Technical Assessing rust - floor panels

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Technical Assessing rust - floor panels

Wanted to add, it may or may not fit in a dryer, that method works best on motorcycle tanks, but anything to shake it up and agitate it with something Inside to scrape around...I've heard not to use Chain as it can get stuck inside...check out YouTube for ideas...
Thanks a bunch, Terry - I have an motorcycle I resurrected that underwent some of this - cleaning with vinegar / water solution + dawn; fistful of nuts and bolts thrown in to shake around, then recoat the inside. I think I’ll go ahead and take it out and see about that scope….
 
Some of these 124 fuel tanks have internal baffles so can be difficult to properly clean out or to fully check out internally, even using an inspection camera (borescope). But I'd certainly have a go at cleaning it out, it doesn't look too bad in your photo, but I'd be more concerned about the internal condition.

The fuel gauge sending unit/fuel pick-up pipe can be removed from the tank, 6 small (7?mm wrench), nuts - I'd strongly advise soaking these nuts with penetrating oil for a while before trying to remove them - they have been known to shear-off.

With the tank gauge sender unit removed, don't forget to check out the often overlooked fine-mesh filter-sock on the end of the fuel pick-up pipe, this gauze filter can become blocked, so worth cleaning before refitting to the tank.

However, before expending time and money trying to the old tank, are you aware that new fuel (gas) tanks are available at reasonable cost e.g. vickauto.com list them at $174; autoricambi.us list various types at $220 - $250 - make sure you order the correct one for your car, some have internal baffles, some don't, also different for carb vs F.I models. Also worth fitting a new filler neck hose (ethanol-resistant rubber) if it hasn't been changed recently, I'd probably also get a new tank-body sealing tape $12.
 
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Well - I took the passenger door off and related trim, pulled carpet bits and sub padding and here’s what we’ve got. And you were right Slotman, the layer of what I guess is fiberglass. Removing that revealed holes. I guess my question now is whether the floor panels I can buy will cover everything that had to go. The rockers look good as well as the center tunnel.
Looking at your pics, I was going to suggest not fitting new floor panels (which is a lotta lotta work!) but instead to do some more cleaning of the floor and then see if it might be repaired by patching (a lot less work). I usually use an air powered needle descaler (which will punch through any weak areas) and a twisted or knotted wire type cup brush on an angle grinder (so higher speed than a wire brush on a drill ) for rust removal, but can be quite aggressive.
In your 1st pic, :-

screenshot-1738374279984.png


The area I've arrowed in red is one of the safety important areas I mentioned earlier, this is where one of the rear axle trailing (locating) arms is connected under the car (the rounded bolt head you can see is one of the threaded studs- there are 4 of them, that extend through the floor) - I'd try to avoid disturbing this and would likely opt to just weld in a home fabricated angle strip to repair the rear of the floor panel and reinforce this axle link mounting - iirc, the other part of this axle mounting panel is under that large box crossmember that supports the rear seat and this would have to be removed to replace the rear floor panel and repair this axle link mounting.

In your 2nd pic, :-

IMG_7602.jpeg


I'd do some more cleaning and see if the section of the floor I've outlined in red could be repaired by welding in a homemade repair section rather than fitting a new front floor panel (which is also a lot of work) - this would avoid disturbing the under floor reinforcement sections and getting involved with repairing or fitting the various seat support/mounting sections. The underneath of the floor doesn't look too bad, but of course, the undercoating could be hiding a multitude of sins.

I'd be tempted also (and I know this is not recommended) to not cut out all the rot, just clean down aggressively as described above) treat the remaining corrosion and paint over with a long lasting paint (SmoothRite or similar), also paint the underneath of the repair section, then overlap the two, prepare the edges and weld in place. If the edges of the remaining floor panels are badly rusted, I think I'd just weld a small homemade angle section to bridge the rusted section, linking good metal to good metal. When all is said and done, who cares or is even going to notice - the inside will be hidden by the carpet, the underneath presumably by undercoating of your choice and as long as it's a solid and safe repair, why not? I'd be more concerned about the quality of the welding that has been carried out - many of the repairs I've seen performed using a MIG welder are just blobs of metal stuck to one or hopefully? both panels. (i.e. inadequate penetration).

