Patcon

I think most people heat a shifter rod and bend it to align with the hole. Most don't want to cut the tunnel because it creates other problems as well as being hard to repair. Search for some images or threads on Google

More pics!!!

I would use the rear suspension. Probably one of the lower control arms to try to minimize the impact on the rear valence. I would be careful if you have to pull very hard or you will tear up the body or the fuel tank.

I would try to find a replacement cowl. You could patch this one but it will be hard to weld this up with out warping the panel.

Some people use Redcoat . POR15 makes a tank liner. Eastwood does. I just recently used a Caswell epoxy product. If you follow the directions closely sealing a tank is a DIY project

That holes going to get a good bit bigger when you get back to good metal, but still better than might be expected all things considered

I plan on reinstalling the factory pads if possible. that is after I have removed the rust, neutralized and epoxy primered the underneath side.

Some people have used CLR in the past. I am confidant that it is a weak acid too which is what makes it effective

I wonder what CLR would do to the valve?

Good excuse to drive the car though

@Mike That is above my paygrade, maybe Mike will chime in...

Ebay for rebuildables but if you source them from Ztherapy they will be correct right out of the box. Might want to find some cores though

It's a thin foam. I believe it is to prevent rattles. Also it is always better to upload the pictures to the site. Mike will preserve them for posterity. We have had more than one thread go bad when the hosting site links were broken

There are websites that can help you locate ethanol free gas. Do a search on Google

I agree, no Nova like demand but multiples more than a Z specific part would demand There are a lot of brands under that umbrella!!!!

Why not just id the size and order some brass bushings online. as long as the ID and OD are close the length can be adjusted

It is very difficult to deal with the underside of the battery tray and an OEM type replacement panel is unavailable. I believe the factory assembled the car and sprayed it the same way we try to do it today. After having done this, I can tell you it is almost impossible to get paint up in there. Even treating the underside of the tray is difficult

Didn't you post earlier all the cross references? So isnt the demand more broad? Also the part isn't large or complex so the mold would be pretty simple with just a few holes to bore. Not a ton of capital cost unlike stamping sheet metal

As a general rule you have DTM "Direct to metal primer" not meant to go over other paint or fillers as substrates Epoxy primers are use many times as a DTM type product. Epoxy is tough and sticks great to most anything. It does not sand very well High build primers are primers that have thicker film build. Which helps deal with minor imperfections and sanding scratches There are also primers that are basically liquid bondo, you see these used on show cars sometimes to allow perfect blocking and really exact edges. Evercoat makes one Sealers are last and are used to seal down the substrate to prevent bleed through mainly. I don't run a sealer coat to date There are tons of products available and most paint lines have multiple ways to get from metal to shiny paint. that is where I rely on the counter guys to steer me to the right products. I don't normally scrimp on material cost because better materials are easier to work with on the whole. Better paper sand better and clogs less. Powder guide coat works really good and the can I have will last me for years. I buy mid range primers, decent base coat and mid range clear coat. I shot single stage in the engine bay and door jambs...

Maybe, but an engine that runs closer to stoich requires a lot less maintenance and responds better to fuel inputs

I never do these things over the phone!!! I also way go into my local finishmaster. I know all the guys names. I make small talk with them and ask how they're doing. They don't see me very often but they know who I am and they are always friendly and try to help. If you can cultivate friendships at a good supplier they will try to help you be successful because they like you, because there really isn't any money in it for them. We DIY'ers are a drop in the bucket compared to pro shops. It's all about building the relationship...

Have you talked to Gemstone Auto Paint Supply. They had good reviews online. I did not see the PPG store listed

@Captain Obvious You could include some O2 datalogging to pick up those qualities

My tool was similar but I used a piece of plywood in the center with 2x4 arms screwed to each end. About 5' long overall. I used some wood working clamps to squeeze it with the bottom half held by a vise. Lots of leverage

The original paint is a catalyzed single stage. If it's solid and well adhered you can paint over it. I would primer first so I could make it smooth and prevent bleed through You can have immediate or long term problems. Some problems show up quick, like solvent pops or fish eyes. Some like untreated rust can show up months or years later...