This rust was a surprise - Impala Tech
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post #1 of 8 (permalink) Old 07-29-2020, 08:17 AM Thread Starter
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This rust was a surprise

I was picking around my firewall as prep for cleaning up some of the extra holes and found an unanticipated issue. I put a needle scaler to the seam sealer along the top of the wiper cowl and it pushed through in several places. This is an intersection of 3 panels: Top of the wiper cowl, bottom of the wiper cowl, and the firewall. I went a little pale and called the paint shop - they won't be ready for me for 5 more months so I'm discovering that I can in fact fix this. The second picture is with the repair started. I'm working in sections because it allows me to clamp the sheet metal together easier and keeps the complicated sections as smaller pieces. I got lucky with the rust stopping before the hood supports.


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1969 Impala convertible build thread here:
https://www.pro-touring.com/threads/...ghlight=impala
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post #2 of 8 (permalink) Old 07-29-2020, 10:09 AM
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That was a fun area on my 63 hardtop as well. I couldn't figure out a way I was going to get to the back of the weld to grind it down, so I just POR-15 the inside of the cowl. This is more a race car that looks good at 10 feet than a show car anyways.

1963 Impala Convertible (Frame off resto-mod in progress)
1963 Impala 2 door hardtop (Pro Street build in progress)
1963 Impala 4 door hardtop (Parts car)
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post #3 of 8 (permalink) Old 08-01-2020, 02:39 PM
BA.
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That would have sucked to come across for sure.

Like you said though, You totally got that under control!

.

HOW A NOVICE REBUILDS A 66 IMPALA CONVERTIBLE:
http://www.impalas.net/forums/blog.php?u=1432
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post #4 of 8 (permalink) Old 08-03-2020, 08:52 AM Thread Starter
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It's moving along and I'm gaining some confidence in working with it. Overall, I would describe the experience as "harrowing." I've gotten through what I think is the worst of it and just have to finish it out. Lot of overlapping panel stampings on this car.

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1969 Impala convertible build thread here:
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post #5 of 8 (permalink) Old 08-03-2020, 11:25 PM
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Just be glad you don't have front rocker extension rust. They don't make reproduction and trying to make the right bends and angles to make the finished product look close to factory was fun. Luckily I had another car to look at so I knew what was visible in the end and how it was supposed to look.

1963 Impala Convertible (Frame off resto-mod in progress)
1963 Impala 2 door hardtop (Pro Street build in progress)
1963 Impala 4 door hardtop (Parts car)
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post #6 of 8 (permalink) Old 08-04-2020, 08:32 AM Thread Starter
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I do have some on the driver side due to a mouse nest clogging the drain for years...

There's enough that I (or the body shop) can copy the shape before cutting it out.

1969 Impala convertible build thread here:
https://www.pro-touring.com/threads/...ghlight=impala
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post #7 of 8 (permalink) Old 08-05-2020, 10:44 AM
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The drivers side is a little more difficult to get all the bends right for the rocker to mate up but this is what I started with and what the piece I had to make looked like.
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1963 Impala Convertible (Frame off resto-mod in progress)
1963 Impala 2 door hardtop (Pro Street build in progress)
1963 Impala 4 door hardtop (Parts car)
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post #8 of 8 (permalink) Old 08-05-2020, 01:02 PM Thread Starter
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Yep, you were a lot worse off.

Quote:
Originally Posted by Deadwolf View Post
The drivers side is a little more difficult to get all the bends right for the rocker to mate up but this is what I started with and what the piece I had to make looked like.

1969 Impala convertible build thread here:
https://www.pro-touring.com/threads/...ghlight=impala
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