Bodywork #1: Full body workout

Update 11/7/09. I’m happy to say this rerun series seems to be doing well.  Todays installment should show clearly why this car is not on the road.  If I can display the same tenacity towards this car as I have the TI or Berlina it will get done.  It’s just going to take a while.

Originally posted May 2nd 2008, my third blog post! Just a quick guided tour of what the body needs. Remind yourself that surface rust looks worse than it is in pictures. The plan at this point is to scrape off the undercoating with a putty knife and use abrasive wheels etc on the rust. I have had lots of suggestions to take the body to the blasters and this is probably what I will end up doing.

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Bodywork #4: Scraping through 47 years of crud

Removal of the gas tank, the aerodynamic panel between the gas tank and rear body edge, the rear axle, rebound straps, clutch linkages, emergency brake linkages and lots of other little stuff was hard work made much more difficult by the presence of about 1/4″ of accumulated crud.  The crud is a mix of grease, road dirt and dust, oil, undercoating, and other debris hardened over the years by continual wetting and drying, heating and cooling.   In many cases I had to use a screwdriver and wire brush to expose the bolts holding an assembly together and clean the treads so I could get it apart.  I can’t complain too much about this crud though because it protected the metal in these areas from the elements and kept it free of rust.

The tools I used for this job were a 3″ wide putty knife/paint scraper with a sharp edge, a dull pocket knife, a wide bladed screwdriver and a course bristle wire brush.  Before climbing under the car I put all 6 of my jack stands under it in case I shook it loose with my scraping, I don’t want to end the project prematurely by having the clutch pivot mounting bracket pierce my lung when the car slips off of a stand.  I should add that I wore a respirator, eye protection, gloves and a ski cap.  Even with this safety equipment I usually went home with dirty fingernails, eyes red from frequently fishing chunks out of them that got around the glasses and black snot (sorry, I have allergies and blow my nose a lot…).  The hat was not so much a safety precaution as a practical way to keep from having to shampoo 6 times to get all the junk out of my hair, like I did the first night.

If not for the rebound strap this shot could be anywhere under the car.  I took this picture so I could refer to it later when putting the restored rebound strap assemblies on the car.

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Bodywork #3: That dent in the corner

Warning:  I don’t have any training at what I am attempting here, this is all new territory for me, so use this as a guide at your own risk! 

I decided I could take on this dent in the corner without much trouble.  I made some measurements and found that the mounting face for the tail light bases had been pushed in about an inch in compared to the same face on the other side.  This is the  not so obvious effect of the dent on the edge.  The metal in this corner is still very sound so I don’t want to cut anything out that I don’t have to.  Secondary to this dent is the shallow dent, right in the seam about a foot to the left of the corner dent.  This will need straightening and shrinking.

I’m not sure how this dent happened, it’s very high and narrow and at an odd angle to the car.

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Bodywork #2: Cutting corners

The scariest part of the bodywork for me is the drivers side headlight area.  The metal has been stretched like ‘wizards sleeve’ to quote Borat, the mounting surface for the headlight bucket is gone and the edge is ragged.  Once I decided I wasn’t going to try and tackle this job myself, I thought about what I could do while working on other stuff.  I didn’t really want to take the whole car anywhere but I needed professional help with this.  I talked to the owner of a restoration shop in Washington when he was picking up a friends car to get some rust repair done.   ”What do you think about me cutting out the corner of my car with the messed up headlight and just sending that part of the car to you?”  I asked.  “Sure.”  Was his reply.  If this goes well, I may cut other chunks off to send to him. 

The extent of the damage is hard to see in this picture, though the headlight bucket mounting ring is obviously absent.

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