John’s 65 sedan
Re: John’s 65 sedan
A few more hours tonight of fine trimming and adjusting, and with the help of my son, we have the panel at what appears to be a good fit. It’s not welded in yet.
I’m really happy with how close this is fitting up.
But it will be coming back off for a couple of additional final repairs before it’s welded on.
I’m really happy with how close this is fitting up.
But it will be coming back off for a couple of additional final repairs before it’s welded on.
- Attachments
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Re: John’s 65 sedan
That's the way to do it... test fit, test fit, test fit, tack weld, test fit again, and then weld some more.
Where the metal is thin, use structural adhesive. It will save burning through a lot of areas.
Where the metal is thin, use structural adhesive. It will save burning through a lot of areas.
65 Monza
Cincinnati, OH
Cincinnati, OH
Re: John’s 65 sedan
You know it. I have about 5 hours of just trimming and fitting in the quarter panel alone, but that’s what it takes.
I still haven’t welded the driver’s side yet, but I’ve started stripping down the passenger quarter panel to assess and it also has issues that I’m going to attempt to repair.
So this week I’ve be working on lining up some additional parts and panels and sections that I’ll be needing.
On the ‘66 sedan donor quarter panel, one area in need of repairing is the back end. It was hit and repaired and in rough shape. (I can’t get a break) So I’m going to attempt to repair by sectioning out and replacing. The one on the ‘65 sedan was also dented and repaired, but I saved the remnants from the ‘66 coupe rear end. The coupe section had a prospective rear corner that has a couple of crease dents, but I’m attempting to repair. One was minor and one was large. I hammered out the small, and heated the large crease with a torch until it was cherry red and it mostly hammered out pretty nicely, I’m hoping to finish it off with a hammer and dolly, but so far it’s looking much better.
Here’s some photos.
I still haven’t welded the driver’s side yet, but I’ve started stripping down the passenger quarter panel to assess and it also has issues that I’m going to attempt to repair.
So this week I’ve be working on lining up some additional parts and panels and sections that I’ll be needing.
On the ‘66 sedan donor quarter panel, one area in need of repairing is the back end. It was hit and repaired and in rough shape. (I can’t get a break) So I’m going to attempt to repair by sectioning out and replacing. The one on the ‘65 sedan was also dented and repaired, but I saved the remnants from the ‘66 coupe rear end. The coupe section had a prospective rear corner that has a couple of crease dents, but I’m attempting to repair. One was minor and one was large. I hammered out the small, and heated the large crease with a torch until it was cherry red and it mostly hammered out pretty nicely, I’m hoping to finish it off with a hammer and dolly, but so far it’s looking much better.
Here’s some photos.
- Attachments
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Re: John’s 65 sedan
Today I stripped the paint from the rear corner piece from the coupe to get a better look at the surface, then worked on hammering out the dents. I might try working it a bit more, but otherwise I’ll leave the rest to a body shop. I’m pleased with my first dent repair and the piece should be a nice repair panel on the donor sedan quarter panel. I put a coat of primer on it and it looks pretty nice.
Then I also started on the removal of the passenger side rear quarter panel from the donor sedan. I was able to get it about 3/4ths of the way removed.
Then I also started on the removal of the passenger side rear quarter panel from the donor sedan. I was able to get it about 3/4ths of the way removed.
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John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Re: John’s 65 sedan
Today I was able to finish the removal of the passenger rear quarter panel from the donor. I’ll next begin the task of attempting to cleanly repair all of the damaged and previous repaired areas. Overall, it should make a great donor once completed.
After I’ve been cutting this car up now, I don’t feel so bad as it clearly had it’s issues with rust and previous repairs. I’m hopeful that I can correct them all and make it look great again.
Here’s a few photos.
After I’ve been cutting this car up now, I don’t feel so bad as it clearly had it’s issues with rust and previous repairs. I’m hopeful that I can correct them all and make it look great again.
Here’s a few photos.
- Attachments
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Re: John’s 65 sedan
Amazing work!!!
Scott
1960 Monza Coupe
1965 Evening Orchid Corsa Turbo (project)
1961 Rampside (project)
1964 Spyder coupe (patina car, running)
1964 faux Spyder (project/parts car)
1964 Monza (parts car)
1963 Monza (parts car)
1960 Monza Coupe
1965 Evening Orchid Corsa Turbo (project)
1961 Rampside (project)
1964 Spyder coupe (patina car, running)
1964 faux Spyder (project/parts car)
1964 Monza (parts car)
1963 Monza (parts car)
Re: John’s 65 sedan
Just amazing, it will be great to see the finished project.
