This is what was cut out and replaced.

 

Ground down my welds and checked with a light to see where I missed when welding. Will need to address the modifications for my upper control arms next. Then it will be sandblast time.

 

Worked on the inner fender again today, I had made a template out of cardboard and marked what needed to be cut out for the control arm then cleaned up the area to be welded.

 

This is the piece I made to cover what I cut out of the fender

 

Sprayed both surfaces with weld through prime

 

Then plug welded the piece in place and cleaned up the welds

 

Here it is installed

 

and from the underside, I have to finish the other side then clean them up for the primer.

 

Great work, John, that's a cool cover you made! Do you have problems with that weld through primer, with splatter and ugly welds? I"ve had that issue with it.

 

I've had the same problems Pat, what I do is after I get it into position I use a small flat screw driver and scrape the paint off inside the holes I'm welding which seems to help.

 

Maybe I'll give that a shot, John. I tried turning up the heat a bit, thought maybe that would help, but then it just burns through the damn metal.

 

IMHO when you weld the area within 1/2 around weld gets burnt off so any protection you gain with the use of a coating is lost and all you get is contaminated weld problems. When I use the lap plug weld method, I pre fit the panel, mark the plug weld openings, clean the coating off 1/2 around all weld surfaces effected, refit than weld. My opinion of using primer as a permanent coating behind a lap does not pass the rust test, I have used the weld thru primer during the build for temporary protection but always end up sanding the majority off during prep work. I use enamel paint between the laps, after the panel is done I prep it for final coating.
This is just my opinion and may not be the right way to others but it works for me and I feel good and that is my disclaimor

 

Using Randy Walker's ( Randy Jack ) method of installing a 78 Bronco tank



Boxed the inside of frame rail where I notched the frame for the filler tube out of 1/4" plate, all I had on hand.

 

Welded a short piece of 3" x 1/8" thick round tubing between the boxing plate and outer frame rail to pass through the filler tube.

 

I had to do some things a little different because of the suspension set up I have, it's a TCI kit so needed to weld this plate to the shock cross member to support the tank.