Patcon

Flux core is not the way to make this repair in my opinion. You need gas and mig with a decent duty cycle. If you're burning holes, then your current is too high or the metal is too thin. A welder with too low a duty cycle can also do this when overworked

Ron, maybe some pictures would help Pictures all the way around the hatch...

But, you couldn't get it adjusted where it looked good? I haven't found the hatch hinges to have excessive slop

Are trying to align the hatch with the shock installed?

I believe the firewall is all there is

Thanks for the complete story!

He evidently has it diagnosed and moving on with a repair

Also that actuator bar looks bent

Be advised, I have cut those before with a flat head screwdriver if they are really stuck. I would prefer a punch or a brass drift would be even better

FYI There is a record line of container ships off the west coast. Supply chain disruption is not likely to get better before the spring. No excuse for not communicating though

40k was probably a good price for that car. Clean and restored worth 2-3x that

Looks great

Norm is Zeddsaver, I believe, my mistake

Is Charlie still making floors or did he retire?

Norm is a real business but I wouldn't deal with him if I didn't have to

How Obvious! 🤣

Looks like the man is growing a thumbnail back!

What did you find? Final cause of the problem?

If that is the question... There is a metal stack, welded to cowl substructure that keeps water from flowing into the fresh air intake. There is a flat piece of metal welded above it to prevent water from dropping into the stack

Which intake?

It really is a shame O2 sensors dont work since all modern cars use them to adjust the fuel mixture (sarc) 😣

@Captain Obvious @Zup

I dont know of anyone who makes the whole inner panel but I think the guy in the UK makes patch panels for that area. His name escapes me right now

These might work too

The factory system is very primitive. A modern efi system with closed loop fueling is miles ahead of the original system. Yes, a complete new system. Very similar to triple mikunis but triple throttle bodies instead. Look up Jenvey's