[usc2001gc]

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:

 

[72 Greenbrier]

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.

 

[B52bombardier1]

Wagons are cool and I look forward to your build.

Rick

 

[usc2001gc]

Had a little help with the initial disassembly.

 

[usc2001gc]

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:

 

[usc2001gc]

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.

 

[usc2001gc]

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.

 

[usc2001gc]

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.

 

[usc2001gc]

Pictures of the lower patch panel.

 

[Chevys#1]

Very nice work looks like you have done this before.

 

[usc2001gc]

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.

 

[DUKE 69]

You are much braver than I would be...nice job!

 

[usc2001gc]

There's a thin line between brave and dumb...lol. Really didn't have much of a choice.

 

[Hotwire]

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! :beers:

 

[Robinls5]

" 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.:thumbsup::thumbsup:
Bob

 

[usc2001gc]

Thanks for the compliments. I'm never satisfied with my work, but it's saved me $1000's over the years. Plus I figured I'll never improve my skills if I don't try.

I'm hoping to get the tailgate in some SPI epoxy this weekend.

 

[cv67]

Nice, loved those wagons even as a kid, just the right size.

 

[usc2001gc]

Time for some updates. So, haven't worked on the tailgate anymore but I figured I'd share some additional progress on the car. I've been going around the car doing rust repair. This is what behind the driver's rear tire looked like. Doesn't look bad on the front side....just a few small pin holes, but look at the back side.
Problem on the driver's side is that with the gas tank on that side, there's really no access to the backside of the quarter panel to do any type of rust prevention. I was planning to do just a rear quarter lower patch for an el camino, but after finding this I decided to buy a el camino quarter skin and do a larger area to get back to clean metal.

 

[usc2001gc]

The el camino fuel door is lower in the quarter, so it has to be cut out and patched. Plan to replace the quarter skin right below the wagon fuel door due to finding previous collision damage when I started working on the quarter.

I kept trimming until I felt like I had clean metal. Ended up with this. One issue I wanted to also address was that someone had previously rolled the wheel well lip by cutting it ever 1/2-1" and bending it upward. Creating a nice place to collect dirt and moisture, causing rust on the outer housing lip.

I addressed this issue on the outer wheel well by buying a outer wheel well for a 69 Chevelle, cutting it to weld in the new lip. I'm not that concerned about the look of the welds on the outside since it will be hidden by the quarter, (I do plan to clean them up better than what's in the photo) but wanted to make sure thing were clean on the inside to keep hands injury free in the future.

I did this welding with a butt joint versus a lap weld (what I normally use) to try and determine which route I'll go on skin. My buddy let me borrow his pneumatic step tool, if I decide to go with the lap joint.

 

[usc2001gc]

Test fit of the quarter skin. End of pictures for now. My weld in the skin next week, but want to do some POR-15 treatment on the accessible surfaces before I close it back up.