The Cage is welded in.

After some cursing, cramping, and contorting the cage is now welded in. Also, I have about half of the gussets in place. The gussets are simple to fit, basically a little time with the grinder and they are ready to go. Tack weld them once the fit, then come back and finish weld them in.

I have finished welding in 12 gussets and the car is back on its own wheels.

Merry Christmas, and the cage is almost done

Yesterday I was able to weld in most of the cage. I took a couple breaks throughout the day so I probably could have got it done yesterday. I have to weld the dash bar, roof diagonal, and the 1.5 of the firewall tubes to the firewall.

I will finish up tomorrow AM and post some photos.

So, as this portion of the project comes to a close I have been reviewing my previous schedule and realise that I am way behind schedule. I am regrouping on what to do next. Now that the portion that I feared most is coming to an end, its nice to see that some projects that I am comfortable with are coming up next.

Once the car is back on the ground, I will be starting the suspension, brakes, steering, etc.

After that will be engine maintenance, etc.

Once this is done we will be painting the interior. It may actually happen before. I will see how the weather cooperates.

More progress

I worked on finishing up the roof diagonal. I also welded underneath the compound joint on the diagonal. This simple task has turned into a major PITA. I had all kinds of problems welding today. Despite preheating, cleaning with a wire brush, acetone, etc, etc. I was getting porous welds. Not everywhere, just in certain positions, mainly on the verticals and occasionally on the overheads.

Not having my certified welder neighbor at hand today, I ran through the troubleshooting process.

-Is it me? No gun position was good, stickout was good.

-Is the current appropriate? I tested back and forth and found that the current was appropriate.

-Wire feed? once again after testing it proved to be appropriate

-Sheilding gas. There was still gas in the tank. Gas is flowing out the nozzle. The nozzle is clean and free from obstruction. Is the flow too high or too low? Tested the too high theory and found it made the problem worse. So I tested the too low theory, BINGO! That was the problem. The setting is much higher than I had anticipated would be required. Regardless, this is apparently the setting that is needed.

I am not sure if the cold air exacerbated the issue or not. I am also running low on gas so this could also have something to do with my issues today. I was also running the heater which I am sure introduced some draft to the area in which I was welding.

I then spent the rest of the time grinding out the bad welds and laying good weld. At this rate, it will be done next June, but hopefully with my new settings, I will be able to move along a little quicker.

After welding underneath, I realized that I now need to refit the joint. I have yet to do that, I needed to shower to get to dinner and then work afterward. Also the weld on the rear down tube looks much nicer in person, the flash seems to exaggerate the shape of it. It is much flatter and much less globular in person.

This is the SOB that was giving me fits today. Basically where it is covered by the tube continually would develop a porous weld. Ugh. Obviously the diagonal tube was not there when I was welding.

The cage is back in the car.

The cage is back in the car

I got the cage back in the car today. I have everything thoroughly tacked in, the outsides which are inaccessible when in the car, have been welded while outside of the car. I am working on fitting the roof diagonal. After this it will be time to finish weld.

As usual, I will get some photos up tomorrow.

Photos

Here are photos from the progress made yesterday. Very exciting progress. Regardless, still alot of work to go. Hopefully, I will find an evening this week to get the welding done, then refit and finish weld this upcoming weekend.

I may do some cleanup while all of the halves are out of the car. It will be much easier to do so while I can freely access the car. All of the dark gray dirt looking stuff are metal shavings. Ugh, a nightmare to clean up.

Right hand cage half.

Left hand cage half.

Door bars in...

I have fitted all of the door bars, cross bars, etc. I have now removed the cage halves for welding the sections that I cannot access in the car. I have a bit of a headache today so, I will not be finishing it up tonight. I will snap some photos tomorrow. Again, I hope to have the cage finished up within the week.

Parts have arrived

The upper door bar has arrived, now I just need to install it. I hope to have some time later this week. I could, in theory, have the cage wrapped up in a week or so. I am just running 2 months behind, but I am glad it will be done right.