Bodywork, replacing rusted metal

[brushwolf]

Surprised there isn't a bodywork or rust repair section, but I guess you all have dry southwestern cars.   

But for those apparently few of you that do not, I wanted to make sure you are aware of some good YouTube videos by a Canadian named Tony Fitzee. He is up in Newfoundland, has 30 years body experience and also builds racecars and all kinds of stuff.

The unique thing is that he does extensive metal work with very basic tools that most hobbiests have. A mig and grinders. But, despite his unassuming nature and minimal metalworking tools he does some amazing work in rust repair on projects or components that most of us would consider beyond repair. Great techniques and tips for metalworking. If it is metal, he can fix it and he shares his techniques, tools and experience.

Take a gander..

Custom patch panels
https://youtu.be/1AiDqIHP5Po

More Custom patch panels
https://youtu.be/S-846X5W7Nw

Crossmember (or core support, or body mount) repairs
https://youtu.be/CeVcNWuoM04

Lower section of quarter inner and outer repairs

Part 1
https://youtu.be/Azez3ZYR03c
Part 2
https://youtu.be/5ZRUyvGKzvA

Repairing a really roached trunk lip
https://youtu.be/XDd4CwIc010

Rusty tail panel repairs
https://youtu.be/FZRuaT2obb4

Classic car floor pan replacement
https://youtu.be/6Fvjq9Xie8Y

Repairing rusty door bottom skin
https://youtu.be/9MPykdZF9YU

Repairing rusty window channels
https://youtu.be/EhGXSM3MZEQ

Butt welding sheet metal the easy way
https://youtu.be/_u31t13QO6A

Rusty hood front repair
https://youtu.be/xxvC3ZQ7N9I

Replacing leaded seams with sheet metal
https://youtu.be/cC6PLc049IA

[Lgcustom]

I've watched a couple of his videos lately. His work is amazing. It requires going slow at times, figure out a way with existing tools and keep at it.
Speaking of southern cars, I found mine in Temple, Texas. It looked ok at first, but i ended up replacing floors, floor supports, inner and outer rockers, lower front fenders and  outer a posts. Even had a hole in the roof!

[brushwolf]

Texas cars do seem to be some of the better ones. A 58 four door and a 60 Impala I have both came from there. The 58 has a few small spots only on rockers, no pillar issues. The 60 has very little outer body rust (surface rust around some quarter trim), but floor and trunk pans are junk from water sitting on floors. Braces appear ok though.

Even a 57 California cop car I had needed front floor pans. Those rubber cowl boots failing or wet feet got to the front floorboards under even salt-free conditions apparently. One side the inner quarter on CA car was pitted up, the door pillars were immaculate as is whole front clip (except for hole butchered in fender for the spotlight)... Front clip, cowl, part of back seat floor, spare tire well, all went to my then rusty MN 57 convertible.

Perhaps your car was not always a Texas car and had some salt exposure once upon a time?

[Lgcustom]

This is a Dallas built car, so probably spent most of it's life in Texas. But, it could have been in a flood some time. There was a lot of sand inside the frame rails. And yes the cowl drains definitely caused the floor rusting.

[mustang6984]

This is a Dallas built car, so probably spent most of it's life in Texas. But, it could have been in a flood some time. There was a lot of sand inside the frame rails. And yes the cowl drains definitely caused the floor rusting.

Some one went to Padre for Spring Break perhaps...more than a few times?

[1930artdeco]

That first one is sooo timely. I have that exact same section to replace so now I have something to go by.

Mike

[SkylinerRon]

The old guy I learned autobody work from did excellent work.

His main tools were a 2x4, 3lb hammer, rubber mallet and a porta-power.

Ron.

[brushwolf]

Sounds like my ex-neighbor back in the cities. Exact same tools that I recall, though he did also install floor pots for posts to use the porta-power for pulling in his modest 2 car garage. I was stunned when he took a hammer and a piece of 2x4 to lower a high spot, when he was showing me a few repairs. But, he did good work too. Just newer rebuilder cars though, so almost no rust repair.

[John Palmer]

I had the same experience watching an old timer bodyman in my youth.  He used this huge grinder with a 36 grit disc on the oil canned flat hood to build some heat in the metal then quickly wiped a wet rag on the metal.  Maybe three passes and the flat hood crown was stiffer than a new hood.

Using the old school tools might look crude, but understanding the metal had to be a learned art.  The guy with the largest tool box in the shop, is likely not the metal shaper.  Most of my metal shaping tools came from yard sales and swap meets.  One of my favorite tools came from the top leaf of a Model A spring.  It's smooth, hard spring steel, has a slight radius curve, and works well as a slapper.

John

[djfordmanjack]

^ that is an awesome tip, John ! Thanx for that !
I have a (pretty heavy) slapper tool already, but tomorrow I'll go out and fish for some short Model A spring leaf in my parts pile !