Cancer dilemmas

[H2O-Z]

I knew there was some cancer, but man!
the joys of a rebuild!

me again.
This '70 rebuild for my son is now pretty much totally, I mean TOTALLY stripped,
but I have a few issues that, believe it or not,
have actually caused me to question whether we should go further.
I never thought it would happen.

There have been several bolts that were so locked in with rust,
that I stripped the heads off while trying to remove them.
Now I have drilled some out, which is very risky in damaging the threads of the nuts,
but the ones I'm not sure what to do with, are the front fender, under rocker panel bolts.
Two per side, all heads off, rusted solid, no easy access.
Any suggestions??....please no sarcasm, I don't think I could deal with it :-)

Also, even more concern, is the rather large hole under the battery shelf,
and the battery shelf needs replacement as well......
ok, ok quit laughing!
"but it's a collector, vin#9623, original 60k, and automatic (for my son)"

[2ManyZs]

I doubt if anyone has ever taken a fender off an old Z without snapping at least one of those four bolts off, the water runs out of the drain for the front cowl area and runs right down the panle and into the front of the rocker panel and there is no drain there to get rid of it.

You have two choices, you can drill them out and try to remove them (you may snap the nut loose trying this) and re-thread them in the next size up or you could just replace the whole rocker panel. Replacing it might be the best route to take, the is the possibility that there is more rust in the rocker under the door you haven't found yet (people like to pack them full of bondo) and replacing a rocker panel is not the most difficult job and replacement panels are fairly inexpensive. If you do replace them, be sure to drill a small (1/8 inch) hole between or near the bolts to drain out any water that may get in there in the future. A little seam sealer on the top flange of the panel is also a good idea to keep as much out as possible.

As for the battery area, if the hole is away from the firewall you can cut it out and make a patch panel without too much trouble. The battery tray itself is another matter, you will probably need to find one out of a parts car that is in better shape than yours as I don't think there is anyone making replacements.

[H2O-Z]

thanx 2ManyZs,

About the battery, or actually inside fender patching, do you recommend 'making' a patch...and out of what guage, and then how to attach.....tach, spot, rivet...what is your best suggestion?

[2ManyZs]

I'd use 18 or 20 gauge sheetmetal. If the hole is not too you could have it spot welded, but if it is bigger than a couple inches I think it would be stronger to butt weld it in place with a Mig. You could check the gauge of the panel when you cut out the rust. I know there are panels that are thicker than others on a Z. Not sure what gauge the inner fender is. Probably 18 but you should check and use the same to patch it.

[EScanlon]

Sarcasm? Here? naaaaaaah

But just in case, could you let me know when the moratorium on sarcasm is over so we can have a bit of fun?