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1964 Chevy Malibu SS - Rust- B-Gone

Installing A New Goodmark Chevelle Trunk Floor

Bob Mehlhoff Dec 3, 2006

Pop the trunk of your just-purchased musclecar and oh no! The trunk's floor is rusted, there's a musty smell, and the water collecting on the bottom of the trunk lid is dripping down. What happened? Well, before you start worrying that your latest and coolest ride is turning back to earth, take heed, because many Chevelles have suffered this fate.

As designed, the rear window of a typical '64-72 Chevelle features a hidden trough just below the rear window's lower stainless molding, which does not drain. When water runs onto the car, it naturally collects under this molding and remains there until it evaporates. This can take days-even weeks-to dry out, and each time the car gets wet the water travels into the trough again. Over time, this sitting water rusts the metal until the water has a passageway to leak into the trunk. On convertible models, the water's path to the trunk may open up even sooner, because the water typically has a less complicated path to negotiate.

Once water arrives unnoticed in the trunk, the large vinyl factory mat traps the water between it and the top of the trunk's floor. After several years of moisture accumulation, the trunk floor is next in line to rust away, just as the lower rear-window sash did a few years earlier. Whether your car is from the Snow Belt or the deserts of the Southwest, chances are water has attacked the trunk floor of your Chevelle, leaving rusted-through metal. In many cases, you even see the top of the fuel tank and/or the bracing below the trunk panel.

As relentless and extensive as this damage is, it's good to know that the repair is straightforward. With a day or two of work, new trunk floor panels, and some common body-shop equipment, you can make your trunk's floor new again. Of course, while you're tackling this project you should also take a look at your back widow sash's condition and repair that as needed.

But for this story we're sticking to the ins and outs of trunk floor replacement. Our candidate for this is a '64 Malibu SS convertible that, although a Southern California car since new, has suffered the same rust problems that many other Chevelles have everywhere. With our new trunk floors from Goodmark Industries and a few tools, we'll have this Chevelle's trunk looking better than new.

It's In The Trunk
Here's a quick rundown of what we used for this story. If your left- and right-side trunk drop-offs are rusted, Goodmark offers those as well. The '64-67 seven-piece trunk floor kit includes three floor sections, two body-mount braces, and two gas-tank braces, and it covers an area approximately 67.5 inches wide by 40.5 inches long.

Goodmark Ind. 4030-725-64S Seven-piece floor $270
  4030-735-64L Trunk drop off, left $60
  4030-735-64R Trunk drop off, right $60

Tools You'll Need
* rotary grinder
* MIG-welder
* tin snips
* cutoff wheel
* seam sealer
* primer


Goodmark Industries
Lawrenceville, GA 30045



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