1965 Chevrolet Impala SS Restoration

This car had seen years of daily driving and occasional racing use, and was showing signs of deterioration. It arrived in our shop having been media blasted and sprayed with a black epoxy primer. At first glance, we noticed some rust around the window frames, in the deck lid, and that the previous repairs were not complete.

Next, the crew began the rust repairs around the rear window frame. These window channels held water and rusted all the way through. The rusty metal was cut out with a thin 3M cutting disc on an air grinder. A new channel was fabricated using a shrinker/stretcher, welded in, and ground smooth.     Gray primer prevented further rust. 

Next, the rear window filler panel was removed for additional rust repair.

The rearmost edge of the structure had rusted away.

A new channel was bent in the Mittler Brothers Box Pan Brake and contoured to the correct shape.

The upper portion of the repair section was punched with a dimple die on a Mittler Brothers punch in order to replace the original flared holes. These holes provided strength for the panel. 

Then, the curved lower section was TIG welded with an HTP Invertig 221 to the upper. Soon, the rusty portions of the structure had been completely replaced.

A new filler panel was obtained from Classic Industries, and welded in place over the lower structure to complete the repair.

A new panel was obtained from Classic Industries, and it was fitted and welded in place. Note the fitting of the deck lid and  tell light packets in this process to ensure all the panels fit properly before welding.

Next up was the lower cowl box on the passenger side. It is very common for this panel to rust, as they routinely held leaves and water and rusted from the inside out. We removed the original, fabricated a repair panel, and welded it in.