John’s 65 sedan

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doug6423
Posts: 431
Joined: Mon Jun 03, 2019 10:57 am

Re: John’s 65 sedan

Post by doug6423 »

That's the way to do it. At the spot welds.

I appreciate you posts. Keep at it!
65 Monza
Cincinnati, OH
Project65
Posts: 509
Joined: Tue Dec 07, 2021 8:03 pm
Location: Pennsylvania

Re: John’s 65 sedan

Post by Project65 »

Thanks Doug. I’m laser focused and will keep at it. (Although I do have another side project in front of me coming up, but will press on!)

:woo: Today I was able to put a few hours in and remove the highly coveted and extremely rare shock tower and shock tower panel from the donor. (Really?)

I drilled out the spot welds and was able to cleanly remove the sheet metal pieces. The panel is in need of some light sheet metal repair. The shock tower has some mild deformation from age, but seems solid still. I may use the one from the passenger side of the ‘66 on the driver’s side of the ‘65 if I can retrieve it cleanly.

Thinking that I’ll move next on the ‘65 and remove the rear quarter panel and proceed with the sub-frame repairs and shock tower repairs.

As an FYI…I’m using 3/16” Norseman M7. Hi-Molybdenum drill bits along with 5/16” cobalt drill bits for drilling out the spot welds. You need really good bits to do this. Cheap bits won’t work. I’m buying them at a local “Fastenal” store. They’re worth the $$$. Note: the harbor freight spot weld drill bits won’t even drill one hole! :banghead: Trust me. I learned this months ago. Plus, that Corvair steel from the mid ‘60’s is hard!
Attachments
Shock tower panel from the donor
Shock tower panel from the donor
Light repairs needed on the donor panel.
Light repairs needed on the donor panel.
Donor shock tower and panel.
Donor shock tower and panel.
Rear Shock tower and panel drilled and still on the car.
Rear Shock tower and panel drilled and still on the car.
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Project65
Posts: 509
Joined: Tue Dec 07, 2021 8:03 pm
Location: Pennsylvania

Re: John’s 65 sedan

Post by Project65 »

So yesterday, I was working on the car with the garage open. Making all kinds of noise.

After I picked up everything, I shut the garage door, went upstairs, then came back down to leave the house. I notice a few things were tipped over. :think:

So my son comes home to find a woodchuck, on top of the ‘65 in the garage! He opened the door and chased it around for a half hour before the darn thing would leave! :rolling:

Here’s a photo…

Something about this car and rodents? :dontknow:
Attachments
Woodchuck on the ‘65
Woodchuck on the ‘65
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Project65
Posts: 509
Joined: Tue Dec 07, 2021 8:03 pm
Location: Pennsylvania

Re: John’s 65 sedan

Post by Project65 »

Today I began to prepare for the next step in my mind, which is the removal of the remaining rear panels on the’65. I’d like to install the rear quarter panel on the’65.

Before I started this thread, I replaced the front floor and subframe on the ‘65 from a donor that I bought from the Corvair Ranch. (Thanks Jeff!). I had to make a pattern to guide me where to cut on the ‘65.

So how I did this previously with the floor is something that I thought up as I’ve never seen this done elsewhere. My approach to the quarter panel is the same.

On the quarter panel along the cut lines I begin with laying down aluminum foil and taping the edge.

Then I use cheesecloth and wet it with the wet plaster, then lay it on the foil. I’m making a cast mold of the fender.

I’ll use the mold to make a 3-d pattern which I’ll use to tell me where to cut. More to come on this !

I also drilled out more spot welds along the rear tail piece panel in preparation for the panel removed.
Attachments
Before.  The raw donor.
Before. The raw donor.
Lay down the foil so the plaster doesn’t stick.  (And believe me it will)
Lay down the foil so the plaster doesn’t stick. (And believe me it will)
Cover with cheesecloth and plaster. Allow to harden.
Cover with cheesecloth and plaster. Allow to harden.
Drilling spot welds in preparation.
Drilling spot welds in preparation.
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Project65
Posts: 509
Joined: Tue Dec 07, 2021 8:03 pm
Location: Pennsylvania

Re: John’s 65 sedan

Post by Project65 »

Making more good progress. Today I had another good 5 hours in and the focus was getting the quarter panel cut from the ‘65.

I began with trimming the plaster cast on the donor down to the cut lines with a razor knife. Nice and clean. Then I split the cast at the rear at the rear window frame fold.

