Well we still have a lot of work to do as far as metal work, there are tons of little spots that are just going to be a pain. Then we still have 100's of holes to plug that were not completely plugged as we just put enough on to hold the panel in. My dads got a rottisery (sp?) and i was thinking we could put it on there and undercoat the bottom end leaving the rear tubs and front frame area alone so we can paint them. We will see, there is still tons of work that needs done and most of it is the stuff that is a pain. I'll post some progress pics later tonight i just came in for a drink

I dont have a problem with the numbers i am not trying to hide anything as the numbers are right there. If people think thats doing a numbers swap then so be it, the car is being built for our enjoyment, and not to resell

Hey everyone,

I did some work but nothing thats really worth a photo even though i took one. I welded all but maybe 20 of the welds on the floor pan. I also started stripping the pan to find any pin holes and then to prep for paint, possibly. I also got in my order of Rust Bullet for the cars roof and insides. Hope the stuff works good as its kinda pricey. I'll update the build cost once i figure how much it was...

Can't wait to see that in color.

Have you decided on one yet?

Alright so the progress has been welding holes

Still have lots to fill, but in the meantime i also have applied Rust Bullet to part of the inside...



Then the scrap pile next the barn, this is just the stuff cut, we still have the cars

Hope you boys have had your tetanus shots. Keep up the good work. I am not commenting much but you guys are inspiring.

Thanks Quikfish, i think we are all up to par in that area, we have all been cut so i think were fine

I got some work done tonight and this morning if you would like to call it that. Started in on the repair of the inner fender on the passenger side. First off here are all the rust spots...






And the donor inner fender...

Next I drilled out the inner fender hinge mount...




Then cut out all the rust...




I have the pieces for everything but the hinge mount, so off to making one, here is the old and outline of the new one...




Front two sections tacked in and the hinge mount taken apart for maximum cleansing and future rust prevention...




Thanks all for tonight it too darn cold to be working in a non heated garage at 29 degrees

Awesome, I only just saw this post for the first time (not been on the general board for a while) and I really have to take my hat off to you. I thought my car had rust problems, but at least I was able to get a lot of decent replacements and also farm out the bodywork for time reasons, so I have to say you have done a fantastic job. You have used what you can get and have really brought that car back from the dead. Not only will it be a great car when done but the satisfaction from doing it all will be immense, and although it has cost you a lot of time it is really remarkable how your costs have been kept so low.

Really inspirational -

Gavin Thanks it means a lot. As it is i find that the serious work is dwindling down. I was always looking for what the next part i need to make. Now its all almost done Kinda scary but its not coming fast enough. Hopefully with can start working the body with some plastic where needed soon

So i did some more work here today and got the front end all placed up!

First off i welded on the other piece of the inner fender...




Then cut the pieces, marked the holes with a center punch, drove to the farmers house up the road, used his drill press, came home, and here they are





This is the other sides inner fender drilled out (notice only two holes, the top two rusted off)




Then tacked those pieces into place...





Then took apart the hinge mounts, they are rusted out somewhat too




The only other place on the front end is this tiny spot on the drivers side, i think im just going to try and use some copper backing to fix this one but if that doesnt work, well i guess you will find out




Then i also applied some more rust bullet, havent decided how low i will go yet but i was thinking of doing the whole interior panel. Then i need to get all that i can inside the webbing...

GREAT NEWS! WE ARE DEPRESSED FROM MORE RUST!!!

Sorry i just had to get that out, this is so discouraging its unreal. I knew about the lip on the quarter but not the wheel wells, or floor pans. Just look...

Here is the lower quarter and tub with some undercoating gone...



Metal cut away...




We have to make all this stuff since we have no donor pieces. Here is the first piece in...




Started scraping some more undercoating, found some of our best friend, RUST!



When stripping the floor to metal we found more rust that was hidden extremely well. The previous owner through some sort of a seem sealant over the whole thing and it looked like it was all good, no its not

Hey guys we got some more work done today. First thing was to evaluate the rust situation at the drip rails. It is crusty in the drain area and part of the roof is gone. So we cut up parts car #1 for the new drip rails. Here is the original on the drivers side...



Then cut up the drip rails, this car is looking slim





Next i drilled of and cut the section of the rail that will be replaced...



Cut the section of the the donor(this are a PAIN to remove in one piece when free let along on the car



Then cut the roof piece out and hit it with some rust bullet, dont work it wont ignite once dry (I tested it on some spare metal)...


Also got a package in the mail

steve, you ryan and greg have done a fantastic job resurrecting a car most of us would have parted. i know i have parted cleaner cars that i see could have been saved. i just found this post and spent the last 2 hours reading it. i may have some upper door panels. they are off a brogham. does your bee have roll down 1/4 windows?

Keep up the awesome work guys. I know finding the additional rust is discouraging...my Rallye is rotted in many of the same spots. But you're making excellent progress!

72gtx4speed Thanks, When we first got it we really did not think it would be nearly this bad at all. Boy were we wrong As far as the rear windows, yes they are roll down. Are the panels different?


DynoDave Thanks! We would not be so discouraged if we had known when we had the whole floor out to just do it then since we have a rust free rear pan, but go figure


I'm in the middle of doing the passenger side drip rail right now, it is crumbling to pieces as i drill it off I will have pictures up later!

So i got quite a bit done tonight but it is just a pain to do. Since i had to apply the other coat of rust bullet to the other side i started in on the passenger side restoration. It is quite a bit worse. Here is the original one, as you can see it is rusted even on the outside lip...



Here is an underside shot...



Here it is removed. If you have ever been lucky enough to remove one you will known that there are large missing areas...





I removed the one off the donor section but bent it up pretty good But it is solid so it can be put back into shape...



Here is the roof and quarter seem it is rusted out here as well as some extensive bubbling...



Thinking i would only have to do a roof splice i drilled and cut it off, then i cut the quarter seam too...





Then i hit the area with some rust bullet and will have to wait for it to dry!



I think we might change the project name to project rust bucket

Steve, that looks great so far. Keep up the good work. Looking forward to seeing more of this car's progress. Bill

The car is looking awesome Steve! Its finally starting to look like a car again

I think the black on black idea would be AWESOME! I wanna build a Duster like that someday. Keep up the good work, too bad the cold is slowing you down. It was overcast and in the 70's today

Thanks Bill and Jon! The cold is kinda bad to work in but its starting to warm up, only dropped to 35 tonight!

But anyways did a little more to pain restoration of the drip rail areas. I welded up the passenger side roof piece and lip. It still needs some touch up but its good for now...



Then i Tacked the actual drip rail in and it fit good! Just need to plug the holes and weld the seems...



Then on the passenger side project, and a project it is, i cut away the inner and upper flanges all the way back past the rear window...



Then cut the donor piece, this is going to be a pain to weld in...