Yep. There were some surprises under that fairly decent paint job.
On one hand, you could argue that we would have been better off selling this car and starting with another for this build because the car really did look nice enough to sell for a pretty penny. While we thought about that, my son Dan and I have played around with this particular car since he was in high school so it has considerable sentimental value to us.
On the other hand, we have no complaints because the car looked great and served us well all these years. Besides, I would have felt terrible if someone had payed me that pretty penny and then found the secrets it was hiding from us all.
Actually, to be honest, we were anxious to have the rear quarters replaced even if NO rust was found.
Our reasoning was that someone had previously installed partial quarters. While there is nothing inherently wrong with partial quarters, we want this car built true and square from the ground up, starting with new full quarters installed while the tub is mounted on a jig. Anything less just wouldn't seem right for a build of this magnitude and caliber.
We knew about the dash being wasted as we could see evidence at the base of the windshield. The black tarish material someone used to mask the rust makes it look even worse in the pics. :
A couple of spots in the floors were a surprise but they look to be easily fixable. V8TV's repairs to spots like these are virtually invisible when done because they only use butt welds and finish both sides so you can not tell they were ever there.
The holes at the top of the A pillars were a surprise:
The inner cowls will need repairs due to the rust above inviting water to congregate within them:
Sorry to say the rust we found so far is not all that surprising for a car that has lived it's whole life in the Chicago and St. Louis areas.
The car is at the media blaster right now. I can't tell you how anxious I am to get the final verdicts upon it's return.
To me, that day will represent the "bottom" of the build. From there on, the car and the project will just get better and better, both physically and emotionally.
If you look through the galleries of V8TV's previous projects you will see they have repeatedly saved numerous cars in much worse shape than this one.