Ed & Chuck's excellent (?!?!?!!!) adventure

**Martin0660** · 03-24-2010, 12:44 PM

Still looking good guys ...

Also remember that the flapper wheels you are so fond of will really pound the heat into a panel as well. It could be relatively flat from welding and sink from the heat of grinding the welds smooth. There is actually a tool out there for shrinking metal that goes on a grinder that works on this principal (except its even finer).

Besdies, you need some place for the filler to go :D

**Ares** · 03-24-2010, 06:47 PM

Originally Posted by Martin0660

Besdies, you need some place for the filler to go :D

Thats right :)

It's actually worked out rather well. Chuck's pic kinda makes it look worse than it really is. All-Metal uses some gold liquid hardener instead of the paste type and being silver in color doesn't help in mixing. I was pleased at how nice the All-Metal is able to be sanded and feathered into the metal. Now the Evercoat I used on top of the All-Metal is real nice to use. Turns a pale blue and is tack free and sandable in few minutes.

Been so much easier if the wheel wells didn't need replaced. Then could have just replaced what was bad. Ah well it will turn out nice in the end. Hell maybe a whole lot less tire smoke in car after those burnouts :D

**CobraII** · 03-29-2010, 10:32 AM

It was only on there for a little bit, before wet sanding it off, but it was nice to see the quarter in one color. I think it's coming out really nice, I'm really happy with it. Ed has a great eye and touch for getting the high and low spots, when he's not yelling at me for oversanding. :lol:

He put the last touches of filler on it, and I'll prime it this week.

Driver's side is going to be a challenge. It's all pretty much prepped, but now Ed has to put the puzzle together. Rot was pretty bad under the taillight itself and at the seam.

It's also bad at the back of the trunk floor, went up higher on this side than the passenger side. But, a piece went on, so that's always good.

**Martin0660** · 03-29-2010, 06:00 PM

Originally Posted by CobraII

I figured it would work out... less air resistance with no hole-y metal! :D

The deeper this goes ... I am still standing by a net loss by putting all that metal back :D

**Ares** · 03-29-2010, 08:29 PM

I'd get more done if someone...cough...CHUCK...would stop removing the body filler when doing some minor wet sanding

**Ares** · 03-29-2010, 08:31 PM

Originally Posted by Martin0660

The deeper this goes ... I am still standing by a net loss by putting all that metal back :D

Seriously the car will be lighter with metal. You had to see the amount of body filler that was removed. Aluminum foil buried in filler was someones idea of fixing rust holes. Stuff was heavy.

**Martin0660** · 03-29-2010, 09:24 PM

Originally Posted by Ares

I'd get more done if someone...cough...CHUCK...would stop removing the body filler when doing some minor wet sanding

Ohhhhh... so he is one of those. So, is he more of a hinderance to forward progress "helping" you work on his car, or just standing there watching over your shoulder :D

Originally Posted by Ares

Stuff was heavy.

;) Just trying to stroke Chuck some ;) Another question, can this be considered a reverse excorcism??? After-all you are removing all that is holey :D

**Ares** · 03-29-2010, 10:15 PM

Originally Posted by Martin0660

Ohhhhh... so he is one of those. So, is he more of a hinderance to forward progress "helping" you work on his car, or just standing there watching over your shoulder :D

;) Just trying to stroke Chuck some ;) Another question, can this be considered a reverse excorcism??? After-all you are removing all that is holey :D

Ah young grasshopper must learn to sand with rice paper, even gentle pressure

Holey, ok thats funny.

**CobraII** · 03-30-2010, 11:05 AM

No such thing as bad student, only bad teacher.

That's the hard part. I feel bad for not being able to do more, but Ed has the talent I don't. I try to do as much prep work as I can to make it easier. We also learned a few things from the passenger side that we're making work on the driver's side. And I'm learning things from him.

Love the reverse excorcisrm line, Bob!

**Ares** · 04-06-2010, 07:39 PM

Woot Chuck updated his pics.

Passenger side done.

Rebuilding driver side tail light area.

