#1  
Old 02-01-2023, 07:04 PM
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Default Ď68 GTO random body work

I figured Iíd make a ďself motivationalĒ pic intensive post to help keep me focused on being road-ready by the time the weather breaks.

The quarter panel wheel arch area led to outer wheelhouse rot, which led to some inner wheelhouse rot, which continued on to what looked like a small portion of the trunk pan @ the wheelhouse. Hereís where the pics start. I noticed a small patch of filler last night and found it was a little more widespread. I have a left trunk floor pan panel here already. So hereís where a few hours got me to.
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  #2  
Old 02-01-2023, 07:10 PM
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Some measurements for when the trunk floor drop off is cut free as well as some scribe lines on the inner wheelhouse above and below where the floor meets.
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  #3  
Old 02-01-2023, 07:18 PM
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I was hoping to have my right seam right down the center of the left spot welded edge of the fuel tank brace, but I might have to continue to the right more. I still have to cut forward towards the hump area for good metal. Left trunk floor brace and fuel tank brace were ordered late last night.

Inner wheelhouse isn’t trimmed to length yet as it’s just held in with magnets for alignment purposes. I spent nearly 3hrs trimming that weld seam for a nearly zero daylight gap at the soon to be butt-welded seam (after the floor goes back in).

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Old 02-02-2023, 03:42 AM
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Damn I hate rust. It's evil. And it never sleeps

I used to do the same thing vis-a-vis posting for inspiration ... makes you feel you are committed to making some progress.

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Old 02-02-2023, 08:55 PM
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Haha yeah exactly. If I canít keep updating then I can see that Iím slacking each time I visit.

Got the rest of the bulk out tonight. Down to the trunk support that Iím hoping shows up tomorrow. Did a little trim on the panel to do a quick test fit.

I really think even JEGS is now sourcing their sheet metal from Classic Reproductions (Vintage Parts Club, or whatever you want to call them) with the ďMade in USAĒ tag. The top left rib profile even matches the CR stampings. Who knows. All I do know is JEGS got the panel here $20 cheaper than VPC even with my discount!
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Old 02-03-2023, 04:13 AM
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Nice looking piece of steel. Had no idea there were US made items out there. Keep in mind every piece of rotten metal you replace makes the body/car stiffer, quieter and stronger.
I always found that to be an inspirational thought while I was working.

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Old 02-03-2023, 11:08 AM
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Your motivational photos are working. Great progress!

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Old 02-07-2023, 07:46 PM
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Feel like Iíve stalled out moving forward while Iím still waiting on those supports. Took the last two days to build a guide fence for my bead roller and also started playing with figuring out the profile for the trunk ribs. I have to extend my patch section forward towards the rear seat area just a few inches. Iím still trying to keep some progress going.
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Old 02-08-2023, 06:59 AM
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Hey you HAVE a bead roller ... that's more than most of us

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Old 02-09-2023, 10:28 AM
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Iím definitely grateful for the tools Iíve collected over the years! I wish I had more time to use the bead roller for other projects, itís a fun tool to mess with. I need to come up with a pair of flat roller dies but one of the tools Iím lacking is a decent metal lathe to make them.

Made a little progress last night (trying to take advantage of the warm spell here) but still waiting on parts to arrive.

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Old 02-14-2023, 11:04 PM
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Moving along... I had to fab a section heading towards the center due to some hidden weak spots just beyond the patch. I probably should have ordered a left patch panel and a center from the start, but this gets it done. Just took an extra 2 days to make and weld on. Maybe I can form the forward extension tomorrow after work and get that welded onto the patch too.

Iíll still send the weld seam back through the roller with 2 flat dies and save on some final hammering. The tank brace and trunk to frame support are finally here too so thatís cool.
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  #12  
Old 02-15-2023, 09:49 AM
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Jeez you are doing some nice work there. I think you have more patience than me

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  #13  
Old 02-15-2023, 11:06 AM
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I think you have skills beyond mere mortals. Impressive!

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Old 02-15-2023, 03:41 PM
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Thanks for the kind words guys. Itís the machines and not me. Iím still getting things dialed in since switching to my HTP TIG machine. I probably did close to 30 linear feet of 20ga sheet strips this past weekend just trying to sort things out. I finally settled on some crazy pulse settings (115A, 0.8P/S, 10% D, 15%BG) and it stays cool and practically welds itself up lol. Fresh metal is a dream anyways so the real challenge will be patch to body panel seams.

That bead roller does way more than I expected for a budget model. I spoke to Heck Industries today and theyíre shipping me out a few sets of flat rollers they had manufactured in the past for exactly what I want to do. Great guys there. They manufacture for Woodward and maybe some smaller house brands.

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Old 02-16-2023, 11:58 PM
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Still plugging awayÖ. Decent test fit tonight with the forward patch section in place. Also tightened up the loosely shaped rib up where my extension is. I rolled a more defined edge on it to match my patch rib profile section and the original. Thatís the only flaw I can find on the ďClassic ReproductionĒ brand panel. Included a pic of how well the rearward ribs match.
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Old 02-17-2023, 03:20 AM
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Looks like you could use some Cleco fasteners ... great for jobs like that.

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Old 02-18-2023, 03:20 PM
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Yep- grabbed them from the basement last night. Iím trying to get the frame to body support in today. Iíll probably do a couple Clecos to that to hold things. Iím addicted to these stupid magnets I got years ago. I donít know what they are but the strength is unbelievable. They always help out when I get to the finer cuts for all the butt welds Iím going to have in here. Only negative is forgetting theyíre there and welding anywhere near them!

I may drop the rear end today and slide it out for more room. That fuel tank top brace/mount really wraps into that axle hump.

On a side note regarding the rear endÖ I canít decide if itís worth tearing into that to rebuild while itís out or just dropping the extra $$$ to slide something new in. Itís the original open 10 bolt 8.2 w/3.55ís. I already have new Dutchman axles and new pressed on bearings but could easily cut my losses I think.

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Old 02-26-2023, 08:38 PM
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Is there a chance anybody could look in their trunk and let me know if the raised area I boxed in on the pic has any other detail on it or is just flat? The same area on the right side of the trunk has 2 raised elliptical looking ribs. Iím extending my repair slightly up into that area after removing the tank brace tied to it below.

Thank you.
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Old 02-27-2023, 09:06 AM
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Here's mine.
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Old 02-27-2023, 11:04 AM
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Although all the tasks taken overall can be daunting, keep going. Do a little bit at a time, and when you get to the point when you're satisfied, the reward of having your car back in shape will be a huge reward. Your project looks good! keep plugging away!

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