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Sunday, March 29, 2009

Out with the Old, In with the...Old!

Since the '64 is officially outside for it's completion, The 1954 Bel Air got the indoor spot. And the Bel Air is getting it's share of attention lately, since the cold spring weather has left the car hobby indoors. I have been wanting to strip and repaint this car for a long time, but there are a few things that I need to do in order to get to the painting stage. This past week I started replacing the rocker panels, and am now almost done fabricating and installing the passenger side.



The rockers were actually well cared for considering the rusted panels were not replaced, but carefully 'glassed and filled. The problem was that the panel's covering had become exposed to moisture since the car was never finish painted...it was left in regular primer. The water was then able to get to these places and formed slight rust underneath the fillers and fiberglass. So I decided to rip the filler off, cut out the panels and fabricate new ones.




Above shows the 'glass and filler removed, and a small section chopped off. This also shows the extensive rust in these rockers that was previously ground and covered.




Here's the picture of my pattern I used to make the new rocker panels. This is the small piece I cut from the gap shown in the previous picture.




Above shows the progress I've made after removing the rest of the rusted area. I used nice sheet metal strips on my homemade metal brake, bending the small angled areas. I then punched the overlap and contact sides with my cheap-o pneumatic flanger tool. This allowed the top panel to slide under the original flooring, and still meet the floor's edge flush. The bottom pieces had two bends formed, and then were carefully laid on the floor upright, while I leaned a 2" piece of exhaust tubing gently on the center. This leaning pushed a matching, gentle radius into the piece, making it fit the concave shape of the original rocker.

The welds will require being ground, but the whole project is turning out fine.

Am I sidetracked? Umm, not really...I mean, I did move the car that I claim to be focused on (the '64 LeMans) outside, and brought the Bel Air in. But hey; out with the old, in with the old!

Saturday, March 21, 2009

Completion (version 2.0)

I managed to get back to finishing the '64 Le Mans. It is officially outside, which means I can continue color sanding, buffing and everything else that was abruptly stopped last May. As said before, this car is many lessons learned. It is also a little bit of a cobble job, but I do still like it...

This Friday I pulled the window channel and wheel well trim from the garage rafters and started the process of getting them presentable and back on the car. The wheel well trim is polished and on the car, as well as the windshield and rear window trim. The pictures below show what's been done, with a little explanation under each.



The above photo shows the little holes on the trunk area that patiently await their emblems. On the left side will sit a Hurst Equipped badge, and the stock badges go where the other holes are.




This shows the windshield trim I finally got on. I had to tap out the few dings, then sand with 220 grit carefully around tapped area. Next used 400 grit wet, then buffed on the small buffer wheel with medium compound and finally on the big 8" buffer with the fine compound. The stainless wasn't perfect, but came out ten times better than it was!




This one above shows the polished wheel well trim on the passenger rear. This piece fit well, using the stock holes and not fighting with the usual "Bondo sculpture".



Here's the left rear wheel well trim just installed, and it hides a multitude of sins...or scars, at least. This entire lower quarter panel was welded in by yours truly, and wasn't exactly an accurate piece, given it was a Canadian repop that had been cut off a GTO. The panel was welded on wrong and warped, so a kind Pontiac lover chopped it off and gave it to me. After much cutting, fitting and MIG work it became this LeMans' quarter panel. I even had to stamp the correct well edge into the area where the trim sits, since the Canadian reproduction panel isn't exactly accurate.
Now, years later as I am putting the shiny wheel well trim piece on this spot, I can honestly say it doesn't exactly fit like it should...but hey, it looks good in the picture. I just have to remember, this car is a nice 20-footer; any closer and your eyes start noticing the hodge podge!



This above pic is the rear window trim finally on the car. This feels good-the '64 LeMans has been a long learning project. The trim polished up nice with the previous mentioned process.



Here is a side shot of the interior work that is in the still-unfinished stage. You can see the new headliner is almost done, and the new correct dome light is installed. So far, I'm happy with how this car is coming out, even though it is truly a first-timer in most ways. I just remember to keep people at least 20 feet away and to take fuzzy pictures in low light. Using those strategies always lets this old '64 look great.
Yes, it looks awesome, doesn't it? Please, don't get any closer...!