60 Biscayne

kb426 · June 08, 2017, 06:39:49 PM

Flintstone floors and wheels. I love it!

That's a lot of spot welds.

idrivejunk · June 08, 2017, 07:48:45 PM

Thanks guys

Wish I could make that scrambly sound like when the Flintstones peel out.

I just barely got it welded up and smoothed out. Stuff down low is welded but not all smooth yet. The quarter? Well of course its going to need attention but I believe its usable. Or will be with more work. I really had just finished grinding with the fat cutoff wheel then smooched it with an angle grinder and DA so it wouldn't look any worse than this... have not put a hammer to anything yet or done any grinding inside. However the big straight edge says it was a go, mission accomplished.

idrivejunk · June 09, 2017, 03:45:07 PM

Heres a look at the inside, front and back.

The outside again, after a few hours of finesse-ing. A hobbyist could take it further, no doubt. Mud man said it looked good. Inside the trunk is not exposed. I did have an assistant hold a dolly inside the trunk, and did some contortions with a spoon up front while I tapped and slapped around on it best I could. Zapped probably half a dozen pinholes up too. My whole idea was to "hide" the seam on the underside of the spear where theres door dings anyway. I am satisfied, relieved, weary, hoping for the best from here on out, and ready to tackle the other side next.

There are some pics that make it look like a million bucks but these are the most revealing and unforgiving shots I got, showing the waves toward the front and over the wheel where access was minimal. Including trimming the patches at the big seam and ending here theres between 15 and 20 hours spent. If you are counting.

chris spokes · June 09, 2017, 04:30:54 PM

good outcome matt, I was worried it was going to suck in real bad but your skills were up to the challenge

idrivejunk · June 12, 2017, 08:57:32 PM

Drama avoidance is the name of my game!

Thanks, man

Theres actually a big glob of factory installed goop between the quarter and wheelwell that I can only assume is to prevent flexing in that area (see black stuff, top pic). So GM knew that was a touchy spot, too. What they didn't know is it held moisture and created rustouts.

When I cut away the bottom of this quarter, I found it to have some tension there over the wheel. Glad its now on the chassis because when my fix is done, it won't be under tension. You can see where a big part of the wheelhouse lip has been loose from the quarter for a loooong time. I suspect the wheelhouse may be slightly out of shape but that won't matter. Gonna be about the same repair as the other side except that bottom front flange seems usable where I had to make one for the other side.

Heres your rust war gore... so far so good. I know you guys can't get enough of these wheels

idrivejunk · June 13, 2017, 08:14:56 PM

Spent most of today cleaning up rust on that whole area. Made my new wheelhouse lip, trimmed the shaggy part and applied coatings. Thats epoxy behind the axle and encapsulator ahead of it. This side had had a skinny new lip patch "installed" so I went about making mine with the old quarter's edge still on the wheelhouse. It lays on there nice but will need tweaks. Not as much room on this side so it will get partially welded from the backside. Found another riveted patch, this one on the inner wheelhouse so I'll redo it nicer and that negates the not having to make a quarter to rocker flange on this side.

idrivejunk · June 14, 2017, 08:29:27 PM

After I trimmed excess off the rear patch and put it up there, and saw how long it was... I moved the long cut up 3/4" and eliminated a rust hole over the axle in the old qtr. Only went as far as the rear patch covers for now. That patch and the lip patch fit together well and both have been screwed into place and fit the car nice now.

That front patch, though... It is for a similar car but not a Biscayne like this. The lip is squared and the wheel opening is larger. I can make the edge meet the old without heavy fuss. Well a little, maybe. I pondered on whether to keep the cut straight and try to add the spear contour to the new patch, or to jog down 3/4" diagonally at the front patch and stay in the flat area. I was able to straighten some of the lumpiness along the botom half of the front of the spear so we'll see. This is as far as I got-

Here is the other quarter with epoxy reapplied over the seam. I'd still like to straighten the same area on this side more. You can see where the ends of the patches were less than a perfect match.

While we're in an X-frame type mood heres a dash of color, the '59 Cat

This is what was happening in the next stall today. Couple more braces to go, across the axle hump, before they rotate. Fortunately this hardtop has extra body mounts under the back seat that the Biscayne does not-

idrivejunk · June 17, 2017, 02:34:21 AM

Here is the road's eye view of that Cat. Monster sized angle iron oughtta hold it steady over the axle. In this pic you can see just how large the trunk is compared to the passenger compartment-

Back on the Biscayne, Here is the lip patch installed. This side squirmed around during welding more than the other so I did have to knock it around a little toward the front-

I ended up making the cut on the quarter a straight line, and putting the spear contour's edge into the patch. In this pic you can also get an idea how much the length of the patch was off at the door opening (see cut started on top right)-

Its working out, I am satisfied with the fit. When viewed from the top, the rear patch's wheel lip is slightly caved in toward the front. More pronounced than the other side probably because using more of the patch. Its something minor enough it will "fix" during the filler stage, but the patch quality does limit the niceness of the repair. In my mind.

