Screamin' Squirrel II

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..I Paid Close Attention To The Depth I Was Cutting As I Was Unsure If The Outer/Inner Skin Was Good Or Not..

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...Once Cut & Pried Apart I Was Able To See Why The Bulge Was There, Plenty Of Rust Within As I Expected...

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....Quite The Mess....

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.....After I Cleaned Out All The Rust Shards I Was Then Able To See Just How Bad The Surface Rust Was On The Inner Faces & Made The Choice To Continue Cutting My Way Through To Continue On With My Original Plan Of Replacing Both Sections.....

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......Rough-Cut......

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.......File & De-Burr All The Surfaces.......

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........I Would Of Loved To Do A Skin Off Restoration Given All The Potential Rust Between All But Maybe Later On In Life, At Least She Would Be A Good Base To Do So After This Restoration........

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.........A Closer Look At The Exposed Sides.........

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..........& Now A Closer Look At The Unexposed Sides.(Scary)..........

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.Back At It Again.

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..Dad Suggested To Grind The Inner Sheet In A-Bit So To Create A Step All Way Round Which Will Help Absorb The Heat When Welding & It Works To, It Greatly Lessened The Chance Of A Blow-Through When Welding (Thanks Dad)..

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...A Few Dummy Fits & Fine Tuning Before Welding, It's Easy To Get Ahead Of Oneself Sorry...

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....I Hit It With A Few Spot-Welds So It Won't Distort When Welding It In....

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.....& Away I Went!

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......Not The Best Job I Know, It's Quite Hard To Weld & Work With Half Rusted Sheet Metal (That Being All The Bellett's Metal) But Dad's Step Idea Helped Dissipate A-Lot Of The Heat & Most Of The Welds Were Fused Correct From What I Can See But I Can Also See A-Lot Of Bad Welds (More So After The Clean Up) & A Need To Go Back Over It Again Haunts My Mind......

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.......After The Welds Are Sanded Back Is When I Get To Check & See If Its All Fused In Or Not, (?).......

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........From The Other Side........

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.........Sizing Up The Next Bit.
I forgot To Say That On The Inside I Should Have Stripped The Paint Back Further As It Got Burnt.........
..In-Put--Techniques--Methods..Knowledge.. All Welcome ..

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.The Boots Inner After A Coat Of Etch Primer.

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