Ivan's coupe: roof stuccowork

[Ivan141]

The saga continues...

Traveled down to the lockup today with full intention to clean last weeks repairs, spray some epoxy primer on all the bare metal, and prepare for undercoating (masking and plugging holes.

As is the tradition, reality intervened. While I was grinding the old welds down I spotted a load of pinholes around the old Bert repairs and started filling them with welds. Then I spotted another hole, and another.. kept on plugging.
Eventually I was scraping away old sealant and found yet another bit of hidden rust on the right quarter panel (which was poorly replaced long ago before I owned it).
Out comes the grinder.


You can see the amount of overlap that was there, and the color will tell you what you need to know about the state of the metal.

Everything got the chop, since the rear end is now so far away from original I wont bother recreating the overlapping sections.


CAD design:


Transferred to metal:

The clamp is holding a huge chunk of copper so I dont burn through as easily.

Weldy, weldy:

I also added some meat to very thin areas around Berts old repair sections to the left.

After another shit-ton of grinding:


And then I finally managed to hit it with a coat of 2K epoxy, using my old Wagner electric spraygun.. It aint pretty but for primer it works fine, not much overspray.

Note how awesome my bottom repair section looks next to Berts ugly stuff. But those bits are out of sight and solid enough, so im not touching them.
The patch above it (done 2 weeks ago) is not exactly perfect, but it was a difficult curve to replicate without proper tools, I think its close enough for filler to save the day.

The inside was also sprayed:


I think I used the same brand primer (Mipa) that was put on by the mediablaster guys, the color is an exact match.

Next episode:
-Fixing last remnant of Bert's work on right doorsill.
-Finish last tube of sealant around the trunk area and in roof rails.
-Clean inside of roof, primer it.
-Scuff up primer around seams, spray primer over them.
-Plugging and masking for the Raptor liner job..