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Username Post: 29 years later .... 1960 Impala build progress        (Topic#324393)
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
02-04-19 08:13 AM - Post#2758957    
    In response to TYTILIDIE

Thanks for the encouragement. I can't wait til the trunk is done either !! It's slow going but its nice to see the panels going in.

Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
Ecklers AutoMotive
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
02-10-19 07:52 PM - Post#2759590    
    In response to 60Impala1837

More progress on center trunk panel ..... had to add a 1/8" repair strip and weld across some big gaps because I butchered the cut on this area of the new panel. Lesson Learned - don't make final cuts until you are sure the panel test fit is fully seated on the braces.

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Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
TYTILIDIE 
"2nd Year" Gold Supporting Member
Posts: 198
TYTILIDIE
Age: 42
Loc: Colorado Springs
Reg: 10-21-15
02-10-19 07:54 PM - Post#2759591    
    In response to 60Impala1837

Looks like you're welding kind of cold. I'd crank it up some. I actually turn mine up to 5 (out of 7) when doing sheet. Makes for a lot less grinding later. Looks like it's coming together.

1959 Biscayne with Impala Moldings, 5.3l LS Swap, 4l60e trans, factory PCM
1992 GMC Typhoon - Bowtie block and heads, forged everything, PTE76mm Turbo, 4L80E, Stock PCM's

"You'll never get anywhere if you keep starting over".

Me


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
02-10-19 08:06 PM - Post#2759593    
    In response to TYTILIDIE

Thanks for the advice. I'm still learning and appreciate the help. I had it cranked up when I was hitting those plug welds into the 16g braces but turned it down when i went back to butt welds with bigger gaps. I'll bump it up on the next round.

Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
02-17-19 09:02 PM - Post#2760160    
    In response to 60Impala1837

Welds came out pretty good after grinding.....

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Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
Brushwolf 
Poster
Posts: 6

Reg: 12-06-18
02-20-19 06:22 PM - Post#2760384    
    In response to TYTILIDIE

Yep, keep the pics coming.. I have to do the same thing in my 60 Impala hardtop (plus full floor which has arrived).

My car was TX/AR origin so I think most of my braces are ok and floor/trunk rust was from water sitting in it which I have found is a whole different ball game than repairing rust from salt.

Wish I could inspect my rear trunk corners for comparison, but currently up to our eyeballs in snow in MN with about a foot just today.

I already am more confident I can handle some of the rust I wasn't sure how to handle though, thanks to having pic examples of how some of these trickier repairs can be accomplished.



 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
02-22-19 10:40 PM - Post#2760536    
    In response to Brushwolf

Glad my pics are providing any level of help. I certainly used many great metal repair examples on this forum to build confidence to tackle this job. Having solid braces is a huge help. My Impala sat outside in Phx for years so my rust was limited to where water pooled from the top too.

When you get the chance to rip out the original factory seam sealer and start poking at the old metal, be prepared to find more holes than you expect.

As this was my first time, I started with many smaller metal patches but then got more confident with bigger pieces. It would be easier to use 22gage, but I’ve been using all 18gage.

You're waiting for the snow to stop and I'm trying to get as much done before we hit 115 again and I have to go back to early morning and evening welding.


Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
Brushwolf 
Poster
Posts: 6

Reg: 12-06-18
02-23-19 02:58 PM - Post#2760572    
    In response to 60Impala1837

Yep, have my son on the roof now clearing off a foot and a half of snow which has a 6 inch thick ice dam at the gutters too. Water backing up under shingles and coming into garage and basement and porch inside the walls. A mess..



 
beagrizzly 
"10th Year" Gold Supporting Member
Posts: 1983
beagrizzly
Age: 68
Loc: south texas
Reg: 08-04-12
02-26-19 11:48 AM - Post#2760851    
    In response to Brushwolf

Strange. I have NEVER had ice in my rain gutter. That's weird, right.

By the way, it's 74 degrees here today. That's with clouds and rain. The sun showed up Sunday, and we hit 80. Not much ice during 80 degree Februarys. haha.

