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Tips

Cylinder hea removal project

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Coat the non-threaded portion of the studs with never-seize to make head removal easier next time. Also, run a thin bead of sealer on both sides of the head gasket along the dist. side of the engine as they are prone to leak in that area. Berry
 
Put studs back between 1/2 and 3/4 and rig a system to use the studs to hold down the liners (big washer, piece of pipe, nut) so as not to disturb the figure eights at the bottom of the liners. Check that the liner tops stand proud of the block on 4 sides. bob
 
Removed the battery to get at a 2" x 4" rust-out hole in the panel under the box. It was covered with a piece of galvanized metal and the plastic battery box. What's the best way to patch the hole short of cutting out all the rusted metal and welding in a new piece?
 
You've got to kill the rust, or it will keep right on rusting under whatever you put on top. Remove as much as you can with a wire brush or whatever; then use a chemical to kill the remaining rust. I've had good luck with phosphoric acid products (like "Naval jelly"), and the spray-on "rust converter" products (eg Rustoleum "Rust Converter"). Others like POR-15 and Eastwood's Corroless, but I've not tried them.

There are probably better methods, but I like using fiberglass cloth (woven, not mat) combined with either fiberglass resin or JB Weld. For a hole that big, you'll need to support it somehow while it hardens, but the support can be as simple as that piece of metal held with masking tape. If you want to remove it later, put a piece of plastic (eg Saran Wrap) between it and the epoxy. The glass cloth tends to come apart while it's wet, so I usually lay down a good layer of epoxy on the metal, then lay the dry cloth over the top and press down until the epoxy oozes through. Let that dry and then you can go back and file away any excess or add more, etc.

Rubber gloves & a mask are probably a good idea; but I don't usually bother for little jobs like this. JB Weld will wash off with water, if you get to it before it starts to set. Otherwise, it will eventually wear off :smile:
 
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