Nothing really new, working on mounting driver side window glass. The driver door glass channel frame turned out too rusted to reuse. That is the U shaped channel that is riveted to the two end pieces. It looks like I will have to fabricate a new channel since I have been unable to find any used ones. I don't have the appropriate metal on hand (either 16 or 18 gage) to make this channel and so far all the easy to get to places like Lowe's or HD was out of stock of this thickness.
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I hope when you get her painted she will be super straight, especially with all the work you have put into the body.
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I hope it will be straight too. Although I consider myself good at filling small areas, applying thin layers of filler across large areas and working it seems much more difficult. In some cases I will need to apply filler across panel gaps in order to make things line up well. These are procedures I have never attempted before.
I'm thinking of using this procedure for the prep and paint.
1 Correct all of the major problems where I either weld or add metal to make things line up.
2 Remove trunk lid, doors, fenders and hood.
3. Paint the jam areas, under side of the trunk lid, etc.
4. Reassemble the car and set all gaps.
5. Mask the Jam areas.
6. Apply final skim coat(s) of Rage extreme to problem areas and work until straight.
7. Apply Epoxy primer to entire car and continue applying until I have a uniform color. The filler tends to show under the gray primer.
8. Final sanding of primer.
9. Paint the car.
My reason for this approach is that I won't have any help in putting the car together and the probability is very high that I would scratch something.
Just when I think I done will all the rust repair, I find the bottom on the driver window channel is rusted. After removing the window setting rubber, I dumped a large amount of rust particles out of the channel. After going over it with a wire brush I have numerous pin holes. The channel has lost about 75% of its thickness. As you can see it's not very straight. It bends very easy and would not do a good job of holding the driver side glass.
Here is a shot of the completed passenger side glass. Power windows work and power door lock also works. Although harder to see, the door and quarter panel align at the top.
Here is a shot of the completed gap work on the upper passenger door.