I carefully removed the cast from the donor and placed it on the ‘65 and pressed it down all over to get a good tight fit making sure the rear seam lined up. The mold fit the body contours perfectly. I checked a measurement by the back window and it matched the measurements on the donor.

Then some grey rattle can primer was applied to mark the cut lines. Then I removed the cast. Cut lines were marked with a 3-D pattern.

I also had to weld in a piece of 1-1/2” angle from the roof to the rocker to serve as a support. Without this you can’t get the proper fit as the roof will sag.

I cut inside the cut line about a 1/4” to give me room to trim for perfect fit. The rest of the removal was a butcher and hack just to get it off.

I’ll next trim everything back down to the frame and spot weld folds for clean surfaces for clean welding. Also, I have to repair a hole in the rear frame at the shock tower.
Attachments
Cast trimmed to the steel
Cast trimmed to the steel
Cast on the car.
Cast on the car.
Cut lines marked
Cut lines marked
Support angle welded in and the quarter panel and inner fender removed.
Support angle welded in and the quarter panel and inner fender removed.
Rear view
Rear view
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Project65
Posts: 509
Joined: Tue Dec 07, 2021 8:03 pm
Location: Pennsylvania

Re: John’s 65 sedan

Post by Project65 »

Started cleaning up the body flanges and assessing their condition. There’s a few bad spots :doh: that are rusted, but are repairable by cutting out the bad and welding in new steel.

Drilling spot welds is sometimes the way, but I’ve also resorted to cutting between them, sectioning out the steel, then simply using a grinder to grind the spot weld and remaining steel away until I’m down to the base flange steel. Especially on the larger welds like on the rocker panels. I find it the only way to get rid of it and minimize risk of damage with also less frustration. :banghead:

I’m down to the deep area of the inner rocker panel at the rear wheel opening. There’s supposed to be a hole with a rubber flap there. It was completely rusted out. I’ll be able to repair the area, while the donor also has some better steel there to work with.

I’m planning on working my way all the way back along the frame and taking it all the way down to make additional reconstruction repairs.
Attachments
Previous rusted out inner rocker panel drain.  It looks hopeless (like the rest of the car).
Previous rusted out inner rocker panel drain. It looks hopeless (like the rest of the car).
Cleaning up the rocker flanges for repairs
Cleaning up the rocker flanges for repairs
Cleaning up the inner rear fender flange.  A few thin areas to repair.
Cleaning up the inner rear fender flange. A few thin areas to repair.
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Project65
Posts: 509
Joined: Tue Dec 07, 2021 8:03 pm
Location: Pennsylvania

Re: John’s 65 sedan

Post by Project65 »

A good long day of working on the car. I put about 8-1/2 hours in. Today was full of challenges. I cleaned down the driver’s side rear frame rail all the way down and assessed the hole in the frame. Drilling more spot welds and chiseling. Once I got the frame cleaned, honestly I was scared thinking either this is the end of the project or I repair the rusted out frame. :dontknow:

I thought about cutting the entire section of the frame from the donor, but thought I should attempt a fabricated rebuild first. I figured it was junk and again, I can’t screw up junk, so cut into it and attempt the fabricated repair. Just kept cutting back until I had thick clean looking steel. It was in the part of the frame that transitions in shape, which was challenging, plus once I cut it and measured the thickness, it was 14 gauge. Thick stuff. I can’t bend 14 gauge. I didn’t have any 14 gauge…so I thought, then remembered I still had some scraps from the ‘66 coupe. :guitar:

It took several cut off discs, splitting spot welds with a hammer and chisel, and hammering on the anvil to get the pieces shaped. :banghead:

Hours later, overall, I’m pleased with the repair and know the welds are deep and the metal is thick and strong and galvanized except for my welds.

I’ll finish it off with a few spot welds on the fabricated flange.

The project continues…. :tu:
Attachments
Badly rusted out rear frame in a tough shape.
Badly rusted out rear frame in a tough shape.
Old scraps from the ‘66 will provide the 14 gauge galvanized steel.
Old scraps from the ‘66 will provide the 14 gauge galvanized steel.
Outside after steel sectioned in.
Outside after steel sectioned in.
Underside after new steel sectioned in.
Underside after new steel sectioned in.
The same spot on the ‘66 sedan donor.
The same spot on the ‘66 sedan donor.
Repaired frame on the ‘65.
Repaired frame on the ‘65.
14 gauge subframe steel.  Thicker and harder to work with, but strong.
14 gauge subframe steel. Thicker and harder to work with, but strong.
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Project65
Posts: 509
Joined: Tue Dec 07, 2021 8:03 pm
Location: Pennsylvania

Re: John’s 65 sedan

Post by Project65 »

Today I worked on further cleaning down the frame rail and after evaluating the rear bumper bracket, I decided that I should replace it due to heavy rust and deterioration.