I'm just sayin'.

Griff

if you're gonna be a bear..................

1960 Biscayne (the 6T)
2005 Yukon XL
2007 GMC Sierra Classic 8.1
2009 Silverado
2011 Escalade ESV


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
02-28-19 09:34 PM - Post#2761030    
    In response to beagrizzly

This is usually the time of year people in Phoenix start predicting how early we'll get the 1st 100degree day. I'm guessing April 18 this year.

I'm from the Ohio, so it still amazes me that the 1st rain in Phx is like the 1st snow in Ohio, people forget how to drive and there are accidents all over the city.

Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
02-28-19 10:25 PM - Post#2761034    
    In response to 60Impala1837

Finished adding a few small patch strips to the edge of the braces so next trunk panel will sit flush on 1st panel.
Finished butt weld across front seam and smoothed out all of the welds on this 1st panel.


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Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
02-28-19 10:51 PM - Post#2761036    
    In response to 60Impala1837

Next up is passenger side trunk panel.
I'm planning to keep the original wheel well trunk mount, but I'm not sure what to do castle nut. I haven't tried to test if body mount bolt is rusted to the body mount nut or not but it looks like it might be.

Any suggestions on how to test and deal with this?
-should i heat up the bolt and see if it strips the threads in the nut?
-if removing bolt does strip threads on body mount nut, can I fix the threads, or weld in a new nut with good threads, or would I have to replace entire body mount?

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I see new Wheelhouse Support Brackets are available, I just was hoping to avoid replacing if I don't have to.


Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


Edited by 60Impala1837 on 03-01-19 09:01 AM. Reason for edit: No reason given.

 
busdriver 
Contributor
Posts: 274
busdriver
Loc: Madrid IA
Reg: 05-26-02
03-01-19 01:02 PM - Post#2761063    
    In response to 60Impala1837

most of mine just unbolted..

Todd
1960 nomad


 
beagrizzly 
"10th Year" Gold Supporting Member
Posts: 1983
beagrizzly
Age: 68
Loc: south texas
Reg: 08-04-12
03-04-19 09:08 AM - Post#2761265    
    In response to 60Impala1837

Drench it in PB Blaster. It's the best I have ever personally used. Let it soak over night. Use an impact, and slowly forward, reverse until you get it to move. Keep up the Blaster as you begin to see threads.

The only ones I couldn't get out like this were the ones into the frame from inside the trunk. I couldn't get any pb blaster to them. I ended up cutting a window in the frame and putting a threaded block in. I'll then have to weld up the windows.

Griff

if you're gonna be a bear..................

1960 Biscayne (the 6T)
2005 Yukon XL
2007 GMC Sierra Classic 8.1
2009 Silverado
2011 Escalade ESV


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
03-04-19 09:19 PM - Post#2761331    
    In response to beagrizzly

Thanks Griff. I got it yesterday with some PB and a little heat. I didn't realize the factory used square nuts that just floated inside the castle and once I broke it loose and the nut started turning with the bolt I thought it might be rusted and just gonna spin. So I opened it up to finish getting the bolt out and make sure the bracket is good to reuse.

The body mount bushing kits I see come the new bolt but not a new nut, i may just clean up the threads and reuse the original square nut.

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Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
03-08-19 10:41 PM - Post#2761629    
    In response to 60Impala1837

Getting right side panel trimmed up and ready for plug welds.
Planning to weld dropdown to panel and install as one piece.
Have to reattached small front-to-back brace below panel in the right spot.

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Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
03-18-19 08:14 AM - Post#2762360    
    In response to 60Impala1837

Making progress getting passenger panel and dropdown trimmed up and ready to weld .......

