Ive been chipping away on lunch breaks this week. Grinding and cleaning up from the seam welding, then spraying the rustoleum primer on the bare metal. Every bit of brown you see is where we seam welded (that I have final prepped. Lots to go on the drivers side, and still some around the door and kick panel on the passengers)
20180501_191051 by Michael Crawford, on Flickr
20180501_191103 by Michael Crawford, on Flickr
20180501_191124 by Michael Crawford, on Flickr
I then moved onto seam sealer. There's only two main areas I want to make sure are “pretty”. The floor, and the engine bay. The rest will never really be seen, and if it is, its either because somebody is buying the car, or I ran them over. Neither of which is very likely.
Remember im using the cheap brush-able seam sealer from amazon. It also looks far better in person than in the pictures. I think this stuff slightly self levels as it dries.
In the engine bay, on the 90-ish degree joints, I wanted a fillet look like you would with bathtub caulk. I could NOT find a way to get it in there I was happy with. In the end, I dipped my finger in the can and worked in it with a finger painting motion. I did wear rubber gloves. The gloves did rip. There is seam sealer under my fingernails on my right hand that got me funny looks at work.
The flatter sections, where the factory did a lap weld seam, I used a 1 inch bristle brush to apply, making sure I worked it into the cracks and crevasses. I smoothed it with a foam brush afterwards, but it really didn't change the cosmetic properties any, if at all. Im still not super happy with how it came out, and hopefully another round (light coating for appearance purposes) makes them come out better.
20180503_160323 by Michael Crawford, on Flickr
the floors were all lap welds. So all done with the 1 inch brush. I laid it down THICK on the subframe connectors. I need to put something in the gaps where the body plugs were, and do another coat here as well. Im also debating skinning the whole floor with some .030 aluminum to give it a better appearance. Well see what I think after paint and lizard skin. I may do some stucco mesh over the black floor pans for visual contrast and floor traction. Haven't gotten there yet.
20180503_160340 by Michael Crawford, on Flickr
in the wheel well, where I don't really care about appearance, I could've used a putty knife or trowel. Instead, I used the 1 inch brush and just worked it in. this will be topcoated in satin black and tire marbles, so should disappear pretty quickly. It definitely needs another coat though.
20180503_160331 by Michael Crawford, on Flickr