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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http://www.v8tvshow.com/1965_Impala_...0.29.13_35.JPG

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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.

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

http://www.v8tvshow.com/1965_Impala_...0.30.13_05.JPG

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]

http://www.v8tvshow.com/1965_Impala_...0.30.13_25.JPG

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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.

http://www.v8tvshow.com/1965_Impala_...1.12.13_02.JPG

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

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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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http://www.v8tvshow.com/1965_Impala_....23.13_073.JPG

Note the support rod welded in to keep the decklid opening the correct size.


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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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http://www.v8tvshow.com/1965_Impala_...1.15.13_20.JPG

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.

http://www.v8tvshow.com/1965_Impala_...1.14.13_03.JPG

http://www.v8tvshow.com/1965_Impala_...1.14.13_05.JPG

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http://www.v8tvshow.com/1965_Impala_...1.15.13_01.JPG

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http://www.v8tvshow.com/1965_Impala_...1.19.13_01.JPG

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A close-out panel was made and welded in to smooth the firewall.

http://www.v8tvshow.com/1965_Impala_...1.26.13_02.JPG

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

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http://www.v8tvshow.com/1965_Impala_...1.26.13_09.JPG

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

http://www.v8tvshow.com/1965_Impala_...1.27.13_04.JPG

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

http://www.v8tvshow.com/1965_Impala_...1.27.13_15.JPG

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The rear passenger floor was riddled with rust pinholes, so a replacement piece was ordered from Classic Industries.

http://www.v8tvshow.com/1965_Impala_...2.02.13_22.JPG

http://www.v8tvshow.com/1965_Impala_...2.02.13_25.JPG

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

http://www.v8tvshow.com/1965_Impala_...2.03.13_01.JPG

http://www.v8tvshow.com/1965_Impala_...2.04.13_05.JPG

The welds were ground smooth to complete the install.

http://www.v8tvshow.com/1965_Impala_...2.04.13_09.JPG

Great job.............................

Ken

Show us more!! Surely there's more to this since the first post in March!

Nice work Kevin. I love to see fab work.