PROJECT " LAID BACK 2 " - 1978 SALON 2 DOOR AEROBACK

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Welding aluminum sheetmetal is not an easy task to master. I actually got I-CAR tested/certified for aluminum MIG just so the shop I work at could meet State Farm's requirements to stay on their DRP program.


It's a totally different ballgame than steel MIG work

Surely you can find a hood without spear...I mean, unobtanium seems to find you pretty often! 👍:banana:
And just so everyone knows... I have YOU to thank for this 🤣. Challenge accepted.
 
My rear axle is already done. I dropped it off Thursday at 5pm, and 48 hours later... Done! I'l pick it up on my day off, Thursday.

I also got the engine harness, and headlight harness restored today. I cleaned each wire by hand, using WD-40, and CRC Electrical cleaner. Cleaned all the connectors with a toothbrush. Then installed new convoluted tubing/conduit/wire loom, whatever YOU call it. I forgot my camera at home, but I will get some pics posted. They turned out good. Next up... tail light harness.
 
If you use the 442 grilles and don't want the stockers, I will buy them.

I filled the holes in my aluminum hood by gluing in patches with panel bond adhesive.
While it is extremely difficult, if you know where to look you can see the holes...
But considering what I had to work with, I'm happy with the result.
 
James, I’m with RibbedRoof on this one. I’d stay away from tampering with trying to weld or close up the holes in that aluminum hood unless you or someone extremely knowledgeable that knows exactly what they’re doing does it. Too many ways for things to go sideways on you, and it may be unrepairable afterwards.
Not worth the risk IMO.
Maybe consider doing like I am with Olds Cool and keep the hood spear, but fill the ornament hole(s) and replace the ornament with a section of second hood spear cut down and shaped to match?
Just a thought.

Here’s how mine looks for reference, minus the hole underneath it of course.

D804D61D-FDC8-4CBB-8B48-26DF5722B05E.jpeg

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D.
 
Thank you Donovan! That's what I needed to see. I can live with that. I knew I had seen it done, I just couldn't remember where to look. Now tell me more about making this spear "tip", please. OR can I read about it in your build thread? Link to the page(s).
 
Thank you Donovan! That's what I needed to see. I can live with that. I knew I had seen it done, I just couldn't remember where to look. Now tell me more about making this spear "tip", please. OR can I read about it in your build thread? Link to the page(s).

No problem my friend, happy to suggest it.
Unfortunately I didn’t cover the modification in the build thread, but it was pretty simple. I had a spare hood laying around at the time, so I just removed the center spear from it.
I had originally planned on just cutting the back section off where it’s already tapered and finished, but the height of that section is considerably shorter than where it needs to match up to the hood piece.

So instead, I cut the section from the front of it, spun it around so that the factory “finished” end met up with the hood piece, then cut to length. The curvature will be slightly different, but if you’re careful, you can put a slight bend into it over your knee until it matches the header panel without breaking anything.

From there once it was the right length and curvature, I did some creative grinding of the front until it looked like something the factory would’ve done. Once the desired shape is achieved, you will have a hollow in the middle because the trim is hollow inside and not solid. This is actually a good thing, because it allows you to pinch the ends together to form the “point”. A tiny little bit of JB Weld to fill in the remaining gap, a bit of sanding and a touch of silver paint, and it was done. It sounds labor intensive, but it really only took me about an hour start to finish.

Here’s about the closest picture I have of it currently, I’m painting both my pieces for aesthetic reasons, but it’s not really necessary if you have decent pieces to start out with. I just have to add my brushed texture to it before installing, and that will be done with 3M double sided tape again like before.
DF1A9359-4411-4DA4-81FC-ABABF1D0AD13.jpeg


At the bottom of the picture is the “point” I created, but you can really make it look however you want.
Hope this helps, and sorry for the long-winded thread jack.
 
If the hood was steel , I wouldn't think twice. I have never welded aluminum... just buy the correct aluminum wire for the welder, or maybe use fiberglass to fill the holes?? Maybe Donovan will chime in on this.
I forgot that it's an aluminum hood.
 
If you use the 442 grilles and don't want the stockers, I will buy them.

I filled the holes in my aluminum hood by gluing in patches with panel bond adhesive.
While it is extremely difficult, if you know where to look you can see the holes...
But considering what I had to work with, I'm happy with the result.
I'll keep that in mind, Blake. Right now, I'm going to keep everything until I'm done with the car, and satisfied.
 
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