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BE Battery Shelf and Firewall repair suggestions

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Trevor Jessie said:
OK, I gave it more thought (head scratching). Get a piece of 3/4" plywood and cut a rectangle in it the size of the bump (where it meets the firewall). Then get a 1/4 inch bit of square stock and cut it the size of the rectangle on top of the bump. (round the edges). place some 20 gauge steel on the wood form and sandwich it with another bit of wood identical in size. Screw them together. Carefully place the metal stock in the center and start hammering. A lot of prep, but I think you could make a decent shape. The down side... those bumps are two different sizes.
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Thanks Trevor. I'll make it work.
 
I did some more cleaning around the battery shelf area. Unfortunately, I found some crispiness and places where the metal is torn on the front lip. Looks like it would be better to cut the entire thing out and replace rather than repair. But I was thinking, maybe I can save the smaller heater hole and graft it into the later heater box shelf. I dunno.

I'm also wondering how much rust I have in the sills! If there is any metal left or if it's all bondo. :laugh:
 
Nothing for you, John - you've tackled harder projects!
 
I pulled off the battery tray
P1060431-1.jpg

Then made a piece from stainless (tough to cut by the way)
P1060434.jpg

I made pieces similar to Duncan and welded them in.
P1080581.jpg

And yes Jack, the holes are from rust, not from shorting battery cables. It comes from the battery acid.
 
Nice!
 
Donn,

Your sprite looks VERY similar to mine! how did you fix the firewall holes?
 
Looks like a great job from here.
 
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