1965 Chevrolet Impala SS 6.0 / 6-Speed Build Thread - Lateral-g Forums

**V8TV** · #1 03-04-2015, 09:17 AM

Next, the crew began the rust repairs around the rear window frame. These window channels held water and rusted all the way through. The rusty metal was cut out with a thin 3M cutting disc on an air grinder. A new channel was fabricated using a shrinker/stretcher, welded in, and ground smooth. Gray primer prevented further rust.

**V8TV** · #2 03-05-2015, 06:46 AM

Similar repairs were made to the window channel around the windshield in the areas where the metal had rusted thin.

Next, the rear window filler panel was removed for additional rust repair.

**V8TV** · #3 03-05-2015, 06:47 AM

The rearmost edge of the structure had rusted away.

A new channel was bent in the Mittler Brothers Box Pan Brake and contoured to the correct shape.

Then it was welded in place with an HTP Quickspot II resistance spot welder.

**V8TV** · #4 03-05-2015, 06:47 AM

Next, the middle part of the structure was measured, and a cardboard template was made to assist in fabricating a repair section.

**V8TV** · #5 03-05-2015, 06:48 AM

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.

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

**V8TV** · #6 10-16-2015, 06:32 AM

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]

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.

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

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.

**V8TV** · #7 10-16-2015, 06:33 AM

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

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.