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Coming along great Patrick. I like how your lizard skin is turning out....I am planning on doing the same thing. Might actually do both the SC and the thermal. I also really like the look of those Pontiac Rallye's. I think that will be a great look for your car. :cool:
 
Discussion starter · #322 ·
Tony, are you talking about the fiberglass gutter? The photo below shows mine wrapped with black duct tape. Thank you for pointing out about the rain water. The Lizard skin might have sealed up the drainage holes. I will check before I start welding the quarter.

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Matt, you like the Pontiac Rallyes?? That statement coming from a Camaro guy is a real compliment. :beers:
 
Discussion starter · #323 ·
Fitting Quarter Panels Part 29 (Weld the driver quarter to the car)
When I first started working with the quarter panels, they acted like a coiled spring when I put them on the car. I had to use ratcheting straps to force them in place. I used many clamps to hold them along the edges. Where I could not use a clamp; I drilled a holes and screwed them to the car. Each time I would take them off and reinstall them they would fit a little different.
They don’t act like that anymore. They fit consistently now because of all of the cutting and bending I did to make them fit. The screw holes line up. The quarters are not under tension or compression anymore. I wonder if I did not take the time to adjust them and just forced them in place if the metal would bend or look wavy after a few years of driving the car.
Anyway, I put them back on the car along with the tail panel, deck lid, and filler panel. I clamped and screwed them in place to make sure they don’t move during welding.
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I removed the tail panel. I know it sounds crazy to install the tail panel and then remove it. The reason I took it off was because the quarter panel has a flange that is hidden under the tail panel. I had to make sure the quarter and tail panel were aligned correctly before I welded the hidden flange to the back side of the trunk drop off panel. I ground the welds smooth and primed the metal. Hopefully this will be the last time I ever see this area.
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I put the tail panel back on the car. I made sure the quarter panels are aligned with the tail panel for the last time.

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Discussion starter · #324 ·
Fitting Quarter Panels Part 30 (Weld the driver quarter to the car)
A long time ago, I punched holes in the quarter panel where I plan to weld. There is a line of holes along the top edge next to the future convertible top. I plug welded them to the car’s inner brace. The quarter has to fit tightly against the car in this area because there is some molding that covers the joint. I have read that some people also braze this area. I don’t think that I will do this.
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I previously punched holes in the quarter along the wheel house lip. I plug welded the quarter to the outer wheel house.
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I welded the trunk drop off to the bottom of the quarter. This is a difficult area to access. Next week when I weld the passenger quarter, I will lift the car with my jack stands.

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Discussion starter · #325 ·
Fitting Quarter Panels Part 31 (Weld the driver quarter to the car)
I welded the front part of the quarter to the B pillar brace.
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I still need to weld that little triangle brace, the trunk gutter, and tail panel area around the lights. I am on a roll now!
 
Looks great, Patrick. Is this the triangle brace you are talking about?

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I'm not sure if the 69 Camaros or Firebirds have the same thing. I'm just trying to get everything straight in my head!!!:eek: Man, I'm excited for you!! I've been sneaking out in the garage lately. I finally buttoned up the side cowls. I'll post some pics soon. Press on!!! Can't wait to see more pics.
 
Discussion starter · #332 ·
Fitting Quarter Panels Part 32 (Weld the driver quarter triangle brace)
There is a little triangle brace that is welded to the quarter panel. This piece is unique to a convertible. In the photos below, the pen show the weld locations on the brace.
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The little brace is hard to see on the car. Mr. Tim’s previous post photos, shows a better view of the triangle piece with the quarter panels removed. I drilled three holes in the window channel opening. The right clamp is covering two of the holes.
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There is one hole on the outside part of the quarter panel.
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There are three holes in the convertible inner brace.

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I welded the holes shut and ground down the welds smooth with the surrounding metal.
I welded the B pillar inner tab that connects the quarter panel to the rocker. I was able to access the area by putting my hand through the large hole that is usually covered by an access plate. I welded shut the three holes and then removed the sheet metal screw. Then I welded the sheet metal screw hole closed.
I welded the holes shut and ground down the welds smooth with the surrounding metal.
I welded the B pillar inner tab that connects the quarter panel to the rocker. I was able to access the area by putting my hand through the large hole that is usually covered by an access plate. I welded shut the three holes and then removed the sheet metal screw. Then I welded the sheet metal screw hole closed.
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I absolutely love watching this thread! Your welds are to die for. It is almost as if you have done about 20 of them now..... Seriously, care to venture a guess of how many plug welds or at least how many pounds of wire you have used since you started this journey?
 
Discussion starter · #334 ·
Drilling plug weld holes in sheet metal
I have a pneumatic hole punching tool. It works great but sometimes I do not punch enough holes in the sheet metal.
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I can drill a hole in the metal but I don’t really make a hole. I just end up with a cone shaped indentation in the top layer of metal. If I would just weld the cone shape hole closed, I am taking a chance the extra metal in the cone will prevent me from getting good penetration. Also, the paint in on the bottom layer of metal will contaminate the weld.
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I have a special drill bit that has the tip ground flat.
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The flat bottom bit will not drill a hole. It will remove the thin cone shaped metal and the paint from the lower layer of metal.
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The flat bottom bit will also remove paint on the bottom layer of metal of an existing hole.

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It is a simple tool that has been valuable in the assembly of my car. I need to mark it with some paint because I am always using it.
 
Discussion starter · #335 ·
Mr. Phil,

I am on my 5th bottle of ArCO2. The bottle is 125 cfm.
I have used 12.5 lbs of 0.035 wire and maybe another 3 lbs off of another spool.
I have used 2 lbs of 0.025 wire.
I have gone through 37.5 lbs of 0.023 wire.
I write all this down in a notebook.

I need to get a life. :eek:
 
Keep going Patrick! Great work!!! I'm following your lead..
Don't forget the little padded braces that go inside the quarter panel and attaches to the rocker...
 
Patrick,
I want to say thank you. I have been rereading your thread and the info in here is priceless. You have done such a great job documenting your work. I am in the preliminary stages of fitting my quarters and reviewing everything you have done has opened my eyes quite a bit. Thank you again.
 
I would also like to say thanks for the good documentation...

I've taken a month hiatus from my project and plan to start back late September when it cools off. Until then, I'm doing a lot of studying so I can get rolling when time comes.
Shad, I know what you mean about the heat! We have had several 100 degree+ days and I just can't spend more than a few minutes out side. I'm hoping Sept will bring a cool down so I can get back to work..
 
Mr. Phil,

I am on my 5th bottle of ArCO2. The bottle is 125 cfm.
I have used 12.5 lbs of 0.035 wire and maybe another 3 lbs off of another spool.
I have used 2 lbs of 0.025 wire.
I have gone through 37.5 lbs of 0.023 wire.
I write all this down in a notebook.

I need to get a life. :eek:
You are not alone. I tend to write everything down too... then I put it in an Excel spreadsheet and keep a running tally of what parts and $$$ I have in the project. It's a nice reference to have, but the pile of $$$ it takes to do a restoration is truly scary.

Awesome project you have going, she's going to be a beauty. :thumbsup:
 
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