bottom of the A pillar.

https://youtu.be/l8wRoFf_Q_0

[Randy]

Cutting out the rusty bits in the back seat area and underneath.
Had to make the bottom of the B pillar where it joins the rockers.
It gets complicated with so many connections rotted out, but I am just taking a bit at a time. Once I get the inner rocker closed up back to the rear wheel well I will start patching under the seat and the floor. Then there is also a hole in the wheel well where it meets the rocker, then I will deal with the outer rocker after.
I may fit the door back on to check for alignment but I am hoping with the welded brace I should not hav3 to.

[Randy]

It much work on the car but I had to make more storage room, so I modified my welding cart to hold the spot welder and the plasma cutter. This frees up more room and cabinets and easy access to use. I added some extra hooks on the side from old long bolts with fender washers on the ends.
The uprights are from and old Sears garage door opener. I only had to cut a piece of 11x16 sheet metal from my car supplies.
Spray paint was a couple of black leftovers.

[Randy]

I still have a bunch of videos to upload, I have been very busy doing some other important things.
I have been working on the panel underneath the right rear passenger door where the electrical line passes through to the fuel tank. It’s a double layer, it looks confusing and it is. There are many parts that intersect the need rust repairs. Including the leading edge of the wheel well and the inner and outer back seat end pieces. I had drilled out the spot welds from under the seat to get one of the old panels out without wrecking too much.
The inner piece is more difficult. I may have to flange weld it to the bottom of the sear as I cannot get to the section that flows up to where the rear pocket or speaker would go. I don’t think that should be a problem for strength at all. I am using 20guage as the steel taken out is at least 22-24 gauge.

[Randy]

I have been very busy wrecking my self, it not like I don’t have enough issues that I had to add a couple more.
I took three months off of running and cycling to allow my body heel to recover after threes years of pain and discomfort. I tried a shock wave therapy using sound waves. Success!
I went back to the gym after almost three years of absents to get the strength to get back to competitive running.
I got another injury that could take three months to recover.
I wrecked my wrist 2 weeks ago trying to hold back a loaded trailer full of junk from rolling into the back of my car.
That why the car is going so slow!

[Randy]

Here is an updated video of the floor patch panel.
This one I am replacing an old repair panel that was never welded in, it had screws and foil tape. No to worry, I hardly drove the car, it was done to keep the mice out.
I used the old patch panel as a pattern to make a new one from fresh metal.

I used the bead roller and a knock out die to make the end of the seam on the floor assisted by a ball pine hammer.

I have a couple more videos to do to get caught up before I get back to work on the car.

Oh, I picked up shrinker and stretcher, I have to make a bracket to bolt them to so they can be held in the vice