Unwelcome rust

Yes, a mig set at fairly low amperage. Thanks for the suggestion about the engine ECU; I have already disconnected the (-) battery terminal, but pulling the plug on the engine ECU (where's the plug, BTW?) certainly wouldn't hurt.

 

Both really helpful suggestions -- thank you!
Guido's suggestion assumes that the zinc primer will still retain its anti-corrosion properties after being subjected to intense heat, no?
The two holes suggestion can work if epoxy primer (which I've ordered but have never used) is fluid enough to spread out to cover the area (a couple of square inches) before the hardener kicks in. I would have thought epoxy would be to viscous, but in primer form might indeed work.

 

The project is well under way. I have all the new metal welded into place. Since I'm tack welding everything, and I'm using low voltage in alot of places to avoid blowing holes through the ultra delicate Ferrari steel, I have a bunch of "pinholes" -- visible only when you shine a light from behind -- that need to be filled. This has been a helluva job, with a steep learning curve for me, this being my first experience with mig welding.
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Hi guys,
Officially done with this project. What a bear.

Today was planning to go for a drive, but I found the battery died. I'm hoping putting it on a trickle charge will be all it takes. But it really shouldn't have drained b/c I had disconnected the neg battery cable for the welding (and turned off the battery shut-off switch for good measure). The only thing I can think of is that in the two weeks or so before I disconnected the battery but the car wasn't driven the open bonnets (engine bay and trunk) caused the drain. But there is no light in the engine bay, and I had disconnected the cable to the trunk electrics when I removed the trunk lid.

 

I pulled only the negative line (the one closest to the shut off); as well as the shut-off switch itself. I also disconnected the engine ECU and of course the cat ECU in the trunk. I thought I had the electrical covered -- they say the negative terminal is the one that matters; nothing I read mentioned removing the lead from the positive terminal as well, although in retrospect it wouldn't have hurt. I'd be surprised if I fried/damaged anything -- it simply has all the symptoms of a discharged battery. Lights and accessories worked, but there wasn't any power to crank; then there was nothing.

 

Ah, iI think it was the battery shut off switch. You flip it on, but the contact is as firm as it should be. Another project ...

 

Thanks, Doug. I painted it myself b/c none of this is visible, from either the inside or the outside. So I just put three coats of epoxy primer to protect against rust, followed by a coat of metallic silver. Actually, the picture you see is the final product, before I attached the bumper.

BTW, did you find a Mondial yet?

 

There was no stainless used in this project -- just regular steel. Apart from the concern you mention, welding stainless, as I understand, requires a special shielding gas mixture and advanced welding skills.