1972 Concours 5.3/4L60E project - Chevelle Tech
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post #1 of 20 (permalink) Old Jan 6th, 19, 9:43 PM Thread Starter
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Eric
 
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1972 Concours 5.3/4L60E project

Figured it was about time for me to start a build thread for my 72 Concours.
I originally bought a 71 Concours, but found major rust issues around the back windows. I decided to put that wagon on hold and bought Pete's 72 that was advertised on his website Home of the Chevelle Wagons - Total resource center for Chevelles, Wagons & El Caminos..
I've already had it a couple of years, but have struggled to find time to work on it.
So far I've rebuilt the suspension, converted the rear to disk brakes, rebuilt the front brakes, have the 5.3/4l60e in the car, and have started working on rust repair.
I've been taking pictures along the way and figured it's about time to get a build thread going.

This is what the wagon looked like when I got it home:
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post #2 of 20 (permalink) Old Jan 7th, 19, 11:59 AM
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Mike
 
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Re: 1972 Concours 5.3/4L60E project

Looks really good in the picture Eric...

Be great If you posted some pictures of the build...I'd especially like to see your rust repair progress as I'm in the middle of that myself.

"LS swap without breaking the bank"

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post #3 of 20 (permalink) Old Jan 7th, 19, 12:33 PM
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Rick
 
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Re: 1972 Concours 5.3/4L60E project

Wagons are cool and I look forward to your build.

Rick

1970 El Camino under Reconstruction - 5.3L LS VORTEC Engine and 4L60E Transmission
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post #4 of 20 (permalink) Old Jan 7th, 19, 8:14 PM Thread Starter
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Eric
 
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Re: 1972 Concours 5.3/4L60E project

Had a little help with the initial disassembly.
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post #5 of 20 (permalink) Old Jan 7th, 19, 8:28 PM Thread Starter
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Eric
 
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Re: 1972 Concours 5.3/4L60E project

I'll start out with my most recent work on the tailgate rust repair. I think the worse part of the wagon was the tailgate.
When I bought the car, i knew it would take some major repair for the tailgate bi I'd previously read that you could use the El Camino skin as a repair panel.
Below is the initial condition of the tailgate:
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post #6 of 20 (permalink) Old Jan 7th, 19, 8:39 PM Thread Starter
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Eric
 
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Re: 1972 Concours 5.3/4L60E project

I started with the small area on the side of the tailgate.

My disclaimer....I am by no means a professional body man, so please be nice.
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post #7 of 20 (permalink) Old Jan 7th, 19, 9:03 PM Thread Starter
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Eric
 
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Re: 1972 Concours 5.3/4L60E project

I then started on the bottom of the tailgate. This is where I ran into some issues and ended up doing some rework.
My initial plan was to make a simple patch for the middle portion of the gate, but once I got the patch welded in and move over to a small area to patched I determined the the metal was too thin from rust on the back side. I then decided to replace the entire lower portion of the tailgate.
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post #8 of 20 (permalink) Old Jan 7th, 19, 9:16 PM Thread Starter
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Eric
 
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Re: 1972 Concours 5.3/4L60E project

I sandblasted the bottom of the tailgate, then decided to drill out the spot welds and remove the bottom outer skin and start over. Plus this gave me the opportunity to apply POR-15 to the inner structure that was exposed.
I then used the pieces I removed as a template to make the repair panels. My metal break wasn't wide enough to make one panel, so I make two pieces and then welded them together.
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post #9 of 20 (permalink) Old Jan 7th, 19, 9:34 PM Thread Starter
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Eric
 
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Re: 1972 Concours 5.3/4L60E project

Pictures of the lower patch panel.
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post #10 of 20 (permalink) Old Jan 7th, 19, 9:49 PM
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Mike
 
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Re: 1972 Concours 5.3/4L60E project

Very nice work looks like you have done this before.


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post #11 of 20 (permalink) Old Jan 7th, 19, 9:49 PM Thread Starter
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Eric
 
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Re: 1972 Concours 5.3/4L60E project

Time to move on to the skin. Below is a picture of the El Camino skin and the area that would need to be cut off to use it on the wagon gate.

As stated earlier, I POR-15'd all the inner structure while it was exposed.

Once cut, I used a pneumatic flange tool to make a step for a welded lap joint. I know most recommend doing a but weld on sheet metal repair, but I didn't feel comfortable with such a wide area. The flange gives some extra rigidity to prevent warping during the welding (I say again, I'm not a professional).
I has access to the back side of the flange and will be able to seam seal the lap to prevent future rust issues.

Now ready for a skim coat of filler to smooth out the weld area.

Not a bad repair in my opinion and I don't think I'll have to worry about anymore rust as long as I have it.
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post #12 of 20 (permalink) Old Jan 10th, 19, 12:58 PM
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Duke
 
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Re: 1972 Concours 5.3/4L60E project

You are much braver than I would be...nice job!
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post #13 of 20 (permalink) Old Jan 10th, 19, 9:45 PM Thread Starter
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Eric
 
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Re: 1972 Concours 5.3/4L60E project

There's a thin line between brave and dumb...lol. Really didn't have much of a choice.
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post #14 of 20 (permalink) Old Jan 11th, 19, 7:56 AM
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Jeff
 
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Re: 1972 Concours 5.3/4L60E project

Doing a fine job man! I wish I'd taken the time to tackle some of this on my car but I'm afraid it would open a large can of worms my stomach and checkbook can't keep up with. Good luck, looking forward to the updates!

*Jeff*

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post #15 of 20 (permalink) Old Jan 11th, 19, 1:00 PM
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Re: 1972 Concours 5.3/4L60E project

" DAM ".................. He does nice work! I am rebuilding a hinge for a 70 two way. A friend was tossing out wagon parts, So they went home with me.
Sure is a lot of " STUFF " inside a two/way gate.
Wagon wheel repairs are done by a " Wheelwright ", With all your nice work, I will call you a " DoorWright ".
Very, Very nice work.
Bob
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