The Basics Of Bodywork
Getting your classic car into tip-top shape requires a lot of work. One aspect that scares a lot of people and for good reason is bodywork. If you’re thinking of doing bodywork on your car, we want to help show you some of the processes for doing so. The point of this article is to show you some of the required work – not necessarily a how-to article.
The basic groundwork of any restoration is to have a rust-free and painted body. Without this, nothing else really matters. A little rust here and there is okay, but in order to really have that high-end finished car, you have to get that all fixed. Rust can cause serious issues and will continue to grow until it’s treated properly. Also, you wouldn’t want to paint over rust as it will only come through the paint and ruin your hard work.
Assess The Rust
The first step in this process is to assess the extent of the rust damage. This will involve removing any loose or flaking rust, as well as inspecting the metal beneath for further signs of corrosion. Once you have determined the scope of the damage, it’s time to cut out the affected areas.
Using a cutoff wheel or a sawzall, carefully cut out the rusted metal, ensuring that you remove all of the damaged metal. It’s important to make clean and precise cuts so that the new metal you weld in will fit properly. You may need to use a grinder to smooth out any rough edges or to clean up the area around the cut.
With the damaged metal removed, you will now need to fabricate new metal to replace it. This can be done using a sheet metal brake and a sheet metal cutter. You will need to cut the new metal to the correct size and shape, taking into account any curves or bends in the metal. Once you have the new metal cut, you can test fit it in the hole to ensure that it fits snugly.
New Sheetmetal
With the new metal in place, it’s time to weld it in. This will require a MIG welder and welding skills. Start by tack welding the new metal into place, making sure it is properly aligned. Once you have the new metal securely in place, you can begin welding it in with a continuous bead. Be sure to clean and prep the metal around the weld area to ensure a strong bond.
Once the welding is complete, you will need to grind down the welds to ensure a smooth finish. You may also need to use body filler to smooth out any imperfections or to level out the surface.
You’ll want to use bodywork blocks that will allow you to sand down high spots and avoid low spots until the filler and metal is perfectly smooth. One way is to spray primer on the patch work area, then sand it down with the blocks to reveal your high and low spots. It can be very tedious and need to be done several times to achieve a perfect result.
With the rust repaired, and body work sanded out, you’ll then need to spray primer over the area. Usually this is done in several layers and sanded back down for an even smoother finish. Finally you’ll then lay down paint and then clear coat. The last step is to sand the clear coat, then cut and buff it.
Cutting out and welding in new metal to replace rusted areas is a labor-intensive process, but it is also an effective way to restore your classic car to its former glory. With the right tools, skills, and attention to detail, you can tackle this job and ensure that your car is protected from rust for years to come.
Luckily, for our beloved classics we carry most replacement panels. This means you won’t have to fabricate a patch panel from scratch. If it’s a bolt on item such as a hood, or front fender, often times it’s easier to replace that item with a rust-free brand new one that repair the rusty original. For our full line-up of sheetmetal parts, visit SS396.com or give our friendly techs a call at (203) 235-1200
