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1967 Wagon Quarter Panel Repair
Part 1 - Figuring Out What To Replace
November 13, 2005
Since I had the gas tank out for cleaning, I decided to fix the rust in
the passenger side quarter panel on my wagon. The picture below shows what
the area I'm working on looked like before I started messing with it.
As you can tell, there is a big spot just behind the wheel and below the
molding. On 220 trim level cars, there is a visible body line just above the
molding. It's there on 440's as well but the molding hides it. There's also
a spot above the trim just behind the wheel opening.
Removing the molding was a bit of a pain since I had to figure it out but
here's how to do it without damaging it:
- On wagons, un-snap and remove the rear carpet, remove the rear seat
lower cushion, the seat back catch, and the interior trim panel. Be very
careful with the interior trim panel. These panels become fragile with age
and are very difficult to find if you break yours.
- With a pair of pliers, gently squeeze the end of each clip and push it
forward (this may take a little force if the sealant hasn't failed). There
are three clips.
- Before you remove the last clip, either get a helper to catch the trim
or put a towel down so the trim isn't scratched when it comes off and hits
Once the trim was out of the way, I started poking at the rust bubbles
until I ended up with what you see below.
The extension panel looks to be in good shape and there are no soft spots
that I can feel. There may be some damage to it but I'm not going to know
that until I cut the rusty metal out of the way.
I then spent a good bit of time getting all of the loose rust and sound
deadener out of the way so I could see how bad things are on the back side.
Things look a lot worse in the picture than the really are. It looks like
what happened is that the sealant around two of the trim clips failed which
let water get in under the sound deadener. Since that water didn't have any
place to go, it sat and caused the panel to rust. I also found that there
was a big glob of the sound deadener in the pinch weld for the rear wheel
opening that allowed water to pool up and the panel to rust just above the
Here's the patch panel I'll be using for most of the repair.
Unfortunately, it has a rust hole above the body line in the same spot as
the wagon. I have an entire back end that I picked up for my sedan that will
provide the patch to fix this area. You've no doubt noticed that the bottom
of the patch is pretty rough looking. This is actually just surface rust.
Paint jobs were done quickly and typically, hard to reach places didn't get
much paint. The bottoms of the quarters on the wagon look like this as well.
Here's the inside of the patch panel. It's mostly nice, clean metal. The
surface rust on the flanges is from gaps in the pinch welds along the bottom
and wheel opening. The body work in these areas is pretty crude from the
factory but I'll spent the time getting them nice when things go back
Up next: Removing the rusty parts.
11/20/05 02:34:10 PM