Re: Holes holes holes - Saab Sonett Bulletin Board - Saabnet.com
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Re: Holes holes holes
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Posted by spiv (more from spiv) on Mon, 25 Feb 2002 11:30:37 Share Post by Email
In Reply to: Holes holes holes, Mic, Mon, 25 Feb 2002 09:19:44
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Jack Ashcraft used to, but he's been saying he'll be downsizing his operation now that he's moved to a new house, so you might want to email him and see. Check classifieds for website.

Note, though, that the "floor pan" in a Sonett isn't just a single piece, so replacing it isn't a drop-in operation. The area you mention is built up from a collection of pieces including outer rocker, inner rocker, front floor section, rear floor section, firewall, and wheel arch.

Replacing some or all of these panels is a big job and might not be worth the bother unless you want a perfect concours restoration (or just really like the smell of welding fumes.) Depending on how big/how bad the damage is, it probably makes more sense to patch it. In many cases that isn't really too tough because a lot of the panels are basically flat -- no tricky compound curves. (I'm completely hapless with tools but managed to do it.)

If the holes are small and widely spaced, you probably could just clean them up, snip out patches from flat sheet metal, weld in the patches, then grind, seal and paint. If there are a lot of holes or if they cover areas with bends, channels, etc., it's probably easier to cut out the whole area, then take it to a sheet-metal shop and have them cut, bend and form a duplicate piece for you; then you weld that in.

One caveat is that the rockers etc. are part of the structure of the car, so if you need to cut out a big chunk you have to support the rest of the car's weight so it doesn't get distorted -- otherwise you can find that you've gone to a lot of trouble to fix the rust, and now the doors won't close. So if you're looking at this scope of work, get an expert to advise you. If it's just a little hole here and a little hole there, though, go ahead and have at it. I dreaded this job for the first two years I owned my car, but once I gritted my teeth and bought a MIG welder and a few sheet-metal tools and got started, I found that it was actually kind of fun. Now the underside of my car looks like something that might have been built by one of the losing teams on 'Junkyard Wars,' but it's solid and it don't leak!

posted by 204.76.1...


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