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  #16  
Old 19-10-2010, 07:00 PM
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Name: Daren
Quote:
Originally Posted by *rayman* View Post
This car was for sale recently wasn't it?

Is this the new owner getting the work done, or the original owner?
Was forsale last year, my cousin now owns it
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  #17  
Old 19-10-2010, 09:34 PM
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Im pretty sure i looked at that 1 when i was looking for mine . Plenty of work ahead but it looks like your getting through it. Keep the pics coming
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  #18  
Old 19-10-2010, 11:57 PM
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Any more details on the firebird?
Quad cam!!
Do tell !!
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  #19  
Old 20-10-2010, 12:36 AM
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The firebird is still a long way off. I just never seem to have any spare time lately. Mainly because there's always another car that pushes into the queue : )

I had to modify the chassis a fair bit to fit the motor in, as it's physically HUGE!!!! I also modified and fitted the power rack that came with the front cut.








So anyway, back to the 69.

There was a bit more rust in the floor that the new floor pan didn't cover so I just cut and plated it.



Once the old piece was cut out the support underneath needed a couple of minor holes fixed, then it was cleaned and covered in acid. It looks quite rusty, but the acid took care of the surface rust.





Next area was the front of the rear shock mount in the floor. Bit of a pain to fix due to its location and also because the support underneath was also rusted.





Here's the inner structure repaired.



This is the piece I made to fill the hole in the floor. I've drilled some holes in it so I can plug weld it to the support underneath.





Next bit to fix was the lowerf corner of the door jam.









I also had to remake the lower front guard mount at the front of the sill.





There were a small patch of rust at the base of the windscreen. There's 3 layers of metal here and they all needed fixing. Luckily it was only a small area.





The top of the windscreen channel had a small rust hole too.





The roof had a row of holes around it from a vinyl roof that needed to be welded up. Also the owner wants the seam to be welded up properly. I also need to remove the bodgy riveted repair.



Nice : )



Looks a bit better with everything welded up.

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  #20  
Old 20-10-2010, 01:00 AM
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I figured I'd fix a door, as I was getting a bit sick of working on the shell.

The left door had the usual rust in the frame. The outer skin was badly repaired to the stage where it will get replaced with a new one.

















Next area to get the chop was the boot floor.



I need to unpick and repair the fuel tank mounting supports.



Just trimming a little bit of rusted metal away : )



Left hand rear chassis rail isn't as pristine as I'd like.





Just keep cutting until you find some decent metal.



Here's the chassis rail fixed and the surrounding rusty metal removed.



Starting to look useable.



The other side was about the same only the chassis was fine.





Here's the fuel tank mounts repaired.



And refitted.



The new boot floor needed a bit of messing with to sit right, but fits well now. I also did the usual set of holes for plug welding. I've also drilled holes to plug weld the new floor onto the fuel tank mounts.







Getting the new tail panel sorted out.



More plug welds.



Here's the bumper mount supports and boot latch support welded back in.



The owner doesn't want the seams around the tail panel, so everything is getting fully welded and smoothed.



Before the new quarter skin can go on I have to clean up where the old skins were welded on. This chook $hit weld is a shocker.



Finally it's starting to look like a car. It's amazing the difference just tacking the rear skin on makes.



I took a lot of time fiddling with the front of the new skin so the door gap would be good.





It was at this stage where my new workshop was finished and I could FINALLY move everything into the new shed!!!!! Happy days.
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  #21  
Old 20-10-2010, 01:20 AM
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Here's the guard welded on.







The new workshop is AWESOME! I finally can have everything in one place AND have some room.



Next job I thought I'd tackle was the left front guard. It had a really bad repair that wasn't worth trying to save so I'm going to just cut the whole lot off and make it from scratch.



The inner support needs some work too.



Old and new. At least this piece was easy to make.



Here's the new inner support welded in. Note the huge overlapping piece sticking out to the left of the support. That's an awesome repair : )



I'm going to replace this area in 2 pieces. The first being the wheel arch lip.



The new lip follows the original shape nicely now.



Next step is to cut the old lip off and weld the new one on.



Make sure the new piece is exactly the same as the old lip.



Then I chopped the rest of the area off.



Here's the old section with the new one I made.



The new piece tacked into place.



After some welding and sanding it looked a bit like this.



Looks a tiny bit better : )





Time to start cutting again. Here you can see the silicon that was holding the outer skin to the wheel tub. Like the other side the lip on the tub has rusted off.



More crap in the sill.



Whoops, the floor fell out : )



Not too much left now.

