69 Nova-AKA Rust/Bondo Bucket

[GTmike400]

My friend bought a '69 Nova. I really wish he had consulted me before throwing his money out the window. The previous owner thought Bondo and fiberglass can fix everything. Bondo of rust does not fix rust. Bondo inhibits rust. There are areas with 1" thick bondo. The car looked good from far away, until I started chipping away what should be steel. I'd say a good 75% of the car is bondo, and a good 90% of the panels will have to be rebuilt.

The underside is all rust, there are holes in the floor pan. The trunk floods when it rains. There are holes in the trunk too. Quarter's are rusted, bondoed, and need lots of care. Rockers are also rusted out. Hood is complete rust. Roof is all bondo. When the owner purchased it, he said it was in great shape. The minute I saw it I knew I was in for trouble.

The owner spent $5500 on it. Its not worth more than a grand. The pictures make it look good. Unfortunately I'm doing this all in my high school shop. Im lacking the man power and the tools. I keep having to make tools such as brakes. I think it needs a new body, or at least replacement panels, but the owner doesnt want to spend the money. I like my level of work to better than I'd accept when its for somebody else.

Lots of work ahead of me. 1500hours in 90 days. Overhaulin at its worst...


Ah, the beginning of it all. The rear glass was removed to reveal a marvel of fiberglass, bondo, rust, and bathroom molding. A huge hole revealed that I was in for trouble.


More rust under 1/4" thick bondo.


Enormous hole under the front cowl. Owner wants me to fix it, but doesnt want me to cut anything... Now there's a conundrum.


Cut out the original piece, which as covered with bondo and fiberglass, and rust, only to reveal, MORE RUST! This piece would be extremely difficult to fabricate as the hinges are attached to it. The pictures dont show the pitting, and holes. Im able to give it a small wack with a hammer and blow through the "rust".