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Discussion Starter · #22 ·
dash going in



its getting there. This is all practice for the barn door. Get ready its all do it yourself from now on.



got the dash completely welded in.
 

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Discussion Starter · #23 ·
some I took after I lined up the top mechanism



I wanted to make sure the windshield post still lined up square


header bow lines up okay but that is the OG header bow so its kinda messed up. plus it has some small rust issues. Hopefully I will find a nicer one. Me and my buddy John tried our best to straighten this one out.

finally before I called it quits.. Im going to dismantle the rack and have it powdercoated.
 

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Discussion Starter · #24 ·
started fitting and tack welding on the passenger replacement quarter panel.

I didnt really like how the repro quarters folded over into the door jamb. They didnt have a tight sharp curve so I cut them an inch back from the OG door jamb metal and butt welded everything up.


everything lined up tits.


also, by doing it this way (leaving and inch of original metal next to the door jamb) I was able to make sure the factory body line was consistently correct eithout the doors having to be on the car..

yeah man, so far so good until I ran out of welding wire
 

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Discussion Starter · #25 ·
I bumped up from .025 wire to .30 gauge and bumped the heat up a little to make sure everything penetrated. Last thing I need is the windshield post to crack on me later down the road. No more Cold Welds!


same on the passenger side...

finally finished this...

also finished up on that quarter panel finally.

finished up the fire wall welding also. I will finish grinding this.

finally finished up the top of the drivers side quarter panel. Its been sitting there tack welded for weeks and I got sick of looking at it like that. I will start on the lower patch panel and that rusted out area tomorrow if Im lucky.

I also should have the trunk floor soon
 

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Discussion Starter · #27 ·
Heres what I have been working on. I started cutting out the lower rear quarter on the drivers side and I will have to section out a small portion of the inner wheel well lip it was rusted.

but no fear, 4 door is near.


the section I had to replace...

after quick weld in, this was before I ground it all down.

some minor grinding and cleaning up. after this I will clean up the whole area, prep it then rust proof everything I can get to.
 

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Discussion Starter · #28 ·
I did get some parts back from the blaster, thats what kept me from welding because as soon as I got home I had to metal etch prime all the parts.




after this I broke out the gun to lay down some etch primer.


parts are in etch primer...
 

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Discussion Starter · #29 ·
oh yeah the passenger side is pretty much done. I just have to weld up the bel air holes and redrill it for Impala mouldings...

heres some more pics of what I have been doing


This is what I had done . I got it all tacked in.



The original 4 door donor is at the end of its road.
 

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Discussion Starter · #30 ·
Also took care of that rust hole that was on the top of the quarter panel


After getting my parts back from the blaster and etch priming them, I was able to locate some areas I will have to fix on the fenders. Its not really bad at all but these areas will be cut out and replaced with good metal.




also this antenna hole. This was so out of place its not even funny.


 

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Discussion Starter · #31 ·
started cutting out some small sections that were pin holed on the front fenders so they gonna get new metal...

so yeah, they needed some attention.

after I cut out the bad area, I rust proofed it inside and out with POR 15

Pretty much had to do the same on the other fender too.

cleaned up and rust proofed

cut the replacement patches off what was left of the reproduction quarter panel that I didnt have to use.

welded and grounded down right quick. still not finished.

welds came out nicer than the pics make them look, I just get crazy with the grinder sometimes.

 

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Discussion Starter · #32 · (Edited)
Scary stuff. You going to put a roll bar in it this time around?

Great workmanship. You must be daring to tackle such a project with only 4-doors and a different make for parts. You can certainly be proud of your efforts.

Big Dave
Thanks Big Dave. I'll post more pics as I go. Prior to this car, I had never done anything more than a simple patch panel before. Im no pro welder but I can tell Ive gotten better since I started on this thing. lol.

What makes these 61's do difficult is that nobody makes repro full quarter panels for 61's for some strange reason. I see every other year but 61. Luckily the 61 and 62 GM convertibles used pretty much all the same sheet metal and parts from the top body line upward. I dont know what I would have done if I had not forund that Buick convertible.
 

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Great job. I think you should submit this to Power TV, Muscle Cars. Lou Santiago would love what you have attempted here.

Big Dave
 

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Discussion Starter · #39 ·
The side of the fender.



I did the same on the passenger fender. I would hit the back side as well as the front adding metal where there was thin metal.



passenger done.



Getting rid of this bitch. This hole has bugged the **** out of me.







grinded smoooth. Its hard to tell with the flash but its nice and flush.

 

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Discussion Starter · #40 ·
started on the rockers. will modify the 4 door rockers to work.

started to do the passenger side first.



started by drilling out the factory spot welds because I want it to go back together like the factory did it up front.







you can get an idea how im taking this **** apart, like the factory put it together.



this rust and dirt just fell out all over the place.

 
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