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  #22  
Old 20-10-2010, 07:48 AM
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My god... I'm getting off on this build thread!

lol your work looks class mate.
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  #23  
Old 20-10-2010, 08:14 AM
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I don't think I've taken a breath in 5mins - Just sitting here wide-eyed in astonished disbelief. Just awesome - Thanks so much for sharing.

Tim, a few quickies if you don't mind;
1) What time frame are we talking about with the above? THe flow of the thread makes it feel like a 'daily update' but is surely weeks?

2) At what stage do you decide to give up on a panel & just buy new?

3) Is the customer/owner still talking to you? Surely nobody could have predicted the amount of work & must have destroyed his budget...

Thanks mate & keep it coming!!
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  #24  
Old 20-10-2010, 08:40 AM
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Thanks guys, glad you're enjoying it.

This has been done over a few months, but due to having to finish another car a lot of the time I was only able to do one day a week on this car. It's really only the last few weeks that I've been able to spend some decent time on it.

As for new panels, well with these cars it's usually cheaper and easier to just buy new ones.

Yes, the owner is still talking to me hahaha. Luckily for me he delivered the car sand blasted, so all the crap bits were out to be seen.

There's still a fair bit left to do so I'll keep posting as it goes along.
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  #25  
Old 20-10-2010, 08:52 AM
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Holy Cow!........that rust never ends
Was there any part of that car that wasn't rusted?
If that was my car I would've pushed it into the corner and ordered a new Dynacorn body

Ken D
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  #26  
Old 20-10-2010, 10:39 AM
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Yeah, the dynacorn idea got tossed around but fixing this one will be cheaper, and more interesting : )

Here's the part of the inner sill I'm going to replace.





Where the tub joined the floor was stuffed on this side too. I feel some de ja vu : )



I had to replace the edges of this rear panel too. At least I didn't have to make the whole panel like the other side.



To make room to do the repair I cut the rear of the inner tub out temporarily.




Again, just keep cutting until the metal is decent.



I made up a new piece with the same lip along the side as the original piece used to have. I will then plug weld the tub onto that lip.



I always attack my repairs with rust converter before I etch prime them.



With the floor bit fixed I could weld the inner tub section back in. I've had to cut the bottom off though due to rust, so this will just get made up once the tub is in.







Now to fix the section of floor and inner tub in front of the shock mount.



More cutting and rust converting.

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  #27  
Old 20-10-2010, 10:54 AM
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bloody hell... I know it looks like a nightmare but this is something I want to do in my old age when I get bored!

Nice work mate.. real nice! You got skills that's for sure!

Sent you a PM too!
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  #28  
Old 20-10-2010, 11:03 AM
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Sorry Ken, I forgot to answer your question. The only panel not getting cut off is the roof. The inner sills needed repair, outer sill replaced, all floors replaced, boot floor replaced, tail light panel replaced, rear quarter skins replaced, boot lid replaced, left hand door skin replaced and it's getting a new flat firewall too, so that has to come out as well. Apart from that I'm not really doing anything : ) hahaha


You'll have to excuse the next batch of pics as my camera batteries died and I only had my dodgy phone camera.

Here's the new bits of floor welded in.



The inner tub section welded back in, less the lower section that needs replacing.





It's starting to look half solid now.



With all the inner repairs done I could finally weld the new outer tub on.



Like the other side I welded the tub in with plug welds, but fully welded the main C pillar support to the tub. Just to make sure it's solid.



It was now about time I did a reprime. I sanded all the bare areas that had rust converter on them and cleaned everything else that was going to get primed.





I primed inside the sill on this side too. Can't hurt to have it all sealed up before the new outer sill goes on.



There were a few repairs on the front guard and one of them was fairly major so it got primed inside and out.





Nearly looks like a car.







I like to have everything in etch primer while doing this work. Not only does it mean everything is sealed up and not getting any worse, it also means it's clean so you can work on the car without needing a tetanus shot : )

There was still a little bit of rust in the rear floor area that needed fixing. The worst part about fixing things like this isn't making the new pieces, it's getting the old bits out. Drilling and grinding out spot welds and rusty metal is not exactly my idea of a great time : )





Finally I could weld on an outer panel. I started with the sill.



More plug welds.



The new floor also scored a heap of holes for plug welding. It sucks a bit drilling all the holes but it makes the fitment a lot easier and is really strong too.



Here's the floor tacked into place.



Here's a small collection of bits I've cut off this thing.

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  #29  
Old 20-10-2010, 01:11 PM
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How many hours do you estimate there will be in bringing this Camaro up to scratch ? I was just curious from a budget perspective.....
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  #30  
Old 20-10-2010, 02:27 PM
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Lots : )
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