Dismantling and rust repair continues

Since most of the car is pretty solid and straight, we figured we wouldn’t need to replace very much of the quarter panels. The rust is limited to only the lower rear portion. We may attempt to fabricate the patches ourselves to avoid buying a costly reproduction panel. However we won’t compromise quality… so if a home-made patch isn’t good enough, the new panels will be purchased. We are using Picklex-20 and Zero-Rust, a rust-encapsulating paint extensively for the restoration of the chassis. The Zero-Rust comes in a nice semi-flat black, perfect for the chassis final finish. PPG’s DPLF primer will be used as the first coating over bare sheet metal. It will need to be scuffed before any other primers or top-coats are applied.

Front floor of 1960 Impala

Lower right rear quarter had some rust, but not too bad. Here it is being cut open.

rear floor of 1960 Impala

The inside panel had some minor rust holes so that was cut out too.

Rust hole by B-pillar

Patch for the inside right rear quarter welded in place after the area was thoroughly degreased and treated with Picklex 20 rust converter.

rust cut out

After the seam was sealed with a heavy bodies seam sealer, some “Zero-Rust” rust encapsulating paint was brushed on for protection.

rust hole with new metal test fit

After the frame was treated with rust-converter, it was sprayed with Zero-Rust. This is a non-catalized paint, so no special breating apparatus is needed, however good ventilation is recommended.

rust hole with new metal test fit

Front part of frame after being sprayed with Zero-Rust. Ahhh nice semi-gloss black!

rust hole repaired

All outside trim and clips were removed.

rusty front floor panel being cut out

Dave removes some of the inside window mouldings.

rust hole repaired

After being stripped and prepped with rust-converter, this door jamb is sprayed with PPG’s DPLF primer.

rust hole repaired

Steve heats up the old undercoating with a propane torch to make it scrape off like soft putty.


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