My car has quite a bit of rust, and some of it even extends into the inner body metal (behind quarter panels). I'd like to cut out and replace this metal of course, but is it possible to fabricate any sheetmetal piece, have it fit well and then weld it in and have it be as strong as the original? Then have it look original?

Another instance is the rear wall in the back of my El Camino. There is a few rust spots there, some of which go through. I might have to cut out this metal and replace it. Is there a way to replace the metal and then weld it and have it be undetectable from both sides? My other options I guess is donor sheetmetal. Thanks for any help!

I realize my car may be too far gone but I'd still like to see what I can do and then I'll decide from there. I'm also contemplating having my body dipped because of all the rust.

Check out this page (http://www.dreamelectric.com/Rust.htm) to see the rust I'll be dealing with.

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1970 Chevy El Camino (Custom) Non-SS (http://www.dreamelectric.com/images/pb040001a.jpg)
Green Mist & Silver w/Green Vinyl Top
350ci/300HP 4bbl & Dual Exhaust
TH-350 - 2.73 Posi Rear
Factory PS, PB, PW, A/C & More
My El Camino Home Page (http://www.dreamelectric.com/index.html)
Team Chevelle Member #995
"..dreams turn into dust and blow away"- Dionne Warwick (1968)

[This message has been edited by Shawn (edited 01-12-2001).]

Is it possible? The space shuttle was fabricated; men have walked on the moon; and cancer is routinely being cured these days. An expert metalsmith can pound you out any almost any shape in almost any type of sheet metal that you desire. But it might not be cheap. Donor sheet metal would be a much more reasonable way to approach the repair.

My $0.02

That's what I was thinking, using donor sheetmetal. Do you think someone inexperienced like me could learn to pound metal into the right shapes? Is it difficult? Right now, I've just been using tin and rivets to patch some holes, but that's just temporary.

Most major panels are available like floor pans,wheelhouses quarters ect.Fabrication is certainly a part of restoration.If you are really serious about this car and it sounds like you are,I would by a small welder,big compressor and some air tools,because your gonna need em.You can by sheet metal and cut and form it to the shape you need with a vise,vise grips and whatever else you can think of.Maybe if there a sheetmetal outfit around you you can have them bend you up whatever peices you need that can't be bought.If you plan on a full restoration i would get the chemical dip,fixing a car like yours can get very expensive fast.you might look for another body if your is that bad. http://members.spree.com/entertainment/ochrisl/

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70 chevelle,400cid turbo400.blue with silver stripes.http://members.spree.com/entertainment/ochrisl/

shawn, it isnt that hard to make patches, it just takes practice. take your time. a couple guys in my class built quarters and rockers for a 72 Gremlin http://www.shelby.net/mgervin/laugh2.gif . project from hell....

also, i built some patches for an el camino project, then welded in new quarters. guess who got done first....

what i'm saying is, yes, you can do it, but if you can afford panels then buy them. itll be done faster, and look better. plus its easier...


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Rich Miller, 1970 Chevelle Malibu 350(soon to be a 468!)
1973 El Camino (wifes car)
My POS(it looks better now, i promise!) (http://www.geocities.com/richrachel_69101)

[This message has been edited by RichsSB70 (edited 01-12-2001).]

Yup, that's what I'd be doing, buying the panels that're available aftermarket and making the patches for what isn't. Alot of the rust extends beyond where the replacement panels reach, like the floor pans where it goes into the kick panels area. Maybe I should've nicknamed the car "patches!" Hahaha, ok so it wasn't that funny http://www.chevelles.com/forum/biggrin.gif. Anyway, it's a very challenging project, but I'd like to test my skills. It'd be a big accomplishment if I could repair it all.

I have done projects like that and it like you saved it, you have performed a miracle or something. It is almost like a heart transplant, without you it would have been scraped. It is very rewording, and when you are done, you will be a master at making panels that's for sure!

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1965 Buick Gran Sport Convertible
1965 Buick Skylark H/T

MartinSR,
Thanks for the encouragement. That'd be great if I could bring a body like that back to life. It sure would feel great if I got it all patched up and could take pride in what I did!
If anyone knows where some donor pieces can be cut, or can cut some for me, please don't hesititate to let me know (elcamino1970@hotmail.com). Thanks!

The only way you'll ever find out is if you try it. What do you have to lose? If it dosn't come out right, do it again and learn from your mistakes. like NIKE says.........

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Triple Black 69 SS 396

Martinsr, this makes me think of the link recently noted on the autobodyshop board showing the guy building the Daytona Coupe Cobra from ground zero on up. If I was computer savy enough I'd post the link. Can you post it here? Thanks!

Ok I'll give it a try.

Heres the site; http://members.aol.com/coupechuck/index.html

Its not Chevy related but impressive metalworking skills worth viewing!

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Elcaminos are special!


work in progress
Big James Elky(AKA Ol Paint) (http://www.chevelles.com/showroom/Big%20James4XL-Ol%20Paint1.jpg)
another shot of Ol Paint (http://www.chevelles.com/showroom/Big%20James4XL-Ol%20Paint2.jpg)

[This message has been edited by Big James 4XL (edited 01-14-2001).]

[This message has been edited by Big James 4XL (edited 01-14-2001).]

[This message has been edited by Big James 4XL (edited 01-14-2001).]

[This message has been edited by Big James 4XL (edited 01-14-2001).]