Battery Box

   Many otherwise rust-free cars have total destruction going on in the area of the battery box. This one was caught just in time to save the stamped in vents in the core support. The rust had however gotten larger than the repair panel at the rear corner which necessitated welding on an extension to the panel. All seams are butt matched, double welded and finished on both sides.

   The repair panel was then bead blasted to remove the cheap "for sale" primer and epoxy primed prior to butt welding in place. Because I would consider it a cosmetic area, after the initial epoxy prime, a little plastic was used to smooth out the welded seam, as it would be difficult to finish lead out in an area such as this. In addition the battery tray will keep the battery from coming into contact and abraiding this area.

   All seams are sealed after the epoxy primer, yet before the final paint, to ensure that this battery box will never be a rusty mess again.

Rear Quarter Panels

   Yes, these photos are older and pre-digital, however, having lost all my digital photos 2005-13, they were all I could find that would show a full sequence of a rather rusty quarter panel restoration. I'll replace this sequence as soon as I finish another such rust restoration.

Body Subframe

   This vehicle had no visible rust anywhere when it came in, just shiny paint and a few blisters starting in the rear quarter panels. It proved to be ALL PLASTIC, over cheesy patches, many times over!

   This sequence is of a body subframe outrigger that is not available. I made a faithful reproduction in 13ga using the original backing nut plate. This was some HEAVY gauge steel to work with. All of the adjacent panels were also rusted away so they were cut back to clean steel and fabricated to the original dimensions and design in 18ga.

Rocker Panels and Floor

   I must say, this was one real ugly floor when I started ...... but it was satisfying to see it done correctly. The patterns for the new panels were made prior to removing the original floor. Note how I left a section of floor in until the very end to use as my work bench for the tools.

   As much welding was done, prior to media blasting as possible. At this point the floor and frame were media blasted, which is covered in the Media Blasting section, so the work could continue.

   A full floor was in order here, complete with inner and outer rockers all of which had to be fabricated. This sequence shows the fabrication of a body mount support structure that was also rusted badly. The reproduction structural members that are available are not constructed as the originals and would be a dead giveaway that the floor and structures had been replaced. By replacing only the downward section it retained a very original untouched look when done. The inner rocker was then welded in and lastly the exterior rust had actually run 6" up into the rear quarter panel as you can see, so that was accurately fabricated as well. At this point it was ready for the outer rocker.

   The rear of the outer rocker was patterned exactly off the original with the welds on the radius being finished inside as well. You can run your fingers anywhere along the backside of the fenders and rockers on ANY vehicle I do and NEVER detect any welding or straightening having been done. After stitch welding the outer rocker in place, the end box section was created, welded in place and then the outer welds and contours were perfected with lead.......... not the stuff in a can!!!

   Finally it's ready for the floor .... remember the floor?...... that's what all this has been leading up to. New cages were made for the body mount nuts and welded in, then the lower firewall pieces that were made previously were welded in place only after epoxy priming the back sides.

   After fabricating the floor panels they are blasted and epoxy primed on both sides, masking off those areas that I will be welding on.

   The floor was spot welded around the perimeter as original, however was continuously welded around the center tunnel for strength as it originally had a one piece stamped floor. All welds were wire brushed clean and seams sealed both inside and underneath the vehicle prior to two nice wet coats of black epoxy prime ..... followed up twelve hours later by a good coat of red epoxy prime inside to start moving it towards the final red paint work.