Lost pretty much all this previous week and weekend to travel.  I was in Boston during the week for some work related training, then drove out to Philly for my sister's college graduation Sat/Sun.  Here's one leaving Boston.

Chassis work 

During the down time I got some abrasive discs for my angle grinder and a bunch of sheet metal for making my patch panels.  (3) 2'x4' sheets of 18 ga and (1) 2'x4' sheet of 16 ga.  We'll see how long that tides me over.  Now I have to look for forming tools, a bead roller would be nice to have.

A bit more progress on the chassis:  cut the rear outer seat mount for the drivers seat off of my replacement panel and tacked it in place to the inner layer of the rocker.  I scribed an outline of the original before removing it so I could line the new one up fairly easily and accurately.

Sprayed the new one in etching primer for now.

Tacked.  This will preserve the right location until I can get the floor patch in.  Once that happens I'll transfer the mount to it, break the tacks loose, then remove that layer of the rocker and continue with the repairs inside to out.

Also worked on the "A" pillar area of the car.  This fucker is where one of the tubes drained to from the sunroof.  I'm going to have to pull this and likely remake it out of 16 ga.  Needs  to be removed to get me access to the inner layer of the rocker so I can cut it out and replace it.

Engine build prep

Also started some work on engine stuff.  I started with removing a boss in the valley area to give the PCV system on my LS6 valley cover sufficient clearance.  Lowe's was closed so I had to cut this with a hack saw.  It was fun.

Guessed about right on the depth though:

I also took some time to start deburring / breaking edges everywhere on the block with a fine file.  Any sharp features are stress risers and provide possible initiation points for cracks to develop.  I did the valley cover, head mounting surfaces, rocker ports, and casting areas near the bottom of the cylinder sleeves. 

Casting flash removed:

Casting flash not removed, you can see how rough it is around the perimeter of the port.

This week I plan on continuing the prep / clean the block for building.  Still need to finish deburring, mask the block and paint the exterior surfaces, clean the internal passages again, and measure everything (again).