542 Photos - Nov 3, 2012
Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Ends up there is more rust than first thoughtPhoto: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Tail gate area is complex and rustyPhoto: Photo: Rust has been patched over a few times over the yearsPhoto: Photo: Photo: Ton of stainless around the many windowsPhoto: Photo: Lots of unusual clips .Also rustyPhoto: Photo: Photo: Photo: Photo: Photo: Photo: Windows leak and the clips are rusted and cant be reusedPhoto: Photo: Rubber inserts with threads hold the roof rackPhoto: Photo: Dry crusty urathane sealant has to all be scraped outPhoto: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: The many panels to be Soda blastedPhoto: We started by grinding some of the Filler out to see the damagePhoto: Photo: Old school body repair methods haven't changed that muchPhoto: This part will be sanded rather than soda blasted. That stuff gets everywhere.Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Cracks on the inner door skeleton. Hard core window cranking must have broke it.Photo: Photo: Photo: Bare metal that needs washedPhoto: The original GM door decal, soda blasting can be very gentlePhoto: Bare metal shows all the damagePhoto: Photo: Panels waiting to get a Vinegar wash then Metal Ready metal washPhoto: Photo: Rust holes are now nice and clean and ready for workPhoto: Photo: The original cowl vent and the fragile screen that goes behind itPhoto: Long dents show the car must have hit a guard rail way back when....Photo: The hood is Soda blasted but the rust has been left so it can be ground down with sand paper then metal washed. Sand blasting the rust would most likely warp the hood.Photo: Metal ready Metal wash is sanded into the surface after a thorough cleaning removing all debris and Soda residue.Photo: The rust is from the reaction of the chemicals coming to the surfacePhoto: Photo: This panel has been washed and ready for final sanding then it is the purist metal that we can make it .Photo: The tail gate will be a challenge to fix all the rust . Not impossible though.Photo: Pinch weld rustPhoto: Crack in the top of the tail gate window channelPhoto: Large dent in the leading edge of the fender. Previous repair just filled in the hole with plasticPhoto: Photo: Photo: Photo: Rusted tail gate , many layersPhoto: Photo: Photo: Photo: Photo: Photo: Clean bare metal ready for epoxy primerPhoto: White epoxy DP primerPhoto: Photo: Photo: Photo: Photo: The hood is very rusty , It will take lots of grinding discs to fix thisPhoto: Deep rust has been festering for years under the white paintPhoto: Fresh primer panels ready to be mounted and body work can beginPhoto: Photo: Photo: Photo: Photo: Deep dents are easy to see with the white primerPhoto: Heavy dent in the front fenderPhoto: This fender is straight but has some rust down lowPhoto: This is most of the panels but not all. This car takes up a lot of square footage.Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Tail gate was very rusty and had lots of cracks from years of abuse. We simply welded the cracks and fabed up some patch panels.Lots of Metal Ready and weld thru primer .Photo: Photo: Bolt holes in the right front door hinges were egged out and needed attention .Photo: Photo: Photo: Photo: Photo: Three layers of rust.Photo: Photo: Photo: Photo: Photo: Photo: Another door was needed due to the amount of damage on the right side of the car.Photo: Photo: Photo: New door did not fit that well so the window frame needed to be cut and moved around the fit correctly with nice gapsPhoto: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Rocker was smashed pretty bad and repairing it would have been dumb. Just cut it out and replace it with a freshly fabricated piece.Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Third brake light is smooth and very sleek.Photo: Third brake light , LED , NicePhoto: Photo: Third brake light fit nicely behind the dome lightPhoto: Photo: Photo: Metal work is now done on the damaged quarter panel. Now we can get to the body work.Photo: The right rear quarter is probably the most damaged and rusty. After rebuilding the quarter panel "dog leg" next to the door , pounding out the dents its time for plastic on top of two coats of epoxy white.Photo: Photo: With the dents hammered out on the right side its a lot better and less plastic filler.Photo: Photo: It looks like the heater core decided to start leaking .Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: