BUILD THREAD JRP's '87 Regal Thread

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Okay, got some actual work done today. Ran over to Harbor Freight and bought an angle die grinder, a 5 inch air sander, some roloc arbors, a bunch of sanding discs and some new brass air line fittings. I was gonna buy a new hose but I had already spent $100 just on that crap, so i held off. Here is the die grinder I got-

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The grinder itself is nice but the HF discs suck. I need to get some actual 3M green corps discs. The HF arbor is okay.

Got home, changed out the fittings, set up the new die grinder and went to work on the firewall. I got a lot of it stripped down, I still probably have another couple hours, which translates to another day or two. The compressor did okay, it kept up with the die grinder though it ran almost continuously. But I never ran out of air and I was running it at 75ish PSI without a lot of breaks. I was getting some water out of it, so it definitely needs a filter.

I was able to remove a lot of the really nasty old seam sealer and factory GM snot that they slopped everywhere. For whatever reason the upper left hand corner especially around the brake booster and wiper motor areas is really deeply pitted and rusty. I'm just gonna have to handle that as best as I can. I haven't figured out how I can get up under the cowl area, and I don't think GM ever figured it out either because there is hardly any paint under there. Its pretty ugly around there.

I also scraped a bunch of paint off from the underside. I think I gonna do this in 3 or 4 sections- firewall, floor from the firewall to the rear seat crossmember, and then floor from the crossmember to the back of the car. I may remove the rear axle to do the last section, not sure yet, I'll see how it plays out. Anyways, here's what I got done today-

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Not in the winter!!!!

I've had really good luck with the PVC/Rubber hybrid hoses. They are usually green but I've seen them in other colors. They are really light and flexible. This is the one HF has-

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This is the primer I want to use for the firewall. This is what is underneath the rest of the car and also what is underneath my truck. It's a lot easier than using epoxy and then going back and spraying a urethane primer surfacer over top. It's really high build, it sands easily, it has some anti-corrosive properties, and it plays nice with pretty much any top coat you put on it.

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Interesting, didn't know they had an Autobody division, just thought they were transmission related.
 
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Got a little more done today, I would've liked to have done more but there just isn't enough time in a day. First I had to get my propane bottle refilled so I wasn't working in the cold. After that I got back and heated up the garage. Then I picked up with the die grinder where I left off. I mostly worked on the drivers side, and definitely found some ugliness.

That doesn't look like factory seam sealer-

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Ah, I was right! Don't think that was factory-

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I've owned this car for almost 8 years and I'm still finding surprises. Fawk! I don't think I've ever seen another one rusted in this spot. Not sure how I'm gonna handle this. The correct way is probably to drill out the spot welds for the wiper motor brackets then cut out the rust and weld in a piece cut from another car. That would mean drilling and welding into my paint. Grr....
It would be in the door jamb where it would be unlikely to ever be seen once the fender is on, but it still sucks. I'm open to suggestions on it.

Then again hey, it's a project and I'm at least working on it. It's not too bad working on it with heat and good lighting and a decent compressor. The compressor did well again today, it ran pretty much nonstop as before, but it kept up. I definitely need a water filter though. Also Home Depot sells a retractable hose reel with a hybrid hose for $71.xx. Best deal I've found so far. Probably my next purchase.

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Here's some other pictures from today-

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Got rid of that tab above the brake booster. Still not sure how to get all that shitt under the cowl without the cowl coming off.
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Spot blaster, scrap metal, tin snips, AutoMix, mud, sand, paint. Seriously, it'll be fine for the next 30 years. It's not a structural piece and not likely to see much, if any, moisture for as long as you own the car.
 
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Spot blaster, scrap metal, tin snips, AutoMix, mud, sand, paint. Seriously, it'll be fine for the next 30 years. It's not a structural piece and not likely to see much, if any, moisture for as long as you own the car.


I know you're right. My brain just doesn't want to think that way. I just need to sleep on it and see if I think of anything else.

I'm guessing whoever had the car before me slapped that filler in there because water was probably puddling inside the car. I guess it worked for them. I'm actually kind of surprised, it was a relatively high quality repair in comparison to some of the other hackjobs I've found on this car.
 
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