Was nice to see the tail light fits like a glove on fresh metal. Trunk floor is 90% done. Two minor areas that need fresh metal. Put outer wheelhouse on, add new lip to rear of inner wheelhouse. Forward trunk floor along inner wheel house needs done. Replace about 5-6" on backside of driver rocker. Mockup quarter and bam

**Ares** · 04-06-2010, 07:55 PM

Back of trunk floor.

Had to hammer out a rib from flat metal to match new floor to original upper.

**CobraII** · 04-13-2010, 11:27 AM

Great progress this weekend. Trunk floor piece finished up, the hole in the back was cut out and new patch in, outer wheelwell went on, Ed made a flange for the back half of the inner wheelwell to mate and weld to the outer. I cut the driver's quarter with a good 2" overlap, we test fit, and the 2" overlap was true. (It was my turn to set the back seat on fire. I had it leaning up against the wall, and didn't realize the sparks from the cutting wheel were hitting it. I went inside for a drink, came out to see Ed pouring water on the seat. Oops. All I know is, if I'm ever dropped in the wilderness, I'm taking a handful of that padding. It ignites if you look at it wrong.) Since we were able to take this side's quarter off in 1 piece, we overlaid it on the new quarter, and Ed measured it out a finger's width all the way around and cut it down. We test fit it... and had a gap on the top back half. Can't figure out how that happened. I was right there with him, all the measurements looked spot on for what we were doing. So, we had to cut the top of the old quarter, and weld that back onto the car. The quarter went on the car Sunday, as did the rocker panel patch and front inner wheelwell patch, both of which Ed made. The only metal left to go on is on the inner wheelwell back half where it meets the trunk floor, the trunk floor in front of the roll bar, and a small patch on the back seat floor.
Hole in the back of the trunk floor, really weird because it's a high spot.

From outside underneath

Outer wheelwell on, gap between it and the inner before the new flange:

Flange:

**CobraII** · 04-13-2010, 11:28 AM

Completed flange

Quarter with the piece welded back on:

Quarter on:

The rocker patches, the one that goes inboard Ed made.

**CobraII** · 04-13-2010, 11:29 AM

To be done, the inner:

The trunk floor in front of the roll bar:

Patch on the rear floor passenger side:

**Tony71502** · 04-13-2010, 11:35 AM

Looks good, are you planning on covering up all of those surgical marks with putty/filler? I know you will on the quarter exterior, but I mean in the wheel wells/trunk area. My first chevelle had to be done the same way.

**CobraII** · 04-13-2010, 11:43 AM

I ground the welds down in the passenger wheelwell, and attempted to use seam sealer to reduce the visisble scars before painting. It didn't work out the way I had it in my head, but that's ok, because it's a bracket car, not a show car, and all the metal is there instead of large holes.

On the driver's side, I will grind the welds again, and hopefully do a better job of hiding the scars. Inside the trunk, I've decided on Rustoleum hammertone gray. The quarters are seam sealed on the inside, with the original spatter paint on the original metal, and I'll do the inside of the quarters, the wheelwells, and floor in the hammertone gray.

**CobraII** · 04-13-2010, 11:46 AM

And, with the wheels on, you won't be able to see most of that anyway.

**Tony71502** · 04-15-2010, 03:25 PM

Rustoleum is nice. I used POR-15 on my first chevelle's frame. For some reason the POR-15 bubbled and peeled like latex if you scratched it....

Spray for gloss, brush for flat...

**Tony71502** · 04-15-2010, 03:28 PM

Originally Posted by CobraII

And, with the wheels on, you won't be able to see most of that anyway.

True, but if he ever decides to show it, it'll be obvious.

My current Chevelle's wheel well...

**CobraII** · 04-16-2010, 12:17 PM

I know my car is no show car, and won't ever be. It's a street car that gets bracket raced every weekend. If someone wants to look in the wheelwells and snicker about the seams, I don't care. I personally think they're cool... if I didn't have them, the life of the car would be severely reduced, instead of greatly increased. :)