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Part 19: Front Inner Fender Removal, POR-15, Rear Sill Repair - My 76 Mazda RX-5 Cosmo Restoration

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Published on Dec 5, 2011

Part 19 of my '76 RX-5 Cosmo restoration continues with sheet metal repairs, but hopefully in a less boring format. First off I totally remove the rotted out front inner fenders by drilling out about a billion spot welds. Then we move onto the very complicated rear inner sill repair. This brings the introduction of POR-15, the first time I have used it on this project and by far, not the last. Included are many tips on working with this product. I promised less sheet metal, but wanted to show the rear inner sill repair because it was by far the most complicated sheet metal repair I have yet done on this car, and likely will remain as such. Included in this episode: drilling out spot welds, air hammering off panels, using MetalReady to prep for POR-15, applying POR-15, POR-15 usage tips, cutting out floor to access rear inner sill, fabricating a new rear inner sill panel, welding it all back into place, nudity of me.

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