The back window area is real bad, the supports on the under side are bad also I’ll have to make new ones lucky they are just bent flat stock, I had gotten this panel from Don quite a while ago, hope to have it done this weekend and move on to the quarter panels.
Forgot photo
Managed to patch the package tray corner pieces together, cleaned off the un- wanted pieces on the lower window panel , I’m going to steal a page from Royce’s play book and submerse the whole penal in evapo rust because you just can’t get to the inside areas , I also soaked the corner pieces with the spot welded pieces it gets right in there, washed and painted,
Whew! Thanks for going to the time and expense to save an important Cougar.
- Phillip
Thanks Phillip, the lower window panel is taking longer than I thought which will probably be the case with all of it
Quite a project Randy. Let me know if you need an extra set of hands.
Thanks Al- John but I should be all set.
Stripping the paint before blasting and dipping I believe I count 7 layers of paint , unbelievable.
Finally got the panel in, this was a serious pain in the A”.a before and after .
Got the one 1/4 off , I kept some internal pieces from one i parted out so I can replace the rusted pieces with the good ones, unfortunately I didn’t keep the rear of the inner sail panel so ill have to fabricate it . My original plan to install the roof has changed a couple of times due to getting it apart and seeing how the pieces are layered, the complication is the top of the 1/4 panel gets welded first to the horizontal structure then the roof but the horizontal structure has to remain with the roof section as it’s part of the roof structure, I think I will put some half moon cuts on the roof flange that will allow me to weld the 1/4 panel through a pre drill hole to the horizontal structure then welded the roof to 1/4 I believe it’ll work, doing the lower window panel first gives a target point.
I got out the 1/4 panel patch’s , the lines aren’t as crisp as the originals and the 1/4 s are good except a small area so I’m going to cut out just a small section below the body line and patch .
It’s hard to believe how much was just gone and the wheel well is almost perfect?
Respect one that does this job outside!
I have a two and a half car garage but it’s not mine by my self it’s the family’s and I couldn’t possibly do weld in side so that part has to be outside.
Thats why ya kick the family out! I tell my wife thats why I got her car with remote start so I can have the garage (FYI doesnt work and she still gets a garage spot 
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I do agree on grinding and welding outside the garage tho. it keeps the mess down. I used to do all the major cutting, grinding and welding in the driveway rather then inside the garage.
Had to make the lower piece of the wheel well after doing some practice welding I believe I’m ready.
Got the pieces for repair cut out of the other quarter and got them ready to weld in.these pieces were just about gone.
Welded on the internal support pieces and fixed the door jam in two spots, test fitted the 1/4 to make sure things are lining up which they are, while it’s in place I’ll spot on the lower part of the wheel house and work on the lower corner of the rear glass.
You’re working hard on securing your ECI status. Keep up the good work.
That’s persistence at work!