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".

[GTmike400]

More rust.


This car is a museum of iron oxide!


The beginning fabrication of the new piece. I had to build a press break to bend it. I used 18Gage CRS. Originally it fit up to the place its supposed to go, but after removal of the bondo the rust let go and now it doesnt fit. So the whole area needs to be rebuilt for this to fit.

[rwhite692]

It looks like you have got quite a project ahead of you, but you seem to have a good attitude going into it.

Have you checked the Nova repro parts houses yet to see about reproduction rear window channel sections? That may save you some time.

1500 hrs in 90 days = 16.6 hrs per day working on it...Ahh, youth...

Just a few words of unsolicited advice...I have over the years and on more than one occasion, done work for friends in similar (in over their head) situations and there is nothing more frustrating than being in a position where you can't fix it "right" (ie the way you'd do it for yourself) because of the way the owner wants you to do the work (it's taking too long, it's costing too much, etc...)...So If I were you, I'd get the ground rules set right from the beginning, and if both parties can't agree on how you are going to proceed...then I'd find a way to get away from it...-Rob

[907rs]

I agree with Rob. Get the ground rules set before you get too far into it.

What's with the tight deadline, access to the shop?

[hotroddr]

accidently light the car on fire then run like the wind.
I wouldnt touch this car with ground rules like that. Its going to need lots of cutting and welding. Tell him you will do it right or not at all. Doing it wrong the first time will end up costing him more time and money in the long run, trust me...

[GTmike400]

Thanks for all the comments. I can rebuild the car the way it should be. Unfortunately the owner is very cheap and doesnt want to buy replacement panels. I can fabricate the rusted out panels, but not in the time frame required.

I say 1500hours worth of work, because thats roughly what it will require. Needs to go out to paint in 90 school days, 3 hours a day in the shop. I simply lack the man power. I am the only person in the school of 2200 that knows how to do body work and weld.

The car can be fixed, the owner cannot. I'll do my best to get the project done right. I dont care if its finished by May 20th or not. Its going to be done right, or not at all. You cant rush things like this or it will end up just the way it started, all bondo.

[GTmike400]

Today I tried talking to him about ground rules, the subject quickly changed to me backing out of it. He's being unreasonable about it, and there is no way I can fix it right with out the collaboration from both parties. I proceeded to explain how I have been killing myself over the project, putting in hours upon hours of my time. He seems to be ungrateful and think that my time is unvaluable.

I am not a person to back out of a project, go against my word, or not finish what I've started but this is far beyond what I am capable of in our school shop, a lot worse than I had ever imagined, and the owner is not cooperative. I am going to finish up the rear piece, and leave it from there.

I hate going against my work ethic, but it is just way too stressful. The owner is not happy right now, and thats stressing me out right now. I didnt want to upset him, but there was only so far this project could go without the tools and manpower.