After taking an even closer look at Rogers work, I have questions. For instant where the panel meets the pinch weld there are (2) offsets. Because of the proximity to the outer panel, what tool would be used to make that cut cleanly without punching through? I suppose it would have to be a small diameter cut-off wheel attached to a die-grinder? Even then I wouldn't feel comfortable.
Sorry it's taken me so long to respond guys. Been out of pocket.
I think the best way to answer your question is for me to provide more detailed photos of the process I used. I'll provide the full-sized photo links.
So here's that initial photo with the lines that show where I decided to make the cuts. Turned out to be a good decision. I used a Harbor Freight spot weld drill bit on the spot welds. Worked very well. An air cut-off tool with a 3" wheel for the sides. Word of warning. Do not use Harbor Freight cut-off wheels. They are junk. I buy American made ones from Roarke Supply. HF air cut-off tools work OK, just don't use their wheels.
https://www.hotrodders.com/gallery/data/4787/IMG_2167.JPGHere's what I had when opened up:
https://www.hotrodders.com/gallery/data/4787/IMG_21722.JPGhttps://www.hotrodders.com/gallery/data/4787/IMG_21741.JPGhttps://www.hotrodders.com/gallery/data/4787/IMG_21823.JPGAfter blasting. None of the areas or spots were thin enough to warrant any repair.
https://www.hotrodders.com/gallery/data/4787/IMG_53922.JPGBrushed on SPI gray epoxy primer:
https://www.hotrodders.com/gallery/data/4787/IMG_54371.JPGNow on to the repair of the removed panel. Here is the underside after removal:
https://www.hotrodders.com/gallery/data/4787/IMG_21772.JPGAfter blasting and the start of welding the holes and thin spots. I used 2 vice clamps and a strip of copper for backing up. Had to be moved a several times in the process but worked well and didn't take all that long to accomplish.
https://www.hotrodders.com/gallery/data/4787/IMG_53841.JPGhttps://www.hotrodders.com/gallery/data/4787/IMG_54071.JPGhttps://www.hotrodders.com/gallery/data/4787/IMG_5415.JPGAfter smoothing with an 80 grit Roloc:
https://www.hotrodders.com/gallery/data/4787/IMG_54201.JPGhttps://www.hotrodders.com/gallery/data/4787/IMG_54241.JPGAfter a session in the blasting cabinet:
https://www.hotrodders.com/gallery/data/4787/IMG_54291.JPGhttps://www.hotrodders.com/gallery/data/4787/IMG_54281.JPGBrushed on SPI gray epoxy primer to the underside:
https://www.hotrodders.com/gallery/data/4787/IMG_54331.JPGWelding panel back in place. Plug welded where the drilled out spot welds were and the sides butt welded.
https://www.hotrodders.com/gallery/data/4787/IMG_54531.JPGSmoothed out with an 80 grit Roloc. A cleanup with a little blasting and the area is ready for primer.
https://www.hotrodders.com/gallery/data/4787/IMG_54561.JPGOne more thing I did afterwards is load a brush of SPI epoxy primer up, and let it drip epoxy down into the bottom to seal the welds on the inside.