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Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
PLS 
"7th Year" Silver Supporting Member
Posts: 1265
PLS
Loc: Smyrna, Georgia
Reg: 06-07-12
03-18-19 04:14 PM - Post#2762417    
    In response to 60Impala1837

Looking good Jim!! I don't know if I would have the nerve to tackle a job like yours and some others that I have seen on here. Keep up the good work and keep the pictures coming. Lamar



 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
03-18-19 10:15 PM - Post#2762438    
    In response to PLS

Thanks Lamar. Funny thing is I've thought the same thing to myself while appreciating all your posts & pictures of the last few years..... I'm just hoping to finish metal repairs someday so I can move on to other fun stuff and drive this thing again.

I'm debating whether to finish the trunk, leave the quarters alone, throw it into epoxy primer, move on to my drive train and put it on the road again for a while.

Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
03-25-19 11:23 PM - Post#2762921    
    In response to 60Impala1837

..... one piece at a time ....

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Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
04-04-19 05:37 PM - Post#2763662    
    In response to 60Impala1837



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Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
04-08-19 10:09 PM - Post#2763862    
    In response to 60Impala1837

A little weld-thru primer, a little panel prep, and finally getting the drop down connected to the panel so i can put in place as one piece.

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Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
04-14-19 10:55 PM - Post#2764241    
    In response to 60Impala1837

Making progress on the passenger side panel and dropdown. It's nice when you finally get to put a panel in its final home.

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Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
04-14-19 11:16 PM - Post#2764242    
    In response to 60Impala1837

Has anyone run into a similar problem with panel to brace gap as I have in the above pictures?

I punched holes for plug welds to line up with that 3/4" brace where I had brace making contact with panel during test fit. But after I got panel into final position and reattached brace to panel with sheet metal screw, I find most of the holes have a 1/8" gap to brace.

Brace is too thick to try the BFH approach from below, I don't really want to pound divits into the panel to push the plug weld holes down, so I'm planning to just crank up the heat to get a nice weld pool in each hole to the fill the gap.

Any better ideas on how to handle this problem?

Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
PLS 
"7th Year" Silver Supporting Member
Posts: 1265
PLS
Loc: Smyrna, Georgia
Reg: 06-07-12
04-15-19 10:58 AM - Post#2764272    
    In response to 60Impala1837

You may have already tried this but could you drill a hole through the brace at one of the punched holes and put a small bolt with washers on both sides and try to pull them together? Lamar



 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
04-15-19 02:12 PM - Post#2764288    
    In response to PLS

Thanks Lamar. That will definitely help get the gap as small as possible, I’ll try it out.

Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
04-20-19 07:20 AM - Post#2764635    
    In response to 60Impala1837

I ended up using the bolt thru a plug weld hole and a some weight to get the brace tight against the panel before welding.

Added a pic of my main two driveway "helpers" and my main two inspirations to hurry up and get metal repairs finished.

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Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
DonSSDD 
Silver Supporting Member
Posts: 7042
DonSSDD
Loc: Nova Scotia, Canada
Reg: 08-21-01
04-21-19 11:39 AM - Post#2764739    
    In response to 60Impala1837

Someone here may volunteer to help by breaking in that motor for you. How many years will it be available for the loaner?

63 Pontiac Parisienne Sport Coupe(CDN Chev mechanically (409, 4 speed),62 Bel Air SC (sold), 59 El Camino (sold), 62 Bel Air SC(sold), 63 SWC Vette (sold),
Member #2194


 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
04-21-19 11:35 PM - Post#2764795    
    In response to DonSSDD

I'd be more inclined to start a loaner program and start taking offers from breakin-helpers if it wasn't so highly probable that everyone here has a heavy right foot and there is a good chance I might get the engine returned as a box of broken parts.


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Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


Edited by 60Impala1837 on 04-21-19 11:36 PM. Reason for edit: No reason given.

 
60Impala1837 
"4th Year" Silver Supporting Member
Posts: 171
60Impala1837
Loc: Phoenix
Reg: 07-06-13
04-22-19 12:06 AM - Post#2764796    
    In response to 60Impala1837

Grinding, grinding, and some more grinding.....followed by prep'ing the wheel well area for next weekend.

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Jim
'60 Impala Sport Coupe, 283/pg
Former:
'65 BelAir (355 / 350 hp)
'68 Caprice (donor)
My Pictures


 
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