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Published on Jul 26, 2011
Episode 17 of my '76 Mazda RX-5 Cosmo restoration moves from the destruction of the last episode to construction as I focus mainly on one task: repairing the floor in the rear passenger seat area. This was some of the surprise damage I found while sand blasting way back in part 6. I've been neglecting the floor for more interesting tasks and because rust is depressing but after uncovering far more tin-worm damage in part 16, I decided it was time to do a little more sheet metal work. This turned out to take longer than I thought and was a rather tedious area to work in. Included in this episode: cutting out rusty sheet metal, cleaning up rust, prepping the areas for repair, fabricating patch panels, media blasting, hand forming patch panels, welding in new metal patch panels, recreating factory beads without a bead roller, corpse removal.