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dscf3593--dr-bpillar-access-hole-welded.jpg | Hits: 40 | Posted on: 11/9/21
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This wasn't my best idea... I started the b-pillar access holes on the passenger side, doing a full cutout. Then I did the driver's side and thought it would be best to leave one corner connected, so I could bend it out of the way to do inner work, then bend it back in place to line it up easier for welding shut instead of just doing an overlapped panel like the TSB.
Well, having gone through this whole project and now being keenly aware how difficult it is to weld this old sheet metal, I was concerned with that planned direction but decided to give it a shot... It actually went pretty well, with very time consuming heat control. But, the problem I didn't account for was the inner roof not really maintaining the same shape as the panel cover. I was able to pull them into alignment on the sides and bottom, using the heat to join stuff, but the top simply had too much to overcome. I had to build up the weld on the roof portion to close the gap. Unfortunately, the plastic panel that goes behind the seat belt anchor doesn't extend quite to the top of the weld line.
I'm not sure how bodywork pros handle that sort of thing. Maybe strong, pinpoint magnets to pull the sheet metal outward as needed. That or stud welding, with multiple hands on deck to pull on the studs to align everything, and cleaning it all up later, Needless to say, I haven't done the passenger side panel yet...
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