This weekend I bought more sheet metal at Classic Industries and chopped up more of the rear inner wheel wells to make the replacement metal fit (roughly). I was then able to locate and measure the rear wheels for axle ordering- which I did today from Frank @ Prodigy Customs. Since I'm going to widen the body a little it allowed me to order a wider axle. Hopefully this will help keep the "wide track" look that Pontiacs are known for.

The car will not sit this low at ride height. This is where we're estimating the full compression of the suspension so we know there will not be any bottoming out issues contacting the body.

patching the window frames
 

This past weekend and the weekend before I spent what available time I had patching the rust holes around my window frames. I had 17 different holes (I squared them off) to patch, created the patch panels from my old quarter panel pieces and welded them in place. It was a great welding practice lesson for me, as welding is one thing I haven't had much experience with yet.

passenger door skin
 

I didn't get much done this weekend, I had company in from out of town. I did have a few hours today after work so I removed the passenger door skin and started to make patch panels for the door structure itself. Then I will re skin the door.

I have 2 of the 3 panels pretty much made, the third is only rough cut out. I used the leftover original door skin for the patch material. A new door skin awaits assembly. I also have a pic of some of the pass side rocker panel area that I had to cut out and will need to create a patch.

While the door is apart I'll also spray some Eastwood rust encapsulator to stop any remaining rust I haven't been able to sand out. Unfortunately, the chemical stripping I paid so much for didn't get all this. Such a waste of $$.

more on the door
 

Still alive, still making rust repairs when possible. Just chipping away at it. I got the pass door fixed, painted with Eastwood rust encapsulator paint and skinned.

I've also repaired the trunk weatherstripping channel and am now onto the pass rocker panel. The panel is requiring half a dozen or so patches. Even as I patch a section, I later learn I should have replaced more metal as I keep blowing through the original thinned metal.

Looking good, man. I know rust is a battle, but keep at it. You'll be happy when it's all gone. I've got two or three small spots to address on mine before I declare a victory........it'll get there:thumbsup:

Thank you. Yeah, I'm keeping a positive outlook on it as it's welding experience for me. I'm getting A LOT of experience with this one :)

I'm taking the next few days off. I should get more rust repair done this long weekend. Will update with pics next week.

Looking good!! Pics look great!!

Nice job on the repairs they look nice. Keep banging them out.

more patching and finally, some frame ties
 

Thank you both.

This week's installment is a little more patching and finally a "fun" project (actually, it's all been fun so far)- building some frame ties.

I had a few extra days off this past week so I was able to get a little more done. I patched the rust spot on my pass fender and I smoothed out the cowl panel to rid the wiper arm protrusions in the metal. Instead of just chopping and patching, I did my best to shrink what metal was there and make smaller patches. It was good metal forming practice, imo. I also built some frame ties out of some 2x3 stock. This evening I rolled the car over to my neighbor's house who will do the heavy welding.

more pics of the frame ties.