I'm aware that fitting new floor panels would be the best way, But I've BTDT several times and regretted (usually in the middle of what I'd just gotten myself into) having not instead opted for a less intrusive, easier approach to the repairs. Had I kept it simpler, the cars would have been back in use much, much sooner, at less cost and far less expenditure of time and effort on my part. I'm just trying to save you time, money, effort and likely frustration or feeling overwhelmed later on. At the end of the resto, who cares as long as you're happy with it.

I'd caution against ordering/buying any panels or any other parts until you've fully assessed and costed what is going to be required to finish the rebuild - you haven't mentioned what the rest of the car is like, outer bodywork, mechanicals, electricals ,trim etc. and this total estimated cost (the final cost is always much higher) needs to be compared with what the car would fetch when finished and also with what a similar car in v. good condition could be bought for at present.

I've done full rebuilds on cars, it was always much more work than I initially thought, much more time, a lot more money and end result - ended up by selling the cars for less than I had spent and nothing for 1000 - 1500 hours of my time. It took me a while to learn that sometimes it would have been cheaper to scrap/dispose of the car after I had stripped it down and before I started work/bought any parts, a lot cheaper and less effort/time.
 
124BC1 thanks for this info! All I had seen are the super expensive ones on ebay....
I've posted these parts suppliers in the U.S. before :-

 
Back at it today: I’m clear that front and rear floor pans need to be replaced. I think I can salvage the seat supports (will need to do a little patching).

The tear-down continues; first look at the rear brakes - looks like someone put new calipers on. Also looks like an elec fuel pump retrofit?? Also am curious if you fine folk think I should replace the fuel tank. It has been sitting for a couple of years.
View attachment 459555

View attachment 459556
Some observations:-

1st things first, that car is not safely supported... jackstands are at the top of their adjustment and poorly positioned, plus front wheels are on wheel dollies (I know they usually have castor wheel locks) but if someone bumped the front of the car, it might swing to one side causing it to fall off the jackstands. Where the rear stands are located under the axle is not secure/safe due to the shape of the axle link ends.

Imho, the safe way to support the car is under the rear axle tubes (which will lower the height using the current stands) or get some taller stands, ideally 4 of them to raise and support the car horizontally (place the front pair under the frame rails unless they're rusted), don't uses the wheel dollies when the rear of the car is raised on stands, remove the dollies and chock the front wheels.
One tip I learned on day 1 in a professional workshop :- after you've placed the car on 4 jackstands, give the car a good shake - if it moves or wobbles, it's not safe enough to go under, so reposition/readjust the stands and shake again until the car is secure - remember that you may be pulling or shaking things quite energetically while under the car. Never, ever, go under a car relying only on the jack (regardless of type) even for 'just a second', always use a stand or, if no stand is available, place a wheel or 2 (if enough room) with some timber/boards on top to support the car.

Rear brakes will need to be stripped down, cleaned, de-rusted having been standing for so long. The front 1/4 part of the brake shield (covers the caliper and completes the circle of the shield) is missing (the mounting bolts appear to be sheared off in the main backing plate (but this 1/4 section is not really needed, wouldn't worry about it). And what do I see hanging down over the rear axle- surely that not's a fuel hose?

Fuel tank - hard to tell whether it can be saved, would need to be removed for checking. cleaning etc. What is that shiny section on the tank to the left of the filler neck protection panel - is it paint or a previous solder repair? attempt that is falling away?

Fuel pump - not a safe installation, hoses need to be moved away from suspension arms/axle and wiring needs to be made safe, especially what might be a live blue? wire hanging down. I wonder why the fuel pump wasn't installed in the trunk beside the fuel tank?

The front section of the exhaust system doesn't appear to be routed correctly - iirc, the front pipe should run close to the transmission and be attached/supported by a bracket that is attached at the rear of the transmission tailhousing.
 