I took on the challenge of fabricating a new bumper bracket. In my previous post, I was incorrect. I do have 14 gauge steel, and I have bent it. I used it previously on the repairs of the inner rocker panels. I thought it was 16 gauge.

So after measuring, cutting, bending, and some pounding, I made a new bracket. I like how it looks. I tried to shape it just like the original one.

Getting the old one off proved challenging; however, it eventually came free.

I tack welded it in place, and for fit, clamped up the other pieces, including the new battery tray and rear inner panel.

I’m debating on whether or not to make a new shock tower or reuse the donor one. The donor is slightly bent from age. Maybe I could straighten it?
Attachments
Rusted out bumper bracket with replacement fabricated bracket.
Rusted out bumper bracket with replacement fabricated bracket.
New bracket tack welded in for fit.
New bracket tack welded in for fit.
All pieces clamped in for fit.  Looks like it will work.
All pieces clamped in for fit. Looks like it will work.
Repaired frame by the shock tower.
Repaired frame by the shock tower.
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Minferrera19
Posts: 83
Joined: Wed Jul 14, 2021 1:05 am
Location: Massachussetts

Re: John’s 65 sedan

Post by Minferrera19 »

Nice work keep at it!
Project65
Posts: 509
Joined: Tue Dec 07, 2021 8:03 pm
Location: Pennsylvania

Re: John’s 65 sedan

Post by Project65 »

I decided to repair the shock tower. It was just bent from age. Took a torch and heated it, then straightened it with a hammer. I thought that I should reinforce it, so I cut a piece of 1/8” plate and made an inside backer, then welded it in for support.

Then after an additional minor frame patch for good measure, I welded the tower from the donor in place.

Look’s good and strong.
Attachments
Bent shock tower from the donor.
Bent shock tower from the donor.
Shock tower inner support plate.
Shock tower inner support plate.
Finished and installed.  Building back one piece at a time.
Finished and installed. Building back one piece at a time.
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Project65
Posts: 509
Joined: Tue Dec 07, 2021 8:03 pm
Location: Pennsylvania

Re: John’s 65 sedan

Post by Project65 »

Had a few hours this morning to work on the Corvair before the family cookout. I decided to repair the shock tower sheet metal panel.

I had a piece of scrap from the donor that looked like it was a piece of siding that used to patch the battery tray with pop rivets, screws and fiberglass. It was the right thickness.

After a couple hours, I have a patched panel that looks pretty good, even if it’s hardly ever seen. I like it.
Attachments
Patch piece roughed out
Patch piece roughed out
Panel repaired.  Looks pretty good.
Panel repaired. Looks pretty good.
Looks like a good fit.  Ready to install.
Looks like a good fit. Ready to install.
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Project65
Posts: 509
Joined: Tue Dec 07, 2021 8:03 pm
Location: Pennsylvania

Re: John’s 65 sedan

Post by Project65 »

Another 8 hours in today and I really made good progress on the driver’s side. By the way, I’m estimating that I’m nearing in around 450 hours into this project. I started this 11 months ago, and to reach that amount, it would take me on average 41 hours a month or 9.3 hours a week. I’m easily hitting that. I could be closer to 500?

After a bit of readjustment to where I thought it should be, I welded the new bumper bracket to the frame.

Next was welding the shock tower panel in place. It feels good and strong.

Two areas on the innermost flange were cut out and repaired with new steel, and one down behind the inner rocker panel.

Then I reconstructed the ragged and rusted inner rocker panel at the rear where the drain flap is. (No drain hole yet). The patch is roughed in, and will need trimmed, plus spot welded on the back side,

At this point, most of the car flanges are clean and strong to accept the donor quarter panel. There’s still some minor things. I still need to clean the upper flange by the rear valence.