Gary Bullman
66 Corsa Convertible
66 Corsa Convertible
Re: John’s 65 sedan
Thanks guys! I just have to keep eating away at the whole elephant one bite at a time.
I started working on the donor quarter panel at the rocker panel back corner. It was full of bondo and tiger hair.
I was able to make a patch from a section of rocker panel that I cut off of the donor. It was rather simple to cut and shape. This will address the outside area, the inside area is another story….
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Re: John’s 65 sedan
Today was a great day for progress! I had about 7 hours in the garage today and was able to finish up the dog leg and rocker section on the donor quarter panel.
Between yesterday and today, I put in around 3 hours of bending and hammering shaping and fitting the small piece for the inside. What a chore, but I like the way it came out. The area was too tight for me to cut cleanly and butt weld the patch in, so I lap welded it in. It fit up really nicely and is very strong.
Then as I did for the driver’s side, I had to fabricate the piece for the back end plate of the rocker panel and weld in the patch.
I also welded in the outer patch and surface finished it. I’m really happy with the end look. Some primer and paint and it will look great! This whole area just feels SOLID now.
Lastly I forgot to mention that this last week, I went to a club meeting with my son and joined up with the WPCC. My late father was a member back in the 80’s and I’m guessing even into the 90’s. He was also a CORSA member. I can’t wait to get my car finished and drive it to a club gathering and am looking forward to hanging out and having fun with the other club members.
Between yesterday and today, I put in around 3 hours of bending and hammering shaping and fitting the small piece for the inside. What a chore, but I like the way it came out. The area was too tight for me to cut cleanly and butt weld the patch in, so I lap welded it in. It fit up really nicely and is very strong.
Then as I did for the driver’s side, I had to fabricate the piece for the back end plate of the rocker panel and weld in the patch.
I also welded in the outer patch and surface finished it. I’m really happy with the end look. Some primer and paint and it will look great! This whole area just feels SOLID now.
Lastly I forgot to mention that this last week, I went to a club meeting with my son and joined up with the WPCC. My late father was a member back in the 80’s and I’m guessing even into the 90’s. He was also a CORSA member. I can’t wait to get my car finished and drive it to a club gathering and am looking forward to hanging out and having fun with the other club members.
- Attachments
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
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- Posts: 83
- Joined: Wed Jul 14, 2021 1:05 am
- Location: Massachussetts
Re: John’s 65 sedan
Nice work!
Re: John’s 65 sedan
Tonight I bounced a bit as I started working on the rear side of the donor quarter panel for the passenger side. I was able to remove the inner panel behind the inner wheels well by drilling more spot welds and cutting across the bottom.
This exposed other areas in need of repair, and as I evaluated the situation, then it hit me. I really need to remove the passenger quarter panel from the 65 in attempt to section out an area that I’ll use to repair the donor. So that means I have to weld on the driver’s side quarter panel to provide the roof support and body stiffness before I can remove the passenger side.
I was hoping to receive a donor dog leg piece to repair a bad area on the donor, but I can’t wait anymore. Clark’s doesn’t make a repair piece for a sedan.
Once I had the donor quarter panel back off the ‘65, I had to think about how I was going to make the patch piece. The piece has a flat face at the wheel opening, then it contours as it gets further from the wheel opening, also it flattens out as the piece gets lower towards the rocker panel. I decided that I had to try to hammer form a piece and make a form pattern in order to do it. So that’s what I did, and after an hour or so of cutting and grinding some thick steel, I hammered out a patch piece and think it just might do the trick. Here’s some pics.
- Attachments
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Re: John’s 65 sedan
Been putting in some late nights and serious hours on the project lately. But it’s steady progress when I’m fabricating and fitting.
Tonight I pieced in the hammer formed dog leg patch and also had to cut out the back side as well and repair with a patch also, so two patches, inner and outer at the dog leg.
I welded it in and think in spite of it all, it looks much much better. The lower weld seam needs a 2nd weld pass and more surface finishing. I’m also planning on putting chrome trim in the wheel openings when it’s done so that might hide a few imperfections.
Once this area is finished, I’ll do some prep work (rust removal, POR15, coating) on the ‘65 and then it’s time to weld the driver’s quarter panel on the ‘65. Can’t wait!
