Rear driveshaft tunnel in 30 minutes

Well last night I decided to try to tackle the gaping hole in the rear of my Edsel. The last owner Lee had to do a quick on the fly fix for the shaft rubbing on a camping trip with friends in the back, so easiest of course was to make a quick cut and bend. Heres where we started:





the 2 pieces to the sides are what I cut off that Lee had bent back. Next I cleaned up the hole a bit



After looking ant the hole and the seat frame, I decided the seat had a perfect shape to mold the tunnel to. I had some s**** metal in the ba*****t that was too ****ty to do anything else with, but it was perfect for this project, so away we went.



Heres a better view to show the shape I was using.



I laid the metal over the gap and stomped it into form. After a basic form, time for a test. Looked pretty close



Actually looked REALLY close:



Cut some excess off the back and it really started to fall into place



After that it was time to make a few relief cuts and tack it into place. Just FYI, I dont weld, haha. Ive literally only done it maybe 2 times in my life, mostly while drinking beer, so this was no beauty pageant, My buddy Chris was there at least to make sure it was working. He is my go to guy for metal work so he brought over his little Lincoln Weld Pak 110 flux and I was seriously impressed with that 150 dollar unit. Im going to buy one myself I think.







At this point I was satisfied. I need to get back and file a few spots and seal it all, but for about 30 minutes of work and literally no cost to me at all, I cant complain.





The drive to work today was much warmer and MUCH quieter. The lake pipes would scream through that hole providing a wonderful drone for miles. I am by no means a metal worker or fabricator, but I figured Id share a simple solution to a problem I bet a lot of us have.

 

STOMPED it into shape! I love it! Came out nice.

 

not bad for a wookie,, err rookie!

 

Make it fit anyway you can!

 

Claw hammer?

A little seam sealer might keep the water and exhaust fumes out also.

 

Yeah, im going to seal it this weekend aagie, like wrote. I just didnt want to spend more time last night than I had to. Had to get the kid to sleep, ba*****t clean, and dishes done. Yes im the *****, haha. And claw hammers for life.

 

Sometimes lo-tech is the answer. Totally functional and who's gonna see it unless you run them over?

Bob