Not a math question. I have a 68 Skylark convertible that I ultimately want to do a complete disassembly on. I need to replace portions of the rear quarter panels as well as the trunk floor.

Please tell me if this sounds like a reasonable plan of attack:
1. Remove the interior
2. Remove the top (should I take it off assembled and down or remove the fabric first?)
3. Cut out the rusted portion of the rear quarters.
4. Remove and replace the rusted trunk.
5. Replace the rear quarters.
6. Remove the body from the frame.
7. Disassemble, clean, rebuild, paint.
8. Reassemble in reverse of above.

Are there any decent books that follow the restoration process of a complete car?

Any help is appreciated before I begin my 5 to 8 year odyssey.

Thanks,
Dale

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As for the order of operations, your way sounds fine. The complete top assembly can be removed in one piece, I just did that this morning on a 69 skylark convertible I parted out. Dont remove the top material from the frame, as measurements from the old top will needed when installing the new one.

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Dave
70 chevelle ss396 conv
66 chevelle ss396 hdp/conv
72 chevelle
55/57/61 chevies
TC member #493
Never forget Earnhardt!

When you removed the top, did you take it off when the top was down? Is it hard to handle by myself (not Charles Atlas) or should drag someone in to help?

Thanks for your response.

Dale

You have to take it out about 3/4 the way up. Remove the back seat and side panels that cover the top cylinders. Unbolt the cylinders from the top frame and set them aside. Remove the 3 frame to body mounting bolts on each side that were behind the cylinders. Check the metal rail under the well liner that is against the very rear of the car, if it is bolted to the car you need to remove all the bolts all the way around the car. I think the 68 has them, my 69 didnt. After those bolts are out, unlatch the top and fold it partway back. You can lift the whole top frame up and out of the car by tilting it and angling it out. Takes some shoving but will come out. You should be able to then fold the top and carry the whole thing out of the car.

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Dave
70 chevelle ss396 conv
66 chevelle ss396 hdp/conv
72 chevelle
55/57/61 chevies
TC member #493
Never forget Earnhardt!

Dale, It is easier to remove the top with two people. After removing mine I suspended it from the garage ceiling in the open position since my fabric top was only a year old. I reinstalled it 5 years later as good as new.
It's a great way to keep it out of your way and not get damaged. Just throw a blanket over it before tieing it off.

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TC #364
Aces #4309
Jeff's 69 (http://www.chevelles.com/showroom/daytonajeff1.jpg)

I'd be careful about cutting panels and trunk floors out and then removing the body from the frame. Believe it ornot, you can actually bend the body. Convertibles are especially susceptible to this. Most people here recommend welding a temporary brace across the door cutout before removing the body fromthe frame. You can tack weld it in place and then clean the spots after you reinstall the body.
You might want to consider leaving the body on the frame until you've completed the sheetmetal repairs, but you'll still need to install the temporary brace across the door openings.

Randy is 100% correct, try too do as much sheetmetal on the car as you can BEFORE you pull it from the frame.. My hardtop flexed a little when I had all of the panels removed ON the frame.. Luckily I caught it, and was able too straighten things out before I got too far... Good Luck!!!

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X-Ray View of my Chevelle :D (http://www.normieschevelle.com/sideview.jpg)
Getting Closer (http://www.normieschevelle.com/passfull.jpg)

Thanks Randy and normie,

I had intended on doing as much sheetmetal work as possible before lifting the body. I don't want it to fold like a book. Being a lazy typer, I combined all of that in steps 3 through 5. I appreciate the heads up though.

This is probably not a problem with your Chevelles, but what do you do when there are no reproduction sheetmetal parts for your car, like rear quarters? Do you fabricate them yourself?

Thanks,
Dale

In the case you have no repo parts available, you can do a few things, cut out the rotted sections and patch them with similar grade and thickness sheet metal. Or you can find a hardtop car and pull donor quarters off of it as long as they are in good shape (in the sections that need repair) but you can bend and form metal pretty nicely as you go too make a seamless repair if you take your time and do it a step at a time. Good Luck...

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X-Ray View of my Chevelle :D (http://www.normieschevelle.com/sideview.jpg)
Getting Closer (http://www.normieschevelle.com/passfull.jpg)

Just a few more thoughts.
After the interior, remove as much outer trim as possible including bumpers, lights, etc.
Buy some plastic bins (Wal-Mart) and lable them. It makes it SO much easier when re-assembly happens 4-5 years later.
The front clip can be removedW/O disturbing the rest of the cars body alignment.

I use Zip-loc bags and put them in boxes. Lable the bag, like RF Seat, LF Seat, etc. then they go into a box labled "Interior". And keep EVERYTHING! DON'T throw anything away, no matter bad it is. You may need it for measuring, look see, you never know.

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Dave Bradley
www.corvetteforum.net/classics/d1_bradley (http://www.corvetteforum.net/classics/d1_bradley)
'69 SS396 ragtop
'33 3W Coupe
'65 Vette BB Roadster