Tonight I pieced in the hammer formed dog leg patch and also had to cut out the back side as well and repair with a patch also, so two patches, inner and outer at the dog leg.
I welded it in and think in spite of it all, it looks much much better. The lower weld seam needs a 2nd weld pass and more surface finishing. I’m also planning on putting chrome trim in the wheel openings when it’s done so that might hide a few imperfections.
Once this area is finished, I’ll do some prep work (rust removal, POR15, coating) on the ‘65 and then it’s time to weld the driver’s quarter panel on the ‘65. Can’t wait!
- Attachments
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Re: John’s 65 sedan
Tonight’s focus was on cleaning up the dog leg patch a bit, with some welding to fill the low spots, repair one additional hole, then prep for welding the quarter panel on the ‘65. This called for a little wire wheel, POR15, and seam sealer in some hard to reach areas on the ‘65.
I wrestled with the panel a bit and made a couple of fine fit-up trims, then clamped it back on for fit. I’m thinking where it’s at is pretty good, and I’ll make one more trim cut just to open the weld gap, then proceed to weld.
I took the rear door off of the donor just to see how the quarter panel fit looks and check the gaps. I think it looks as good as it’s going to get. It’s something to see the car with a solid door and quarter panel on it. I haven’t had a door on it since Late January.
Here’s a few views.
I wrestled with the panel a bit and made a couple of fine fit-up trims, then clamped it back on for fit. I’m thinking where it’s at is pretty good, and I’ll make one more trim cut just to open the weld gap, then proceed to weld.
I took the rear door off of the donor just to see how the quarter panel fit looks and check the gaps. I think it looks as good as it’s going to get. It’s something to see the car with a solid door and quarter panel on it. I haven’t had a door on it since Late January.
Here’s a few views.
- Attachments
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Re: John’s 65 sedan
I’ll start off mentioning that last Wednesday August 3rd marked 1 year from when I went into the woods and started working on the car. I was armed at the time last year with a can of PB blaster and a can of deep woods OFF. I emptied the PB Blaster into the door locks in effort of trying to get into the car that was there for over 25 years. It was last on the road in ‘91. The mosquitoes were fierce and I covered myself with the deep woods OFF. It’s been a lot of work over the last year.
Tonight I thought that I will shift gears and turn back to the dash panels and glove box.
It was 2 months ago when I bought the custom blended rattle can “color match” paint for the dash panels, dash and door panels. The dash panels are silver and the dashboard is gold.
I really like how the silver looks. It’s not too shiny. Also, what’s great is the light coat of paint also let’s the original crinkle texture show through. I love it! I only wish the car was finished and I could put the interior together. (Hopefully next year…)
At the time, I asked if it was a gloss finish or satin. The guy who mixed it said it was a gloss. So I bought a satin clear coat; however, likely because it’s textured, it really not too shiny. Possibly the gold for the dash and doors might be too bright? These panels don’t have the satin clear coat. They’re “as-is”.
Tonight I thought that I will shift gears and turn back to the dash panels and glove box.
It was 2 months ago when I bought the custom blended rattle can “color match” paint for the dash panels, dash and door panels. The dash panels are silver and the dashboard is gold.
I really like how the silver looks. It’s not too shiny. Also, what’s great is the light coat of paint also let’s the original crinkle texture show through. I love it! I only wish the car was finished and I could put the interior together. (Hopefully next year…)
At the time, I asked if it was a gloss finish or satin. The guy who mixed it said it was a gloss. So I bought a satin clear coat; however, likely because it’s textured, it really not too shiny. Possibly the gold for the dash and doors might be too bright? These panels don’t have the satin clear coat. They’re “as-is”.
- Attachments
John
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
1965 Monza Sedan “The Phoenix”. Rebuild in Progress.
Re: John’s 65 sedan
Keep up the good work John. You are doing one hell of a job. Not to many people would tackle a project as as big as yours. Most people have no idea how much work it is to restore a car. I often get the comment, "are you still working on your corvair?" They think you throw a coat of paint on it and your done. It is kind of frustrating some times. I totally rebuilt my 62 mechanically but i left the original paint alone. I still get people asking me when i am going to finish it. They just don"t get it when i tell them it is finished. My 65 will get a new paint job but that will be the last step and i have no idea when that will be. Until then i just have to put up with the "your still not done?" comments.
Re: John’s 65 sedan
Fantastic progress with the body work, and the painted dash parts look amazing! Keep up the great work!
John
1966 Corsa Convertible
1966 Corsa Convertible