ohhh, ok,

If that is an original header panel, then I would have it sandblasted. Reproduction parts, no matter who made them or what part of the car they fit, are NO WHERE the quality of original GM. Get that sucker sandblasted and prime it and you'll be happier in the long run. You shouldn't have to worry about any future rust issues if its properly blasted and primed

I get what you're stepping in, but ... there are still OEM header panels out there to be had and it's cheap insurance against rust. I don't want to do this level of rust repair again!

Rick's still has a few left, so that's the plan.

Thanks for chiming in...

Look for some local shows and swap meets. I had to replace mine due to dent damage and I found a NOS one at a show for $75:) Of course that was quite a few years ago, but I know you can see find them, just might be a little more

I think I found a used one in Colo Springs ...have to go look at it first.
Thanks

GM the only way to go!!!

Update 5/12
 

:thumbsup: NOS is the way to go .... everything else is mediocre!

My goal for today was to finish the driver's side inner rocker repair, got most of it done and then my air hose started to hiss with a leak ....:mad:
Anyway, I finished the driver's fender and started on the rocker repair today, didn't get it all welded but she's' close and I'll finish the outer rocker welding tomorrow.
http://img191.imageshack.us/img191/697/120512483.jpg
Driver's side NOS fender prepped!
http://img805.imageshack.us/img805/1575/120512473.jpg
This is where I started today:thumbsup:
http://img27.imageshack.us/img27/8441/120512499.jpg
Cut the patch to fit.
http://img585.imageshack.us/img585/1629/120512494.jpg
Welded the top inner rocker ... upside down welding .
http://img29.imageshack.us/img29/6725/120512500.jpg
Outer rocker almost ready to weld :thumbsup:

The temperature only made it to 46 degrees and I had to get out the heater ..... I thought I was done with the cold garage and now we have this cold snap?
Well, more tomorrow .... when I can get the garage above 50 degrees!

Thanks for looking!

5/13 Update
 

Finished the inner rocker panel :thumbsup: Long day to get it right ... but she came out nice. I think I might cut out a patch for the front and close this off and prevent any further issues, GM should have done this from the beginning, now it's good for another 45 years.
The next big project is getting ready for some epoxy primer, hey!!!
Take a look at the pixs....

http://img402.imageshack.us/img402/9790/120513503.jpg
Think I'm gonna close off the front!
http://img190.imageshack.us/img190/7499/120513505.jpg
Waiting for the side cowl to finish the front.
http://img69.imageshack.us/img69/2926/120513509.jpg
Overall she came out nice :thumbsup:

Thanks for looking .... one day at a time!

5/16 Update
 

Had a good couple hours in the garage tonight. Bought some 18ga to close out the front of the rockers and ... the firewall. So I fired up the cnc machine (read poster board and the plasma cutter) and cut out the rough shape to smooth the firewall :thumbsup: :thumbsup:
Think I'm gonna wait til I get the side cowl panels mocked in before I cut the original firewall. I am gonna flange the bottom for strength and try to flange the curve up towards the top ... then weld. Should be stronger ...yes?
Here's the pixs ....

http://img560.imageshack.us/img560/2580/120516516.jpg

http://img85.imageshack.us/img85/2483/120516517.jpg

Still needs final outline smoothed, but she's close!

Thanks

lookin good