Wanted to add, it may or may not fit in a dryer, that method works best on motorcycle tanks, but anything to shake it up and agitate it with something Inside to scrape around...I've heard not to use Chain as it can get stuck inside...check out YouTube for ideas...
I've heard the suggestion of wrapping the tank in a blanket, strap or wedge it in place inside a concrete mixer and switch on. :unsure:
Or, I wonder if the tank could be attached to one of those paint mixing machines in diy stores and given a shake? :unsure:
 
Some of these 124 fuel tanks have internal baffles so can be difficult to properly clean out or to fully check out internally, even using an inspection camera (borescope). But I'd certainly have a go at cleaning it out, it doesn't look too bad in your photo, but I'd be more concerned about the internal condition.

The fuel gauge sending unit/fuel pick-up pipe can be removed from the tank, 6 small (7?mm wrench), nuts - I'd strongly advise soaking these nuts with penetrating oil for a while before trying to remove them - they have been known to shear-off.

With the tank gauge sender unit removed, don't forget to check out the often overlooked fine-mesh filter-sock on the end of the fuel pick-up pipe, this gauze filter can become blocked, so worth cleaning before refitting to the tank.

However, before expending time and money trying to the old tank, are you aware that new fuel (gas) tanks are available at reasonable cost e.g. vickauto.com list them at $174; autoricambi.us list various types at $220 - $250 - make sure you order the correct one for your car, some have internal baffles, some don't, also different for carb vs F.I models. Also worth fitting a new filler neck hose (ethanol-resistant rubber) if it hasn't been changed recently, I'd probably also get a new tank-body sealing tape $12.
Super helpful; I’ll get to the fuel tank this weekend. Will take pics and follow up.
 
Looking at your pics, I was going to suggest not fitting new floor panels (which is a lotta lotta work!) but instead to do some more cleaning of the floor and then see if it might be repaired by patching (a lot less work). I usually use an air powered needle descaler (which will punch through any weak areas) and a twisted or knotted wire type cup brush on an angle grinder (so higher speed than a wire brush on a drill ) for rust removal, but can be quite aggressive.
In your 1st pic, :-

View attachment 459730

The area I've arrowed in red is one of the safety important areas I mentioned earlier, this is where one of the rear axle trailing (locating) arms is connected under the car (the rounded bolt head you can see is one of the threaded studs- there are 4 of them, that extend through the floor) - I'd try to avoid disturbing this and would likely opt to just weld in a home fabricated angle strip to repair the rear of the floor panel and reinforce this axle link mounting - iirc, the other part of this axle mounting panel is under that large box crossmember that supports the rear seat and this would have to be removed to replace the rear floor panel and repair this axle link mounting.

In your 2nd pic, :-

View attachment 459731

I'd do some more cleaning and see if the section of the floor I've outlined in red could be repaired by welding in a homemade repair section rather than fitting a new front floor panel (which is also a lot of work) - this would avoid disturbing the under floor reinforcement sections and getting involved with repairing or fitting the various seat support/mounting sections. The underneath of the floor doesn't look too bad, but of course, the undercoating could be hiding a multitude of sins.

I'd be tempted also (and I know this is not recommended) to not cut out all the rot, just clean down aggressively as described above) treat the remaining corrosion and paint over with a long lasting paint (SmoothRite or similar), also paint the underneath of the repair section, then overlap the two, prepare the edges and weld in place. If the edges of the remaining floor panels are badly rusted, I think I'd just weld a small homemade angle section to bridge the rusted section, linking good metal to good metal. When all is said and done, who cares or is even going to notice - the inside will be hidden by the carpet, the underneath presumably by undercoating of your choice and as long as it's a solid and safe repair, why not? I'd be more concerned about the quality of the welding that has been carried out - many of the repairs I've seen performed using a MIG welder are just blobs of metal stuck to one or hopefully? both panels. (i.e. inadequate penetration).

