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Discussion Starter #1
First pic show the section I replaced today and second pic shows the rear panel in place and the lower rusted part I still need to repair.Will the lower part of the repair panel I have to make bend outward and be spot welded with the rubber bumper filler covering it when installed like in the third pic or does it bend inward and get welded from the inside of the trunk?It already had a prior repair so nothing original to go by for what I'm doing thanks and any good original pic's of this area would help also.


 

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The original trunk floor doesn't extend out as far as your panel in pic 1 shows.
The piece you fabricated is actually part of the rear panel of pic 2. That panel extends under the bumper in the shape you made.
Confusing?
The piece you have to make bends outward and is welded to the trunk floor that extends about 1" outside the trunk.
I can email you some pics of what I'm using to follow while I repair mine.
It will be a lot clearer seeing some pics.
 

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I'll email you the pics I have, tonight.
You are right, it really isn't a big deal that the trunk extends out further.
If you need some measurement, I'll see if I can take some of my car with
a ruler as reference.
I looked at some of your pictures in an old post you made, and the existing
dimensions look about right.
 

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Discussion Starter #5
I'll email you the pics I have, tonight.
You are right, it really isn't a big deal that the trunk extends out further.
If you need some measurement, I'll see if I can take some of my car with
a ruler as reference.
I looked at some of your pictures in an old post you made, and the existing
dimensions look about right.
Sweet.Im interested and seeing what you got thanks.
 

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I really really wish some enterprising young lad would make a marketable patch panel for this section, it is just as rust prone as the lower windshield panel! I have the same problem with my 65 that I will be tackling this winter.
 

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Discussion Starter #8
I really really wish some enterprising young lad would make a marketable patch panel for this section, it is just as rust prone as the lower windshield panel! I have the same problem with my 65 that I will be tackling this winter.
Its not too bad a job depending on how you decide to tackle it.I used thick steel I had set aside for my inner rockers on my truck so it will last much longer but a little harder to work with.The center section where it angles in is the hard part to recreate but doable.

If you guys don't mind, can you email me your pics? I am in the same boat. If I had to guess pretty much everyone with a '64 - '65 is.

[email protected]

Pat Routier
Madison SD
'65 Chevelle (ground up resto)
Copy and save any pics you see that might help.Ill be posting more for this thread maybe tomorrow to show how its coming along...A note also the third pic I found out today when test fitting the bumper that the rubber do dads were on the wrong sides.Right was on left and left on right.Its been apart for 9 years so I forget things.
 

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Discussion Starter #9 (Edited)
Here is what it is so far.Replaced up to the trunk lip to remove all the rusty metal.Ended up running a 1/4 in weld bead the length of it and will smooth it and go over the weld with some filler to make it look like one piece.The thicker steel worked out good because there was no burn through problems.The vertical section from the trunk lip down was replaced in stages with 5 sections but welded together.Some loose ends still left to finish but the majority is replaced.







 

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Well you answered one question I have, I was worried about welding around the neck of the gas tank. Is that just a pop bottle over the gas cap? My car smells a little fumey so I think that would be good insurance working around that area. There is little to no gas in my tank, which maybe would make it worse?

I was at a junkyard this summer with a 65 with a mostly intact but rusty tail. I took masking tape and made a template. I will make mine in the next few months and maybe I can make paper templates for others???? I will only do this only if the template works successfully.

Jeff
 

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I need to do mine, yours turned out great!!

Be careful with the tank there. Saw a guy here or on pro-touring doing the same thing and damn near blew himself up. Tank had been empty for years and blammoooo!!! He has pics of the damage from the fireball to his garage....Smoked and melted everything!
 

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Discussion Starter #14
That Gatorade bottle is OSHA approved isn't it:confused:LOL...A friend of mine blew his house up working on a bike tank.He went upstairs to wash his hands and the water heater kicked on and boom.Blew up the house which was rented/his bike and half his car melted from the fire.The look on his face in the paper was funny as hell.
 

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With the help of a friend I did this repair last year on my 65. Your's is turning out pretty good. The upper panel should curve out and weld to the edge of the lower panel, which is an extension of the trunk pan. As stated nobody makes this peice, which would sure be nice!


We made several pieces with 90 degree bends and while it's not identical to original, it is all covered by the bumper. Be sure to fit the bumpers while you are doing it, so it will clear when it is mounted. I left the rubber flap off my car. I just see it as a dirt catcher and maybe some of the reason this area is so prone to rust out. There are pix of my repair in this link.
http://s229.photobucket.com/albums/ee27/matts65/1965 Chevelle/
 

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Discussion Starter #16
Wow 2 years have gone by. Little update on my 64. Finished all the welding and small things that needed to be done. Sandblasted half the day today and it's just about ready to go to my brother for some paint. Some not so great pics of how it cleaned up with the blaster.
 
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