The cut!

It's time! The couch will be cut to its final length. 

Started by making sure the "car" is in level with a spirit level. Then a construction laser level was set up to mark where the cut is to be made. 

Drew with a "thin" permanent marker a line where to make the cut. Same procedure was done on both sides of the car.

Before making the cut some additional supports are added.

Making the cut.

On the inside of the car the laser does not work so thread is used for marking where to make the cut. 

Separated!

Some more rust repairs.

 Before cutting the "car" I want to have "healthy" metal where the cut is made. Right side quarter panel is in bad shape. Tape shows where the cut is planned.

Shaping of this piece is mainly done by hand.
   

To check the shape I'm comparing repair piece to my car. Reshaping and comparing until I'm happy with the result.

Masking tape on backside of repair piece to not scratch the paint. 

Welding preparations.

I use a technique where I tack weld the repair piece on top of the damaged piece, this is just to hold it in place for now.   

Then I cut along the top side of the repair piece and and push in so that the repair piece and car sheet metal are flush and tack weld in place. 

When one have cut around all sides of the repair piece the replaced piece should hopefully be possible to take out as demonstrated in the video. 

After some more welding and grinding this is how it looks. There are still some holes in the welding joint that will require some more welding and grinding.

Frame for the sofa.

Although not all rust repairs are done yet I decided to get started on the frame for the sofa.

I bought some 30X50X2 mm pipe for making the frame.

Frame for couch bottom ready!

Manufacturing of backrest frame.

 Mocked up. Not happy with how it looks! Reluctant to weld in place. 

After some thinking back and forth how to proceed I decided to use backrest and weld it in place. Preparations.

Welded an angle bar behind the backrest frame for making it easer to install the backrest. Uncertain if this will be left on the ready product, basically it should be enough to just leave the parts connecting backrest to car. 

This is a milestone and next one is approaching fast! Soon time to cut the "car" to its correct length.