I'm aware that fitting new floor panels would be the best way, But I've BTDT several times and regretted (usually in the middle of what I'd just gotten myself into) having not instead opted for a less intrusive, easier approach to the repairs. Had I kept it simpler, the cars would have been back in use much, much sooner, at less cost and far less expenditure of time and effort on my part. I'm just trying to save you time, money, effort and likely frustration or feeling overwhelmed later on. At the end of the resto, who cares as long as you're happy with it.

I'd caution against ordering/buying any panels or any other parts until you've fully assessed and costed what is going to be required to finish the rebuild - you haven't mentioned what the rest of the car is like, outer bodywork, mechanicals, electricals ,trim etc. and this total estimated cost (the final cost is always much higher) needs to be compared with what the car would fetch when finished and also with what a similar car in v. good condition could be bought for at present.

I've done full rebuilds on cars, it was always much more work than I initially thought, much more time, a lot more money and end result - ended up by selling the cars for less than I had spent and nothing for 1000 - 1500 hours of my time. It took me a while to learn that sometimes it would have been cheaper to scrap/dispose of the car after I had stripped it down and before I started work/bought any parts, a lot cheaper and less effort/time.
Thanks again for your terrific advice: a few comments:
- I’ll go at the rusty bits with a sander head on the angle grinder and see what I can get to. I *love* the idea of not doing full pans if I can manage patching.
- I have a spreadsheet going on costs. My wife is very good at emphasizing that :)
- what gauge metal would you suggest? I’ve seen 18 and 20 suggested elsewhere…
- the trailing arms both are bent a tiny bit (really a dent) where someone jacked the car from them
- electricals are all there but will need full diagnostic whenever I get things back together
- I’m considering pulling the engine as I was told that there is a “cracked head” - but suspect maybe blown head gasket. I would feel better about it if I could get all the way into it. Some suggest pulling engine only, others engine and trans together. Your thoughts on that ?
- I’m considering trailering the body to a proper body shop to take care of the outer bits and give it a paint job - budget will tell though
- I’ll have to fix the front seats and do something about the ripped rear plastic window on the rag top. And I’ll have to straighten out the heat levers by the parking brake (all bent up)
- one bumper piston on each end of the car has been depressed a couple of inches. I need to remove the bumpers and see if those can be returned to full extension

Hmmm… that’s all that’s on the current list!
 
You'll save yourself a lot of time and aggravation (and money:)) if you can repair rather than replace the floor panels but of course you won't know if this is doable until you can clearly see the extent of the rust damage. Cleaning back is a very dirty job, please remember to wear appropriate protection, heavy gloves, safety goggles or visor, and a dust mask as a minimum. Those power operated wire brushes can throw metal wires at high speed in all directions, jagged metal can give a nasty gash and you don't want rusty metal dust in your lungs - also, if applicable, it's advisable to keep children and pets away from the work (they don't understand the dangers), and sweep up at the end of work so no-one walks on metal shards.

A Spreadsheet is a good idea, so easy to overlook items of expenditure otherwise. Have you set a maximum budget for the entire job - I've found that doing this stops me spending too freely in the early stages which could cause me to run over budget towards the end. I often use the criteria of - 'can this part be repaired/rejuvenated/refinished'? i.e. can I make it fit for re-use or do I absolutely have to buy a new one, lots of parts won't be seen when installed or in the case of cosmetic/trim items can be easily swapped out for new at a later date if it's condition/appearance bothers me. I'm sure your good wife will rein in any extravagant spending :)

I think either 18 or 20 gauge metal should be fine for the floor - any thickness is going to be better than what you have (or haven't?) in places at the moment. Iirc, the outer body panels are either 22 or 24 gauge and the floor panels are a little thicker, I wonder if there is any mention on the websites selling replacement panels of the metal thickness being used. Consider also that thinner gauge will be easier to bend/form to the required shape. I strongly recommend that you make paper/cardboard templates of any repair sections to be used and maybe even leave a little extra margin for final trimming/ adjusting in situ (this can save a lot of waste of metal).
 
