Restoration: 1978 Honda Civic (1200) Part 2

[Randy]

Since this repair will be hidden I won’t be doing anything fantastic. I am just cutting out the worst of it and spot welding on top. The final skin is going to be tricky, I am rethinking to use the big chunk I took out and repair it on the bench rather than make a new one from scratch as it has recessed square depressions that I cannot shape into new metal. There might be just enough left of the crust to make repairs from the back.

My air saw broke so I have to do with what I have until a new one comes in the mail.

[Randy]

This is how this all started way back then.

https://youtu.be/35P4YnMYeIk

[Randy]

I will be doing a cut and but method where I tack weld in places and then start cutting the old panel out from below the new piece and as I cut along the edge of the new pice breaking the first tack weld then pressing it level with the material below and just continue to cut tack and weld along the length until done.

This helps get a perfect matching cut parallel to the old panel. In the end the scrap rot will fall off the the floor when done. I will be doing the cut and butt along the back.

[Randy]

This is the rusty bits that fell off as I cut and butt welded. I used a drummel tool with a larger cut off disc.

Not finished yet, so I thought I was and found a hole and ….. it got bigger. Trying to save as much as possible ends up being a little thinner.

It’s hard to see in the photo that I was able to retain the recessed dimples. I hope to finish this welding tomorrow and bend the flange along the bottom for the floor. I wish I had a bead roller tipping die would make it easy as the floor is not flat in the back and I don’t have a shrinker either.

[Randy]

A little bit of work tonight, soon I will make a second pass on the welding and smooth it over to get ready for the final patch on the rear drivers side. Then I can put the finished inner rocker in, level up the floor and start spot welding the bits in.

If I don’t post again this year have a good Christmas and a New Year.

[Randy]

Got the bit of floor tacked in place. I used and Eastwood V flanging tool. Look really good, I find if it is not a perfect fit I could hit it from behind to close up the V a bit and does a good job of a quick fix. Elsewhere might not be able to get in from behind. I have some bits of welding to do from underneath later.

[Randy]

That’s done, check out my welding clamp, it’s almost cut off.
Is the outer rocker next, that could get nasty. Last time I did one was on my black civic and hammered it into shape using angle iron and the edge of the workbench. This time I have a manufacturers pre-made one.

[Randy]

It’s the last day of 2021, what a year it has been.
So one I get with finishing off the inner rocker panel. The front jacking point has to be welded onto the repaired panel. First I have to grind off what left on it from the rusty section I cut off. I had put som marks on the back from the old section so I would know where it goes back on. It seems strange the jacking point was only held on by 3 spot welds near the top, I am going to put 6 total, 3 top and three along the bottom.

I will be fitting it and then trimming the bottom nod the rotted rocker off so I can prime it for welding.

https://youtu.be/jwvo6wiVw5g

[Randy]

https://youtu.be/XB1HUQbeu7Q

Here are some before and after pictures below.
I am working on a new video fitting the jacking point and welding it on, I mention in the video that I may not put the three big plug holes back in. I do I some dimple dies on the way but I am wanting to get the panel back in. The dies are coming from KMS in BC and I am not sure how long it will take knowing how their roads got badly damaged in a storm. I also have a tipping die for my bead roller, I could have used that for the floor in the back corner.

Rusty Below

Before

Rust Evicted Below
Ready for fitting and trimming the bottom off.

I should take a better picture of after to post later.

After

[Randy]

Making the dimple holes without a dimple die. When I do get them I can do a comparison.

https://youtu.be/1z2kKD5Oz6M

I used a 1” and 3/4” Electrician’s K/O punch dies.
First I drilled a hole to the size required to match the original hole. I punched a 1/2 hole using the same punch set.
Then I put the 1” die behind the hole and then took the ball from a large ball pean hammer and drove it into the hole, not too hard now, just enough to create a lip to align the dies in the vise.
Then I took the 3/4 die and placed it in the dimple just made with the hammer and put the 1” die behind it and put it in the vice and cranked it in enough to make the dimple.
Not perfect as no one will see it anyway.
I plan to use the holes to put rust treatment into the rocker.