Lastly I started to clean up the donor quarter panel. I cut out the remaining rusted battery tray and began to assess the general condition. I need to really clean up whole thing and begin repairs in a few areas. Off the car and on a set of horses should make it as easy as possible.
Attachments
New bumper bracket
New bumper bracket
Shock tower panel welded in.
Shock tower panel welded in.
Flange repair #1
Flange repair #1
Flange repair #2
Flange repair #2
Flange repair #3
Flange repair #3
Rear most inner rocker panel repaired.  No drain hole yet.
Rear most inner rocker panel repaired. No drain hole yet.
Rear lower quarter panel.  Beginning prep for repairs.
Rear lower quarter panel. Beginning prep for repairs.
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Project65
Posts: 509
Joined: Tue Dec 07, 2021 8:03 pm
Location: Pennsylvania

Re: John’s 65 sedan

Post by Project65 »

I started working on the donor quarter panel tonight. The rear area with the bulge behind the bumper seems to be where they all rusted out early on. The area on the ‘66 donor had a nice large hole after I pulled out the wad of tiger hair from. The one on the ‘65 was previously patched with steel brazed in, but is dented, however, it seemed to be my “easiest” option to patch with metal and was the best of what I had. I was interested in patching the upper area first as my Clark’s replacement lower rear quarter panel looks like it will cover up to the lower half.

Just took my time with the prep and fitting, then gently welded it in. My patched area will need body filler to smooth it out. It’s mostly behind the bumper anyway.

The metal is old and thin here. I also had to puddle weld in a few holes.
Attachments
Large hole  in the donor area with tiger hair.
Large hole in the donor area with tiger hair.
‘65 was previously patched, with dents, but no holes.
‘65 was previously patched, with dents, but no holes.
‘65 patch tacked into the ‘66
‘65 patch tacked into the ‘66
Welded in and small holes filled.
Welded in and small holes filled.
Clark’s panel should mostly take care of the rest.
Clark’s panel should mostly take care of the rest.
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Project65
Posts: 509
Joined: Tue Dec 07, 2021 8:03 pm
Location: Pennsylvania

Re: John’s 65 sedan

Post by Project65 »

Tonight’s focus was on the lower inner fender area behind the wheel opening. It was previously patched, and was once again rusted out. :banghead:

I cut along below the body line, where it was previously repaired and welded, and carefully removed the outer metal (and Bondo I might add) to expose the inner fender metal at the lower wheel opening. Once exposed, I then cleaned it up and proceeded to reconstruct the inner fender metal. The rear panel is more or less flat, however the other 2 smaller pieces were twisted and this made it tricky. There’s also an indent near the bottom to allow clearance for the outer lower rear quarter panel indent.

Now it’s really solid and strong and the Clark’s panel can now be securely welded to that area. It looks good, but hey, it will be covered up anyway with the outer sheet metal and eventually some undercoating. :tu: The battery tray flange is also cleaned back and ready to accept the panel also.
Attachments
Rusted out lower inner fender
Rusted out lower inner fender
Reconstructed with welded steel.
Reconstructed with welded steel.
Front view
Front view
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Project65
Posts: 509
Joined: Tue Dec 07, 2021 8:03 pm
Location: Pennsylvania

Re: John’s 65 sedan

Post by Project65 »

Yesterday and today I made repairs to the back end of the rocker panel at the front of the rear wheel opening on the donor quarter panel. It was completely rusted out.

I found the perfect piece of scrap metal to use. It was a scrap leftover from the Clark’s front floor pan.

Figuring out the angles was tricky. I really like how it turned out and think the fit-up to the car will be really close.

I need to repair a small area of the flange yet to the left, but that will be simple. But not until I hold up the panel for fit to the car. Just want to be sure all the flanges fit up close. And still need the clean-out hole drilled.
Attachments
Before.  This is a tough area to repair, especially if it was on the car.
Before. This is a tough area to repair, especially if it was on the car.
After.  I’m really happy with end product.
After. I’m really happy with end product.
Another angle of the finished patch.
Another angle of the finished patch.
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Project65
Posts: 509
Joined: Tue Dec 07, 2021 8:03 pm
Location: Pennsylvania

Re: John’s 65 sedan

Post by Project65 »

I had to step away from the project for the last week and take care of a few other items. (Some work on my truck and still working on firewood. I still have more firewood to do though.)

Today I began fitting up the ‘66 rear quarter panel to the ‘65. It’s a slow and cautious process, and no helping hands either. By the way, my plaster pattern method worked great!

After a few hours of on-measure-off-trim-repeat…. I’d say it’s nearly there. It still needs some minor trimming. (Maybe an 1/8th of an inch). It’s amazing to see how this really begins to transform the look of the car. I can hardly believe my eyes. Here’s a couple of photos.
Attachments
Not welded yet.  Just held with vise grips.
Not welded yet. Just held with vise grips.
Even the inner rocker panel is lining up really close.
Even the inner rocker panel is lining up really close.
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
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