Next up to deal with is the battery support. When I started this resto in '97 or so, I removed the battery support to repair that corner's sheet metal. Had to replace several areas completely. I'm not really sure what my thinking was at the time, but when I put the battery support back in I did an amazingly bad job and have never been happy with it. So I cut it out again to correct it without any real idea as to how I would go about it.
This is the only before picture.
What's significant is the tack welds I used at the lower support - specifically, I burned off(?) any protective coating when I welded it back in, thereby guaranteeing a future of new rust. The angle between the inner fender and the battery support bracket is so acute, it will hold anything and everything and never let it out. So, sand, dirt, leaves, insects, etc. are all guaranteed a place to stay forever - or least until the sheet metal rusts away again.
Upon removing the support, what I saw made me glad I did it. When the car was sandblasted it revealed some good perforation damage. Having had no other way to deal with the problem, I had applied mud to the rust holes in the support.
This car has not been wet since 1997 and you can see new rust already forming around the rust holes.
After seeing what MSA wants for a new support (the better part of $500!), I decided to make a new one. After taking that decision, I struggled with how to reattach it. It seems the idea of welding in the area is asking for trouble. So I decided to make it removable. Two bolts in each of three flanges to permit easy access for cleaning (though infrequently) and any remediation of rust that may occur. To further improve complicate it, I will use snap-in plastic nuts for the bolts to provide isolation from paint-to-paint contact, allow some air space between the parts, and eliminate the need for wrenching on each side of the fender.
If I could cut square holes, I'd just order them from McMaster as individual nuts, but I ain't spending a couple of hundred dollars for a square chassis punch. That means I get to print them. Image below is concept. I will make them a bit more rugged. It's surely be no fun to be driving along with a battery dragging under the car attached by two cables. 😁
I should have the new support finished up tomorrow. More to come.