file 1965 Chevrolet Impala SS Restoration

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23 Dec 2014 21:09 #225 by oestek
Next, the rear window filler panel was removed for additional rust repair.



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.



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23 Dec 2014 21:10 #226 by oestek
Then it was welded in place with an HTP Quickspot II resistance spot welder.



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





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23 Dec 2014 21:10 - 23 Dec 2014 21:22 #227 by oestek
The upper portion of the repair section was punched with a dimple die on a Mittler 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 with an HTP Invertig 221 to the upper. Soon, the rusty portions of the structure had been completely replaced.

Last Edit: 23 Dec 2014 21:22 by oestek.

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23 Dec 2014 21:10 - 23 Dec 2014 21:24 #228 by oestek
A contoured lip as added to mimic the shape of the original.







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.

Last Edit: 23 Dec 2014 21:24 by oestek.

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23 Dec 2014 21:11 - 23 Dec 2014 21:20 #229 by oestek
A new filler panel was obtained from Classic Industries , and welded in place over the lower structure to complete the repair.





Last Edit: 23 Dec 2014 21:20 by oestek.

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23 Dec 2014 21:11 - 23 Dec 2014 21:16 #230 by oestek
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.





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

Last Edit: 23 Dec 2014 21:16 by oestek.

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