You'll save yourself a lot of time and aggravation (and money:)) if you can repair rather than replace the floor panels but of course you won't know if this is doable until you can clearly see the extent of the rust damage. Cleaning back is a very dirty job, please remember to wear appropriate protection, heavy gloves, safety goggles or visor, and a dust mask as a minimum. Those power operated wire brushes can throw metal wires at high speed in all directions, jagged metal can give a nasty gash and you don't want rusty metal dust in your lungs - also, if applicable, it's advisable to keep children and pets away from the work (they don't understand the dangers), and sweep up at the end of work so no-one walks on metal shards.

A Spreadsheet is a good idea, so easy to overlook items of expenditure otherwise. Have you set a maximum budget for the entire job - I've found that doing this stops me spending too freely in the early stages which could cause me to run over budget towards the end. I often use the criteria of - 'can this part be repaired/rejuvenated/refinished'? i.e. can I make it fit for re-use or do I absolutely have to buy a new one, lots of parts won't be seen when installed or in the case of cosmetic/trim items can be easily swapped out for new at a later date if it's condition/appearance bothers me. I'm sure your good wife will rein in any extravagant spending :)

I think either 18 or 20 gauge metal should be fine for the floor - any thickness is going to be better than what you have (or haven't?) in places at the moment. Iirc, the outer body panels are either 22 or 24 gauge and the floor panels are a little thicker, I wonder if there is any mention on the websites selling replacement panels of the metal thickness being used. Consider also that thinner gauge will be easier to bend/form to the required shape. I strongly recommend that you make paper/cardboard templates of any repair sections to be used and maybe even leave a little extra margin for final trimming/ adjusting in situ (this can save a lot of waste of metal).
Thanks, sir - yes I’ll have my gear on AND I’m only going to do this outside of the tiny shed/shop I have under cover in nice weather.

And I was just thinking about the repair / restore vs buy question and keep that as my mantra. I spent probably too much on the car ($2400) and have $3500 available. More depending on our retirement situation - but won’t know that until a few months have passed. I would like to reserve a good chunk for a body/paint shop but don’t yet know if that is even doable with my current allocation.

First things first though…
 
Thought I would mention, went on the vic website and they have tanks, it says $174 but once you click on it the price goes to $204 plus $30 shipping .....still not bad, I'm considering purchasing one, I looked today at the inside renew kits and a kit delivered is about half that and there's all the messy work to do and the end result depending on the tank itself might not be worth it compared to bolting in a nice new one...
Terry
 
Thought I would mention, went on the vic website and they have tanks, it says $174 but once you click on it the price goes to $204 plus $30 shipping .....still not bad, I'm considering purchasing one, I looked today at the inside renew kits and a kit delivered is about half that and there's all the messy work to do and the end result depending on the tank itself might not be worth it compared to bolting in a nice new one...
Terry
I checked out this item again and the price jumped just like you experienced. It appears they're charging $30 as an oversized box fee and it's being shipped at the actual shipping rate not at the usual VAS discounted shipping scale. If you click on Local Pickup in Cleburne, Texas, the cost seems to revert to $174?
So, to save $30, all you have to do is collect it from Cleburne, Texas - is this far from you? :giggle:
 
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You'll save yourself a lot of time and aggravation (and money:)) if you can repair rather than replace the floor panels but of course you won't know if this is doable until you can clearly see the extent of the rust damage. Cleaning back is a very dirty job, please remember to wear appropriate protection, heavy gloves, safety goggles or visor, and a dust mask as a minimum. Those power operated wire brushes can throw metal wires at high speed in all directions, jagged metal can give a nasty gash and you don't want rusty metal dust in your lungs - also, if applicable, it's advisable to keep children and pets away from the work (they don't understand the dangers), and sweep up at the end of work so no-one walks on metal shards.

