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What is different about the mistake tail lights? Do you have wiring diagrams? Let’s see if we can help you simulate them. You have gone too far with This project not to. The car looks great!

I have good luck with placing washer over the hole and going in fat and hard with Mig. I have never tried with flux core, only gas Mig. your hole looks very deep but I think at this point you have little lose. How deep is it? I do t think I have had any that much more 5/16” below the surface.

Flap discs on the angle grinder is the way to go. Try to get a multi pack with assorted grits and you won’t be disappointed.

Mig works well. Set the welder high. You want to go in hot. Wait 10 seconds and then unscrew it. A Johnson bar may be a better choice than a ratchet. you may to work it in and out a bit as you unscrew it.

You can do a lot for $1,300. As mentioned you should start by making the panels with card or poster board. That will give you a good idea of how the layout with go with only simple bends and cuts. Is it fair to assume that the current plastic ones are more complex shapes than the example you...

Define “way to much”. I’m this could easily turn out like every project I do and take way more time and cost more than it would to purchase ready made. Of course there is a lot of satisfaction in making it yourself…

You will find that muffin pans are handy for keeping bolts/ screws when dissembling. It really helps keep them in groups. One cup for each stage or subassembl.

Or do this. There are companies that sell these butI made this pretty cheap.

One advantage to the dedicated grinding attachment is you will get a consistent angle. When you are starting out it is helpful to control some of the variables so you can focus on the other parts.

As mentioned an automotive wheel bearing is going to be a good option. They are already extremely weather proof and can withstand the abuse. Depending on the load you can spec one from a car or pickup truck.

I’d the cage mild steel or chromoly? What welding method is required? i Assume mod steel and Mig welding will be fine for this. Do you have a pipe notcher? You will want one if you can swing i. There are ways to do it without but not as user friendly. You will want an angle gauge, level. take...

I started brazing at 13. Learned how to Arc and Mig weld in high school.

Why did you guys wait until so late in life to start welding?

They have their place alright. In the garbage pail. I havespnt the better part of 25 years doing 12 volt electrical diagnostic and repai. I can’t think of a single situation where they would be my choice.

This an old thread but.. https://www.garagejournal.com/forum/threads/1-4-npt-thread-repair-kit.14819/

This is Garage Journal. Buying a new tool is always the best answer!

I wouldn't hesitate to weld one chrome bolt or other small application. I have welded my share of chrome items over the years. I’m sure I have suffered more damage from brake cleaner fumes and other stuff we didn’t think twice about using in large quantities. And besides I’m almost normal. ;)

I’m not familiar with that tune. Could you sing it for me?

Yes, they are in the kitchen. I wanted them to match the finish of the flooring. I had originally planned on fabricating a metal mpunt recessed into the back of these. When I did some research I found that it wasn’t necessary.

I made these from solid oak. They are mounted with 3/8” lag bolts threaded into the studs (2x6 16” oc). I but the hex head off, drilled 3/8” holes in the shelf to match. I put a small squirt of PL adhesive in the hole before knocking the shelf on using palms. My hands were sore afterwards but...