Radiator Support Repair – Part II

At this point most of the rust has been cut out of the 81 Trans Am’s radiator support. Unfortunately some of that rust exteneded to one of the stamped bosses to which the battery tray bolts. Luckily, the passenger side has an exact duplicate of the required boss. To make this feature, a rectangular frame was welded together and lined with aluminum foil. Resin was then poured into the form taking the shape of the feature. After a good curing period, the second half of the mold was poured using the first half of the form. Two nuts were welded on each side of the two forms for alignment purposes. When the dies were cured, a piece of sheet metal was cut to fit between the two. A 12 ton bottle jack press was used to stamp the piece.

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