A Spreadsheet is a good idea, so easy to overlook items of expenditure otherwise. Have you set a maximum budget for the entire job - I've found that doing this stops me spending too freely in the early stages which could cause me to run over budget towards the end. I often use the criteria of - 'can this part be repaired/rejuvenated/refinished'? i.e. can I make it fit for re-use or do I absolutely have to buy a new one, lots of parts won't be seen when installed or in the case of cosmetic/trim items can be easily swapped out for new at a later date if it's condition/appearance bothers me. I'm sure your good wife will rein in any extravagant spending :)

I think either 18 or 20 gauge metal should be fine for the floor - any thickness is going to be better than what you have (or haven't?) in places at the moment. Iirc, the outer body panels are either 22 or 24 gauge and the floor panels are a little thicker, I wonder if there is any mention on the websites selling replacement panels of the metal thickness being used. Consider also that thinner gauge will be easier to bend/form to the required shape. I strongly recommend that you make paper/cardboard templates of any repair sections to be used and maybe even leave a little extra margin for final trimming/ adjusting in situ (this can save a lot of waste of metal).
Just following up on this - I have only found 16 gauge and then a jump to 22 and higher gauge steel available at local big box stores. I think I'll procure a piece of 22 and see how it feels and if it seems too flimsy, then I'll go to one of the steel fabricator shops in the area and see if they have any stock that would be in the 20 gauge range.
 
I checked out this item again and the price jumped just like you experienced. It appears they're charging $30 as an oversized box fee and it's being shipped at the actual shipping rate not at the usual VAS discounted shipping scale. If you click on Local Pickup in Cleburne, Texas, the cost seems to revert to $174?
So, to save $30, all you have to do is collect it from Cleburne, Texas - is this far from you? :)
Thanks for the info - I'll see if I can peek around in the existing tank and see what's up. $200 seems very reasonable for a new tank... And I'm a 2 day drive from most places in TX, so don't think I'll be doing that!
 
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- what gauge metal would you suggest? I’ve seen 18 and 20 suggested elsewhere…
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I did a bit of checking and found the following info on the thickness of the different gauges of sheet metal (I didn't know that U.S. sizes were very slightly different from those over here). I red-arrowed the U.S. sizes for the different gauges :-

Scan_20250202.png
Scan_20250202 (2).png


So 18 or (the thinner) 20 Gauge should be fine. There are sheet-metal gauges available - the type I've used was a flat metal plate with calibrated slots around the edges corresponding to the gauge size i.e. if the sheet metal fits into the slot, that's it's size. You could alternatively use a micro-meter or vernier calipers (if you happen to have either) to measure the thickness and look up that figure on the tables of figures I've posted, or just compare the metal thickness to the blades of a set of feeler gauges (as used for setting gaps -valve lash, points, plugs etc.) and make your best guess :giggle:

As regards a source of sheet metal, When I was starting out (a long time ago, and couldn't afford to buy full sheets of metal), I started by using the metal from old office filing cabinets or stationery storage cupboards, then I got the bright idea to go to the source ;), found an office equipment manufacturing company and asked (actually, I begged) if they had any scrap pieces of sheet metal that I could use to repair an old car. The foreman, no doubt thinking he was being funny, told me I could have as much as I could carry (I had arrived on a bicycle). So, I returned later with a pick-up truck and left with, as he had agreed, as much as I could carry .(I got the entire contents of a small dumpster...). :giggle:
See what I meant about not spending money unnecessarily... there's nearly always a cheaper, or even free way, to achieve the same end result, you just have to find a way.

So, as 'Slotman' suggested earlier, grab that welder and some scrap metal offcuts and start practising - maybe your neighbour who's gifting you a welder could show you the basics?
 
Just following up on this - I have only found 16 gauge and then a jump to 22 and higher gauge steel available at local big box stores. I think I'll procure a piece of 22 and see how it feels and if it seems too flimsy, then I'll go to one of the steel fabricator shops in the area and see if they have any stock that would be in the 20 gauge range.
!6 gauge can be somewhat difficult to cut, bend and shape, 22 is a lot easier - consider that if you can knock some recesses into it to mimic the original pressed swagings? used in the floor panels, the thinner metal will become a lot stiffer, plus when welded in place, it won't seem so flimsy anyway. Iirc, the outer panels, fenders etc. are only maybe 24 gauge and are fairly rigid when a few curves are included.
 