This one shows the outer wheelhouse extension at the rocker, in progress.

There are some rust holes up at the window area that I will probably repair before welding up this side, so the crap can fall out the bottom there. And theres another patch to do on the inner wheelhouse. All coming soon. So glad I have already done the bolt on parts because when I wrap up this body, I don't have them to look forward to. Thats another mind thing

Doesn't matter if I've finished because the stream of jobs seems to be un-ending. Can't say I'm not looking forward to a change of scenery, but I am enjoying doing these quarters. Hope the customer likes them

kb426 · June 17, 2017, 08:19:23 AM

Does anybody in the shop referee to that car as patches?

Will the Cat be blasted?

UGLY OLDS · June 17, 2017, 10:09:28 AM

Did the owner know the REAL condition of this car before starting the project :?: It seems like a LOT of metal replacement for a less popular model than say , a bubble top or convertible ...
Nice work as always , but seems like a lot of work on a sedan ..... :?

Bob...

idrivejunk · June 17, 2017, 01:20:54 PM

Quote from: "kb426"Does anybody in the shop referee to that car as patches? Will the Cat be blasted?

Well if they ain't, they ought to be.

Seriously that nickname is worn smooth from usage.

Wasn't Patches a hobo clown? It fits.

I believe the Cat gets a more extensive blast job than the Biz and that's why the roto. At a glance it is not as badly rotted but the parts pile will probably look similar.

idrivejunk · June 17, 2017, 01:46:58 PM

Quote from: "UGLY OLDS"Did the owner know the REAL condition of this car before starting the project :?: It seems like a LOT of metal replacement for a less popular model than say , a bubble top or convertible ...
Nice work as always , but seems like a lot of work on a sedan ..... :?

Bob...

Thanks. Apparently yes, Bob. Based on the amount of exploratory sanding and blasting done, and the parts bought before I got near it. Everything was in plain sight. I can't explain the justification. There are lots of folks out there who take their pet to a vet, for example... If your pet is sick and you can't fix it yourself, you pay. You want the vet to tell you the price first but go ahead with the surgery. Never mind the lecture about it's age in pet years. If it costs two grand to cure a sneeze, then you don't want anyone rubbing your nose in the how much it cost. If that vet suggests a .22 shell for anything serious, you're at the wrong vet. Unable to imagine the mental processes of affluent people, I just fix what they bring me, and raise a red flag when I see cost options available on a repair. I cannot explain anyone's behavior but my own! But I hope the analogy brings it closer to home for you.

Rrumbler · June 17, 2017, 04:33:36 PM

I like and appreciate the work you do and the pictures and explanations that go with. In this case, I also like the model of car more than usual. But in looking at the pics, I got to wondering if those long, straight lines in some of the panel patches are easier, or are they more work due to being more prone to warping?

idrivejunk · June 17, 2017, 05:14:40 PM

Quote from: "Rrumbler"I like and appreciate the work you do and the pictures and explanations that go with. In this case, I also like the model of car more than usual. But in looking at the pics, I got to wondering if those long, straight lines in some of the panel patches are easier, or are they more work due to being more prone to warping?

Thank you. I'd have to say that for me they are more enjoyable because there's enough real estate to run around on. Once it is in place, the welding is more continuous than it is on a small patch. So you get more pleasure of welding per hour than you would doing 6" long patches. I have learned how to be better at knowing when a nasty warp is trying to happen vs the little inevitable waves right at the seam, the ones that even out when the weld is complete. Staying calm can be a challenge.

I actually pushed my luck on that last quarter once the tacks were about 3/4" apart by welding that much at a time. Longer breaks were needed but there are less penetration worries and pinholes that way. But yeah, long straight welds go faster with less risk than things near edges or stampings. You just gotta work very evenly on straight stretches. One part that may be more difficult about the straightaways is the grinding while monitoring heat. Just as much warp potential and less forgiving on appearance and actual flatness.

kb426 · June 17, 2017, 06:48:35 PM

I enjoy reading your explanations but you have reinforced that anytime there is heat, there made be an adverse reaction. You have made me certain that we may have warpage until it's done.

The one that surprised me was the roof of the 34. When you removed the bracing I was caught off guard. Being able to use the camaro panel was great. The Ford and Chevy crowds should be able to discuss that for a long time.