ConVerTT

A dozen spot welds to go and .... out of shielding gas ...grrrrr!!!

PSA: Make sure your tetanus immunization is up to date. I had mine done last week - 20 mins, painless and better than death by a thousand rusty cuts ?

Finished final fitment and coated the inside surfaces with epoxy primer. Welding them in on Sunday !

A couple of pics for those that might have missed the DS assembly .... There are two stiffening panels that need to be welded to the inner rear quarter and the inner sheet metal In front of the doors. They were part of the original sheet metal stampings but if your rockers are bad enough that you are considering this repair, then the stiffeners are likely rusted away as well. These panels get sandwiched between the inner and outer rocker. They add rigidity and a larger weld surface to the assembly. (The inner rocker gets welded to the floor, the firewall and the stiffeners. Then the outer rocker gets welded to the outside).

And fitting the PS rocker is going a lot faster after doing the DS .... Hopefully I can prime the PS rocker tomorrow and weld it in this weekend ?

Got the DS outer rocker welded on ...

Just read all 4 pages! Great work! On the doors: personally I would focus on the trailing edge gaps by the dog legs and leave the leading edge gaps alone.

No. The first one is a generic water / oil trap. It's fine for air tools but probably not good enough for paint (some water oil gets through it). The second stage is the oil filter. The third one is a desiccant vapor filter. It's pretty dry here so it might be overkill, but it's also a pretty minor expense in the big picture. (I am a decent "painter" but a crappy "blender" so I need to minimize rework and do a series of one takes ?)

Done!

Tool day today: Added in-line vapor trap, filter and dryer to the booth so I can have a paint quality air tap available in the booth. No more rattle can primer for me!

Also found a part number ... "Body side panel and sill -From Aug 1973"

The pocket is built in to the inner rocker. The boxed section gets sandwiched between the inner and outer rocker. Exploded view ....

Haha - quite possibly!

Do you ever do anything half-a$$ed? - I love it!

Also, here is another Interesting NOS piece from the garage sale ... I don't know what it is called but its the inside section of the driver's rear quarter. Interesting how the rear rocker panel support is stamped right into this piece ... No obvious part number on this one, but I am guessing that it is from a 74 or later. It doesn't exactly match the earlier stamping as near as I can tell.

All cleaned up ... l Level... set to 7 degrees ...

So the seat brackets are actually a) very important as they tie together the floor, trans tunnel and inner rocker and b) actually quite complicated to replicate. So I bead blasted the old one, cut away the rust and am butt welding new metal in place in an attempt to salvage /re-use it. Progress pics ... need to weld in the curved bit and clean it all up ... tomorrow ....

Great minds must think alike ... I am coveting your wall art and I also own some project s30's, a "few" 90s 300zx's and an 01 NSX. Looking forward to following this one.

I absolutely love this! Nice!

And started welding ...

Exploded view pics of the rocker assembly ... (I think I promised @grannyknot these about 10 months ago ooops)

Thanks - I am back in action through April!

Awesome fit!

Got a chance to test the painting in the prep booth with some rattle can 2k epoxy primer.... It worked great . You can see where the overspray got drawn into the filters .... Parts came out fine ... welding them in tomorrow hopefully.... Rattle can epoxy primer is ridiculously expensive though. $23 and that took the whole can ...so definitely a laziness tax included in the price.

No. The shop has a draw though exhaust that flows in the same direction - intake louver by the door, exhaust fan on the back wall. I considered hooking it directly to the booth but it flows too much air.