Radiator core repair

[77 step]

Here is what I have been playing with this weekend.  My core support was rusty and had some weak spots.

[77 step]

I made a patch piece for the lower passenger side where the inner fender mounts.  I welded hex nuts (which I had soaked in muratic acid to remove the zinc coating) to the backside.  Then I welded the patch in and ground it smooth.  By the way, I rinsed the nuts with baking soda and water to neutralize any acid left on them.

[77 step]

There was also a rust hole near the passenger side mount.  I drilled out the spot welds, and cut out the pieces that were rusty.

[77 step]

Then, I cleaned up the inside, and made a patch piece.  I straightened all the bends out in the original piece, and traced it on a new piece of steel.  Then cut the patch out with the plasma cutter, and folded it into the original shape.

[77 step]

Next, I welded in the patch, and ground the welds.  I have to get a piece of 16 gauge to make the inner "box".  That meant done for now, time for some beer .

[77 step]

Sorry, the title of the thread should have read "Radiator core support repair".  I tried to change it, but I was unable.

[hotrod24]

did you go to modify and try changing the subject

[77 step]

Yes, Hotrod, I did.  I get a white screen with:

Database Error: Lost connection to MySQL server during query
File: /vservers/chevy/htdocs/smforum/Sources/Subs-Post.php
Line: 1895Database Error: MySQL server has gone away
File: /vservers/chevy/htdocs/smforum/Sources/Load.php
Line: 2030
Warning: Unknown(): A session is active. You cannot change the session module's ini settings at this time. in Unknown on line 0

Maybe a moderator will see it and change it for me?

[JJSZABO]

Good job - I had to do the same to mine

[Captkaos]

There is a bug in the forum software that won't allow you to change the first post.  Sweet work BTW.

[77 step]

Well, here's what I did tonight.  I reattached the passenger side mount, got my piece of 16 gauge, cut it out, and folded it into shape.  Next was punching holes in the new piece for plug welds.  Then, I clamped it in place andwelded it in.

[JJSZABO]

That is some nice work 77 - where did you learn to do metal work?

[77 step]

Lastly, I finished welding the mount, and test fit it.  Pretty much done now except for a little bolt hole stretching and some paint.  Time for a cold one.

[77 step]

Thanks Jeff. 

I learned most of it here in my garage (welding,cutting,etc) . 

I work as a mechanic for a roofing company, so I do have the benefit of having friends who make flashings, downspouts, chimney caps, etc.  I have learned some of the "folding" or breaking from watching them.

[JJSZABO]

Thats great - good ole DIY knowledge - awesome job