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#1
11-19-2006, 09:01 PM
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I also used the welder to recreate the missing broken sections by gradually building up material until it replicated the original contours. This took about three hours today to get the rough shape of the broken sections.
Before: Last edited by njsteve; 11-19-2006 at 09:15 PM. |
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#2
11-19-2006, 09:16 PM
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After:
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#3
11-19-2006, 09:18 PM
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Before:
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#4
11-19-2006, 09:20 PM
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And After:
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#5
11-23-2006, 12:28 PM
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It's Thanksgiving so I'm hiding downstairs since my wife threw me out of the kitchen. Here are the reproduced sections after more welding, filing and sanding:
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#6
11-23-2006, 12:28 PM
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And here's the last stage of the broken face bar's repair. The uneven area underneath is actually the factory clearance cut out for the mounting bolt:
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#7
11-23-2006, 12:29 PM
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Here are the two edge sections. Both were heavily cracked due to the fact that factory molding process injected very little plastic on the ends of the panel. The main area of the valance is about 3/8" thick while the outer edges are only about 1/16" thick. I had to reproduce a missing section from one end as evidenced by the different color of the polyurethane material in the second photo. I also heavily back-filled the thin areas around the edge so now they're about 1/2" thick:
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