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  #11  
Old 03-05-2015, 08:47 AM
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Next, the middle part of the structure was measured, and a cardboard template was made to assist in fabricating a repair section.





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  #12  
Old 03-05-2015, 08:48 AM
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The upper portion of the repair section was punched with a dimple die on a Mittler Brothers brothers punch in order to replace the original flared holes. These holes provided strength for the panel.



Then, the curved lower section was TIG welded to the upper. Soon, the rusty portions of the structure had been completely replaced.

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  #13  
Old 10-16-2015, 08:32 AM
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A contoured lip as added to mimic the shape of the original.

[img]http://www.v8tvshow.com/1965_Impala_SK/slides/1965_Impala_SK_10.30.13_17.JPG[img]





Once the piece was welded in place, it was cleaned with a wire wheel and 3M rowlock abrasive discs, and then sprayed it with primer.



A new filler panel was obtained from Classic Industries, and welded in place over the lower structure to complete the repair.







The tail pan section was rusty and damaged, so the crew removed the original panel by drilling out all the spot welds holding it in place.



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  #14  
Old 10-16-2015, 08:33 AM
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Note the support rod welded in to keep the decklid opening the correct size.




A new panel was obtained from Classic Industries, and it was fitted and welded in place. Note the fitting of the deck lid and tell light packets in this process to ensure all the panels fit properly before welding.





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  #15  
Old 10-16-2015, 08:34 AM
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The dash steel at the base of the windshield had rusted through, so we replaced the steel after fabricating some new pieces in-shop. The challenge here is that this is 3 layers of steel welded together, so they had to be replaced in the same manner.























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  #16  
Old 10-16-2015, 08:35 AM
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A close-out panel was made and welded in to smooth the firewall.



The rear package tray was damaged, so new panels were cut to size and welded in place.





The panel was strengthened by adding ribs with a Mittler Brothers bead roller. They were held in place with some Eastwood panel clamps.



After welding, the panels were ground flush to complete the repair.



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  #17  
Old 10-16-2015, 08:35 AM
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The rear passenger floor was riddled with rust pinholes, so a replacement piece was ordered from Classic Industries.





The perimeter of the panel was punched for plug welds, and then sprayed with weld-through primer.





The welds were ground smooth to complete the install.

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  #18  
Old 10-16-2015, 05:11 PM
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Great job.............................

Ken
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  #19  
Old 10-16-2015, 06:47 PM
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Show us more!! Surely there's more to this since the first post in March!
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  #20  
Old 10-16-2015, 10:36 PM
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Nice work Kevin. I love to see fab work.
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