1969 Chevelle Metal Transplant

With the last scrap of the old quarter-panel edge removed, Valdivia media-blasted the inner structure, aka the edge of the outer wheelhouse, revealing just how deep the rust damage had progressed.

We note for the record that a reproduction patch panel is available for the rust-ridden area in question, but in many cases-including this one-Studio prefers to fabricate the pieces in-house using 20-gauge cold-rolled steel. Valdivia began by placing a piece of steel against the remains of the original structure and tracing its shape onto the new panel with a pencil. He added 1/8 inch to each side before cutting, allowing extra metal to work with.

We're skipping ahead a bit, but Valdivia basically trimmed and fashioned the new piece of metal until it was the right shape and size-only then did he cut away the rusted section of the wheelhouse. He attached the piece with a few spot welds, then welded around the edges, working in short spurts so as not to overheat the metal.

The inner structure rehab continued with a second slice of sheetmetal, which was bent into shape before being placed against the outer wheelhouse. Again, he used a pencil to trace the pattern onto the steel.

He cut the resulting piece to size with a pair of metal shears. Valdivia points out that these tools come in both left- and right-handed versions; which one you use depends on which direction you're cutting in.

Again skipping ahead, he trimmed and formed the second piece until it fit right into the vacancy in the edge of the outer wheelhouse. He welded it into place, and in surprisingly short time, the underlying rust damage on this Chevelle was eliminated.