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Rust revival

Been a bad boy and did no updates in far too long!
I'll restart now and try to get the build thread to the point the car is now.

the upper cowl area drivers side was a sore point for several reasons. Didnt realize just how big a sore point until I started to dig into the area.
Apparently Chrysler saw no need for water drainage in this chamber.
They were wrong.

I repaired the upper firewall...
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...and then cut the flange area away from the cowl top.
The amount of rust is obvious.

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Once the initial shock wore off (2 seconds...I'm used to it now! LoL) I went ahead and reconstructed a new flange all around. I did that now because it assured me of getting the height right. If I did it off the car it would have been more involved and less likely to work.

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Then I cut the top off as planned...exposing the hidden rust!

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I kinda got into the repair a bit too deep and forgot to take many pics of stuff getting made and welded but you can see from the completed pics that I made the pieces in sections so they could go in without stressing the wiper pivot mount. i basicly made the new over the old and the cut the last remaining connections to the rusted bits out from inside the car.
Worked out good and the pivot and pivot hole in the cowl top remained aligned.
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due to having to get a good layer of seam sealer right under the windshield pinchweld area I actually had to weld on the outer section again and recut it off lower!
By doing it that way I was able to seam seal without having the final weld burning it up.

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This pic shows it welded and recut...sealed and painted inside.

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Then it was final welded into place...

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...with a nice big drain hole that Chrysler forgot to include!

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More soon!
 
nice work on shaping the metal around the corners.
 
Wow! You continue to amaze me with your approach and execution as you erase all the corrosion on your car. I don't think I've seen anyone hand fab so much to save a car with this much hidden rot. Press on friend, I'm curious to see whats next!:headbang:
 
68sportsatelliteragtop said:
Wow! You continue to amaze me with your approach and execution as you erase all the corrosion on your car. I don't think I've seen anyone hand fab so much to save a car with this much hidden rot. Press on friend, I'm curious to see whats next!:headbang:
Click to expand...

That little kick in the butt PM you sent worked...to get me posting again anyway! LoL
The car is on the back burner for the summer, but I have a lot done since this so I can put up a number of updates that you'll find interesting (like a train wreck!) I'm sure!

A friend is picking at the brakes for me while its in storage at his shop and I just ordered a pair of front fender/headlight sections from Member "ike61" to repair my non-existant ones.
I could repair them but sometimes its just better to get a panel or repair section when you can.
The shipping is what really kills me, being so far off the beaten path...

Anyhoo....I'll keep it going as I get the chance! :grin:
 
I'm very impressed! I saw that you hang out at the H.A.M.B. Me too, great place. Metal Meet is another great site for all things metal related. I'm gathering parts for my 64 Polara and love the neat beadding tool you made for your chisel. My floors are good except for the drivers side front where somebody repaired it wrong. Great tool!
 
wedgeheaded said:
I'm very impressed! I saw that you hang out at the H.A.M.B. Me too, great place. Metal Meet is another great site for all things metal related. I'm gathering parts for my 64 Polara and love the neat beadding tool you made for your chisel. My floors are good except for the drivers side front where somebody repaired it wrong. Great tool!
Click to expand...

Hope you can make use of that beading tool yourself...pretty easy to make!

Yeah...been on the HAMB for years. I'll keep an eye out for you.
Hot Rods are at the very top of my list, but to be honest...my list is very very LONG!
I guess if it has an engine its there! :headbang:

Metalmeet is incredible.
I used to go there and check things out but the skill level over there made me feel hopeless in comparison.
Nothing I can do compares.
I'm just a hack...but I'm having fun!!! Hahaha
 
Black63 said:
Hope you can make use of that beading tool yourself...pretty easy to make!

Yeah...been on the HAMB for years. I'll keep an eye out for you.
Hot Rods are at the very top of my list, but to be honest...my list is very very LONG!
I guess if it has an engine its there! :headbang:

Metalmeet is incredible.
I used to go there and check things out but the skill level over there made me feel hopeless in comparison.
Nothing I can do compares.
I'm just a hack...but I'm having fun!!! Hahaha
Click to expand...

My list is long too. H.A.M.B. and Metel Meet both mak me feel quite humble. Here are some links to some of my junk. http://www.flickr.com/photos/75992550@N04/sets/
 
I love seeing work like this. It's inspiring, and it shows what can be done without having to look for pre-stamped panels. Keep at it!

-=Photon440=-
 
Sure would be nice if they did Poly1963!

Once the top was back on that side i went ahead and finished off sealing the rest of the chamber, painted it inside and then repaired the top piece over the brake master cylinder area.

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Then...finally, I was able to put the top back in place and consider the cowl done! (other than the grinding and bodywork of course!)

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The inside was also sanded, primed and seam sealed as well.

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Around this time i was also fitting the front and rear suspensions back together and getting the bits painted up etc.
Not really getting crazy with detail...just cleaning up any rust, priming and then hitting with satin black.
It's clean and looks fine to me!
Ignore the rusty rotors...they're just rollers.

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Because I adapted springs I had a bit of an issue with getting the tires to fall exactly where I wanted them, so I ended up redrilling the pads to move the rearend slightly forward. Seems to be alright now...but I left the U bolts only tight rather than fully torque them just in case. If I still need to move the axle a bit in final assembly at least I won't have to buy more!

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Had to get her rolling...'cause the frisky ol' gal has a date across town!

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