{"id":4031,"date":"2023-08-27T16:25:03","date_gmt":"2023-08-28T00:25:03","guid":{"rendered":"https:\/\/www.billdugan.com\/scout\/?p=4031"},"modified":"2023-08-27T16:25:03","modified_gmt":"2023-08-28T00:25:03","slug":"major-surgery-parts-6-8","status":"publish","type":"post","link":"https:\/\/www.billdugan.com\/scout\/2023\/08\/27\/major-surgery-parts-6-8\/","title":{"rendered":"Major Surgery, Parts 6-8"},"content":{"rendered":"

Thursday’s progress looked kind of misleading because I was working on lots of fiddly stuff, and I did a terrible job of taking many pictures. I started the day camped out in the garage because of threatening rain clouds, so I started by working on a patch for the cowl itself out of some 20 ga. steel. When I had the pattern the way I liked it, I laid it on top of the cowl and cut around it, then trimmed it with the grinder and cut some notches in the lip.<\/p>\n

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Carefully bending it at the same curve, I tacked it into place and then used my patience to finish welding it in. While that cooled, I busted out the sanding gear and cleaned up the other sides of the cowl to even things out.<\/p>\n

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When I had that in place I banged out some of the obvious bends with a hammer and skimmed it with some body filler. As that dried, I flattened the original air baffle from the driver’s side and traced two patterns out on some fresh steel. I bent them both according to the pictures I’d taken on disassembly, prepped the vertical face of the inner cowl, and welded them both into place. Then I put both flappers in and hooked the vent cable back up to the driver’s side\u2014I still have to drop the heating unit out to refurbish that, and there’s no easy way to reconnect the cable up unless it’s out of the way.<\/p>\n

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There was lots of sanding, priming, sanding, and priming, and I used some ACE Rust-Stop International Implement Red to coat the entire inner section of the cowl.<\/p>\n

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On Friday I got lots more little fiddly bits done and ready for welding the cowl back in on Sunday. I skimmed some body filler on the welding seams on each side to smooth them out so that when water runs down to the drains it won’t get stuck in the texture from the seam sealer.<\/p>\n

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The cowl is prepped for welding and will probably need some touch-ups to the body filler after heat warps some of it, but that’s OK. I did a test-fit to ensure it isn’t warped and that the welds still line up.<\/p>\n

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I also worked on some Scout stuff too; I still have to adjust the timing and do some minor maintenance.<\/p>\n

On Sunday I welded the cowl back in place. I test fit and trimmed and test fit and trimmed and then clamped the crap out of it and started tacking it into place slowly.<\/p>\n

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By about 5PM I had the whole thing in, the welds ground down, and a coat of etch primer on all the bare metal.<\/p>\n

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The perimeter of the windshield frame has two coats of IH Implement Red in preparation for a clean new gasket and brand new windshield. The bottom of the cowl has some Bondo that I skimmed over the welds, and that will get smoothed out before I paint the rest. Now I just have to screw up my courage up to attempt the window installation.<\/p>\n","protected":false},"excerpt":{"rendered":"

Thursday’s progress looked kind of misleading because I was working on lots of fiddly stuff, and I did a terrible job of taking many pictures. I started the day camped out in the garage because of threatening rain clouds, so I started by working on a patch for the cowl itself out of some 20 […]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","jetpack_post_was_ever_published":false},"categories":[68,69],"tags":[],"class_list":["post-4031","post","type-post","status-publish","format-standard","hentry","category-travelall","category-welding"],"jetpack_featured_media_url":"","jetpack_shortlink":"https:\/\/wp.me\/p58Ac2-131","jetpack_sharing_enabled":true,"_links":{"self":[{"href":"https:\/\/www.billdugan.com\/scout\/wp-json\/wp\/v2\/posts\/4031","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.billdugan.com\/scout\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.billdugan.com\/scout\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.billdugan.com\/scout\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.billdugan.com\/scout\/wp-json\/wp\/v2\/comments?post=4031"}],"version-history":[{"count":1,"href":"https:\/\/www.billdugan.com\/scout\/wp-json\/wp\/v2\/posts\/4031\/revisions"}],"predecessor-version":[{"id":4043,"href":"https:\/\/www.billdugan.com\/scout\/wp-json\/wp\/v2\/posts\/4031\/revisions\/4043"}],"wp:attachment":[{"href":"https:\/\/www.billdugan.com\/scout\/wp-json\/wp\/v2\/media?parent=4031"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.billdugan.com\/scout\/wp-json\/wp\/v2\/categories?post=4031"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.billdugan.com\/scout\/wp-json\/wp\/v2\/tags?post=4031"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}