I did a bit of checking and found the following info on the thickness of the different gauges of sheet metal (I didn't know that U.S. sizes were very slightly different from those over here). I red-arrowed the U.S. sizes for the different gauges :-

View attachment 459936View attachment 459937

So 18 or (the thinner) 20 Gauge should be fine. There are sheet-metal gauges available - the type I've used was a flat metal plate with calibrated slots around the edges corresponding to the gauge size i.e. if the sheet metal fits into the slot, that's it's size. You could alternatively use a micro-meter or vernier calipers (if you happen to have either) to measure the thickness and look up that figure on the tables of figures I've posted, or just compare the metal thickness to the blades of a set of feeler gauges (as used for setting gaps -valve lash, points, plugs etc.) and make your best guess :giggle:

As regards a source of sheet metal, When I was starting out (a long time ago, and couldn't afford to buy full sheets of metal), I started by using the metal from old office filing cabinets or stationery storage cupboards, then I got the bright idea to go to the source ;), found an office equipment manufacturing company and asked (actually, I begged) if they had any scrap pieces of sheet metal that I could use to repair an old car. The foreman, no doubt thinking he was being funny, told me I could have as much as I could carry (I had arrived on a bicycle). So, I returned later with a pick-up truck and left with, as he had agreed, as much as I could carry .(I got the entire contents of a small dumpster...). :giggle:
See what I meant about not spending money unnecessarily... there's nearly always a cheaper, or even free way, to achieve the same end result, you just have to find a way.

So, as 'Slotman' suggested earlier, grab that welder and some scrap metal offcuts and start practising - maybe your neighbour who's gifting you a welder could show you the basics?
Love it. I have been to a place in a town nearby that I bet would have some scraps for me. Thanks for these words of encouragement !
 
- the trailing arms both are bent a tiny bit (really a dent) where someone jacked the car from them
- electricals are all there but will need full diagnostic whenever I get things back together
- I’m considering pulling the engine as I was told that there is a “cracked head” - but suspect maybe blown head gasket. I would feel better about it if I could get all the way into it. Some suggest pulling engine only, others engine and trans together. Your thoughts on that ?
- I’m considering trailering the body to a proper body shop to take care of the outer bits and give it a paint job - budget will tell though
- I’ll have to fix the front seats and do something about the ripped rear plastic window on the rag top. And I’ll have to straighten out the heat levers by the parking brake (all bent up)
- one bumper piston on each end of the car has been depressed a couple of inches. I need to remove the bumpers and see if those can be returned to full extension

Hmmm… that’s all that’s on the current list!
Now, to try to answer the above questions -

The trailing arms being a tiny bit bent? I wouldn't be too concerned providing they're not weakened and they're both the same length (measured between the centres of the bolt holes (not end to end). As these arms locate the rear axle, any significant discrepancy could cause misalignment of the rear axle leading to 'crabbing' as you go down the road. A little dent, I doubt is going to make any real difference. However, check they're not weakened by rust coming from the inside out (look for any perforations, shake them and see if any rusty dust falls out, tap them lightly with a hammer - the sound will change if you hit a weak spot) and that the rubber bushes are in reasonable condition (the older arms had changeable bushes, later ones iirc, not so).

Electricals - don't give as much trouble as many might suggest, most problems (remember your car is c. 46 years old) are down to poor grounds, poor connections, and being messed with by the 'ignoranti' over the years. Nothing that can't be fixed and usually quite cheaply, more time than money. I certainly wouldn't advise 'fitting a new wiring harness', as others often suggest (they're either part of the ignoranti or trying to sell you a harness or both!).

