63 Pro Street Project - Impala Tech
Restoration Corner Aimed at Originality

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post #1 of 9 (permalink) Old 05-25-2020, 08:36 AM Thread Starter
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Location: Coopersville, MI
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63 Pro Street Project

After getting the bad rocker replaced and cutting out the floor I brought in a guy to blast the body to metal. Let me tell you that this process will find all the locations where your sheet metal is thin. Most people doing a restoration would probably write this body off, but that is the reason I chose it for a Pro-Street build. Once you modify a body for Pro-Street it is next to impossible to ever take it back to a factory build.

My daughter has taken an interest in the project as well and in one of the pictures you can see her applying the epoxy primer. I was really surprised that this can of Dimension DP800 Epoxy Primer still mixed and applied good after sitting in my unheated garage for 12 years. Tonight I'll see how well it stuck to the metal.
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BA. and 67 Sedan like this.

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 #2 of 9 (permalink) Old 05-30-2020, 08:52 AM Thread Starter
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Got to working on the fire wall. The passenger side cowl panel was pretty bent up, unfortunately I had left my cell phone at work on the day I started it so I don't have any as found pictures. But in the picture with the section cut out you can see the part above that I had to hammer and dolly to a semblance of straight. Then you can see the panel I fabricated fit up and ready to be welded in. If this was more of a classic restoration I would probably take more time to get the fit and look more like a factory panel. Also would have replaced the outer cowl panel as the lower lip took a lot to get straight and is missing some pieces. In a pro Street car though nobody will ever see it. Was going to buy factory heater delete plates, but after pricing everything up (Less than $20 of steel and some mig wire) I decided against the $70 delete plate and will just fab up some steel and weld them shut. By the time the frame is done this car will not be able to go back to an original configuration without considerable amounts of work, as the frame is welded to the body.
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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 #3 of 9 (permalink) Old 06-29-2020, 01:49 AM
 
 
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Looks like you have lots of things to do. Good luck and keep us posted.
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post #4 of 9 (permalink) Old 06-29-2020, 10:54 AM Thread Starter
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I've made leaps and bounds of progress on the firewall. Attached are some pictures. It shows how I fit things up. Unfortunately I can't find after welding pictures. The next picture is of the all Metal applied, followed by a skim coat of bondo. The last picture has it in POR-15. I will sand the POR-15 with 320 grit then apply a flatter black, not a good idea to use gloss under the hood as anytime a chemical splashes on it, it discolors a little.
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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 #5 of 9 (permalink) Old 06-29-2020, 10:59 AM Thread Starter
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Now I have moved on to the front of the passenger side quarter panel. I should have just bought a full quarter for this side, but live and learn and now I get lots of practice piecing things together and probably tons of sanding later. Looks like I will have to split the panel and put a small filler piece in to stretch the panel so the upper body line matches the door. But since this isn't the door I will use I will have to buy the new door before I start that process. This door has a lot of bondo in the lower part of the door and the lower part of the door seams to be a little out of wack. I guess I will move to the drivers side while I wait for the new door.
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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 #6 of 9 (permalink) Old 06-29-2020, 11:56 AM
BA.
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Looking good man!

Your first picture there of the front-quarter section cut out reminded me of the total PITA I had trying to get a good weld there on my own Imp. I'm not a welder but was learning and the cheap Asian replacement part I had was blowing through easily compared to the factory quarter. Ugh!!! Hard and painful lesson there....


Good luck - keep at it!!

HOW A NOVICE REBUILDS A 66 IMPALA CONVERTIBLE:
http://www.impalas.net/forums/blog.php?u=1432
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post #7 of 9 (permalink) Old 07-23-2020, 07:50 AM Thread Starter
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Drivers side quarter panel front patch

I had to reinstall the door to get this panel on right. We have a picture of the panel as it arrived. It is a Sherman patch panel and really not happy with how it fits up, but you will see more on that when I post on the passenger side as I went up further on that side. We have it roughed in, then welded and in primer, ready for All Metal. Finally since the panel wasn't long enough you will see a picture of the angle piece I had to weld in so the inner rocker (next post project) has someplace to weld too.

Yes as a note I basically POR-15 anything that will not be seen when the car is done.
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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 9 (permalink) Old 07-23-2020, 08:33 AM Thread Starter
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Driver side inner rocker

In these pictures you can see the issues I started with. Then I had to play around and fabricate a piece for this as I don't know of anyone that makes an actual patch panel for this area and even if they did, a lot of additional disassembly would be needed including the removal of toe boards. I didn't go that far. I made a piece that allowed me to cut out the rust and weld it in. A little all metal in the right areas and some sanding and it will look good. It will not look factory, but it will look good. The final picture shows the rocker support patch I put on and it is all POR-15 and ready for the inner rocker.
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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 #9 of 9 (permalink) Old 07-23-2020, 08:36 AM Thread Starter
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Inner rocker installed

A lot of confusion exists if you go to some parts places they are calling the inner brace of the rocker the inner rocker and that is incorrect. It is a three piece rocker and here I have attached photos of the rocker panel and the rocker panel installed. Probably be a little neater if it wasn't being installed with my make shift front section. Again I POR-15 the inside of the rocker before installing, but I taped off the areas where spot welds would be to keep from contaminating the weld. These panels came with a weld through primer on them.
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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)
Deadwolf is offline  
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