The first step was trimming away the unnecessary metal from our donor tail piece. We scavenged it off a wrecked '70 SS396 Chevelle we found hidden away in a local junkyard.The first step was trimming away the unnecessary metal from our donor tail piece. We scave In our last story dealing with the rebirth of our rust-stricken Chevelle, we had finished up getting the keel of Project XS set in place. For this installment, we began to repair the rusted-out tail section and grafting in our donor tail piece. Since Project XS lived most of its life in the rust belt, salty winter road spray had really done a number on the back end of the car, along with the natural moisture-attracting tendency of the gobs of factory seam/body sealer that had been slathered in the corners of the rear fenders. After we cleaned up our donor tail piece, we found it had some issues of its own, requiring some custom metal work to get everything solidified so we could look toward our next step: installing new quarters and widening our wheelwells for some fat tires capable of handling the torque of the 572 big-block we've got for powering our A-body. This part of the car, even though difficult to fix, provided a great opportunity to show you, the reader, a great example of when it's time to get some help on your own project. Since custom metal work requires specialized tools that most DIYers aren't going to have in their garage, taking this particular job to a shop is a viable option to be considered. A good shop will have no problem fixing just one part on your car, and though you'll have to shell out some money for the labor, it'll still be better for your project budget as opposed to buying the necessary equipment to do the job yourself. Follow along and we'll show you why. Before drilling out the factory spot welds, the heavy wire brush had to be used for cleaning away the surface rust and paint. This heavy wire wheel does a much better (and quicker) job of cleaning the metal than a regular wire brush, or a cleanup wheel.Before drilling out the factory spot welds, the heavy wire brush had to be used for cleani Using a special spot-weld drill bit, Tommy Barber of Classic Automotive Restoration Specialists began drilling out the numerous factory spot welds.Using a special spot-weld drill bit, Tommy Barber of Classic Automotive Restoration Specia With all the spot welds drilled, next up was the air chisel for splitting apart the stamped pieces. If you're doing this in the area of metal you need to save, use patience and caution with the chisel.With all the spot welds drilled, next up was the air chisel for splitting apart the stampe Two major collisions in the right rear had really mucked up this part of the car-and the rust certainly didn't help. Tommy uses the cutoff wheel to remove the beat-up parts, but takes care to save the originals. When you're working on a car, try and save everything you remove. Take care when cutting away old metal. You never know when it'll come in handy.Two major collisions in the right rear had really mucked up this part of the car-and the r After blasting the donor piece clean, we found some hidden rot issues. A couple of spots in the channel area were rusted out. Fortunately, parts of the original tail section were still useable, so Tommy began marking off areas to cut away for other metal grafts. Measuring is one of the most important keys in metal work/replacement, just as with carpentry.After blasting the donor piece clean, we found some hidden rot issues. A couple of spots i Here's the section we'll be taking from the original tail. It's a little bent in a couple of spots, but these are easy to straighten out, and far easier to repair than rust in this case.Here's the section we'll be taking from the original tail. It's a little bent in a couple Calling the cutoff wheel back to action, the sparks were flying. Good time to remind everyone, when doing anything that sprays sparks, make sure you don't have anything flammable (including solvent/oil soaked rags) nearby that could ignite and cause you more headaches than just some metal repair.Calling the cutoff wheel back to action, the sparks were flying. Good time to remind every After cleaning the graft, Tommy flattened the edges on the belt sander. Fits like a glove. After clamping the piece in place, Tommy uses a TIG (Tungsetn Inert Gas) welder to join everything. TIG welding offers better heat control than MIG welding, and unlike that process, doesn't need a filler metal. It can fuse two pieces together, like when creating butt welds.After clamping the piece in place, Tommy uses a TIG (Tungsetn Inert Gas) welder to join ev With the welding finished, a grinding disc was used to clean up the welds and smooth the seams.With the welding finished, a grinding disc was used to clean up the welds and smooth the s Since both the donor and original parts of the car were rusted in the upper channel/top of fender area, a replacement piece would have to be made from scratch. Tommy starts by using a piece of heavy paper to mark out and rough out the shape of the new piece.Since both the donor and original parts of the car were rusted in the upper channel/top of This part of the car, quite frankly, was in (insert expletive here) shape. For most car guys, repairing this piece would be outside their skill set. Don't get riled or offended; being a good builder (and a smart one) is acknowledging your limits, and choosing the right way to handle the problem you face. This is where seeking the help of a professional shop is a viable, and most times, smart thing to do.This part of the car, quite frankly, was in (insert expletive here) shape. For most car gu Using a piece of AK steel, which has more flexibility for bending and shaping than regular steel, Tommy marks out an approximate area that will provide the necessary amount of metal needed to make the new part.Using a piece of AK steel, which has more flexibility for bending and shaping than regular After cutting out the piece, Tommy starts shaping it using a nylon body hammer and shot bag mounted on an old grinder stand. Mounting the bag on a stand allows you to more easily work/shape larger pieces of metal. The bag itself is nothing more than a heavy/thick leather bag filled with steel shot.After cutting out the piece, Tommy starts shaping it using a nylon body hammer and shot ba Shaping and making custom metal requires several specialized tools that most people don't have in their garages. If you have an interest in learning the skill, then your project has provided the perfect opportunity to learn said skill. If not, then finding a skilled shop capable of making your piece is the best course of action.Shaping and making custom metal requires several specialized tools that most people don't Instead of making the replacement part out of one piece of metal, it was decided to use two pieces then TIG weld them together for easier construction. Here Tommy measures out what's needed for the other part.Instead of making the replacement part out of one piece of metal, it was decided to use tw Using the original as a template, both parts are shaped and modified, then clamped together for welding.Using the original as a template, both parts are shaped and modified, then clamped togethe TIG welding provides better heat control than MIG, so it's easier to avoid warpage of metal pieces you're joining together, and it can fuse parts together without using a filler/bridge metal. This is why it's used for assembling parts like this.TIG welding provides better heat control than MIG, so it's easier to avoid warpage of meta Using a heavy brake, the sharp bend for the bottom part of the corner piece is shaped. After a little more massaging and tweaking, the bottom bend is ready to be joined with the other piece.After a little more massaging and tweaking, the bottom bend is ready to be joined with the After being clamped together, a hammer was needed for a little more massaging. Some finish welding and grinding is needed, but here's the new piece installed on the donor tail panel. The same process will be used to repair the other side also. Because this area of the car was filled with so much seam sealer from the factory, it's normal for Chevelle's to rust badly in this area.Some finish welding and grinding is needed, but here's the new piece installed on the dono After the passenger side is repaired, our donor tail panel will just need some minor patching and finishing work before being installed on our Chevelle. If you're restoring a car at home, you shouldn't be afraid to farm a complicated repair like this out to en experienced shop. In the long run, you'll save yourself time, effort, money, and a lot of headaches.After the passenger side is repaired, our donor tail panel will just need some minor patch SOURCES Miller Electric 1635 W. Spencer Street Appleton WI 54912 920-734-9821 www.millerwelds.com Classic Automotive Restoration Specialists Inc. 8235 Nautical Point Drive Belews Creek NC 27009 336-595-3900 www.classicautomotiverestoration.com By Patrick Hill Enjoyed this Post? 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