Possible cracked head? - Does the engine run? If so, what symptoms? Those twincam engines rarely crack a head, but can blow a head gasket as they get older and perhaps have been neglected as regards coolant changes or allowed to overheat (blocked rad, failed thermostat, low coolant level due to a leak, cooling fan not working, can also overheat if pressure cannot build up in the system e.g. due to a leak or failed rad cap etc.). Head gaskets can fail simply due to age - the heating/cooling cycles can cause the aluminum head to 'squirm' on the iron cyl. block, essentially wearing away the sealing (fire) rings around each cylinder _ I used to re-torque the heads at c. 30-40,000 miles, this also tended to avoid oil leaks developing at the front of the head.
The normal check for a failed head gasket or a cracked head would be to perform a cooling system pressure check and a 'sniff' test or use a special liquid that changes color in the presence of combustion gases in the expansion tank - both are best done hot. (difficult to do if the engine doesn't run...). Remove the spark plugs, if one is very clean and the piston top is also devoid of carbon, then this would indicate that coolant has been getting into that cylinder. any drops of water on any of the plugs - lots of things to look out for that might indicate a problem and the possible cause.

Pulling an engine - I try to avoid this if possible. Not a lot of difference between removing the engine only or engine and transmission as a unit - the top 2 bellhousing bolts are a bit difficult to remove in situ, you'll need lots of socket extensions ( the official Fiat factory supplied tool was approx. 3 feet long with a 19mm swivel (flex?) socket on the end) and a suitable engine hoist or similar, ditto removing the starter motor, there's 3 x 13mm headed bolts, iirc, one of which is recessed into the bellhousing but not that difficult. But it's probably easier to refit both as a unit if you can handle this on the hoist you're using (an adjustable 'load-leveller' is useful to have to get the correct angle of approach and then tilt the unit as it's lowered) (some people leave the cyl. head off until they've refitted the' long block' and trans., for this reason, then fit the head)- remember there's a crossmember, that carries the lower suspension arms under the engine, that is not so easy to remove (front suspension coil springs have to be compressed to remove them). With a suitable engine hoist, I'd remove both engine and trans. as a unit.
If you remove and strip the engine, you're inevitably going to find wear, which equals expense...

Re. bodyshop? going to be expensive. Your car doesn't look too bad in the pic you posted. A bit of rust on the passenger front fender. another bit on the rear wheel arch, or was this the best side of the car you showed? Have you tried cleaning and cutting back a section of paint to see if it might polish up?
Or maybe you could do some localised repairs and blow in these areas yourself at home? You might surprise yourself...

Seats? Yes, worth doing, given that you'll be sitting on them. Flattened foam can sometimes be plumped up using a steam generator or re-packed to make them more comfortable, covers are available but don't buy them now, wait until most everything else has been done.

Rag top rear window? Can be replaced on it's own by professionals if the rest of it is in decent condition, could save money by removing the rag top yourself and then bringing it to a prof. to do the window or why not have a go yourself.

Heating control levers? Can probably fix these yourself, new units are available (at a cost), maybe you can source a s/hand unit - any auto breakers/dismantlers near to you or other enthusiasts that may have a store of old parts?

Bumper pistons collapsed? I don't know much about these but I've heard that once collapsed they can't be un-collapsed, they're available but pricey. If I wanted to save money, I think I'd just fabricate a spacer (maybe from a hardwood) and insert this to even up the spacing of the bumper from the body. I believe some people have instead collapsed the other spacer to even up the bumper and move the entire bumper closer to the body which some feel looks better.

Final bit of advice, don't tear into everything all at once, try to fix one area at a time e.g. a section of floor so that you don't start feeling overwhelmed but instead experience a sense of accomplishment and enjoyment when you see your efforts paying off.

Someone recently asked me - what was for me the most important thing about a classic car?
I responded, what do I see and feel when I'm driving it?
So, the only paintwork I can see is maybe a bit of the hood, so the condition of the paintwork or how much it cost isn't important -
The dashboard and instruments - everything working, clean and reminding me of a past time.
The seat - has to be comfortable, most important.
The controls - should work smoothly and as well as they did 'back in the day' i.e. not necessarily perfectly.
And then of course, the sound and the sensations when driving a little piece of motoring history.
But, maybe it's just me that thinks like this?

Q. Why do Irish people talk so much?

A. Because it's the only thing that isn't taxed over here (yet :giggle:)
 
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