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Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: Darrin ()
Date: January 11, 2018 12:29PM

The bitter cold in the DC area over the holidays kept me inside and got me back to doing rust repair on my 65 Corsa. I have had this car on a rotisserie for awhile and was glad to get back at it.

This thread shows that an unskilled enthusiast with a bit of time can get decent results in addressing rust repair.

First pic shows the seam and part of the front passenger side corner of the car already cut out. Note the rust inside the wheel well lip. That was one patch. Next was the curved part on the bottom (Eastwood shrinker/stretcher works very well for a hobbyist like me). Then the flat extension on the bottom of the corner...then the flat that fills in the wheel well. That part is just tacked in so far. Final patch will be the body exterior panel...will try to cut a piece from the parts car for this patch to get the curve right.

All in all, five patch panels needed for a crunchy front corner. Poor welding skills combined with persistence work out pretty well for me.

The whole front panel has been replaced and brazed in in the past...fun to hit some brazing with the MIG...good light and spark show.

anybody can do this with a MIG welder and high pain threshold. Second pic shows my cardboard mock up of three of the needed patches taped together.

Darrin Hartzler
Bethesda, MD

Corvairs in two states of the Union and varying states of disarray.

Northern Virginia Corvairs & Group Corvair

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Re: Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: Darrin ()
Date: January 11, 2018 12:31PM

First patch. Lots of blobby welding....leading to grinding...etc.

Darrin Hartzler
Bethesda, MD

Corvairs in two states of the Union and varying states of disarray.

Northern Virginia Corvairs & Group Corvair

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Re: Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: Darrin ()
Date: January 11, 2018 12:33PM

second patch. Mostly stretched with Eastwood tool. Welding getting better.

Darrin Hartzler
Bethesda, MD

Corvairs in two states of the Union and varying states of disarray.

Northern Virginia Corvairs & Group Corvair

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Re: Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: Will NM ()
Date: January 11, 2018 12:36PM

Thanks for posting! I have a beater that I'm going to start practicing on before I try something I care about. You give me hope!

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Re: Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: Darrin ()
Date: January 11, 2018 12:38PM

third patch..the easy one!

Darrin Hartzler
Bethesda, MD

Corvairs in two states of the Union and varying states of disarray.

Northern Virginia Corvairs & Group Corvair

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Re: Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: Darrin ()
Date: January 11, 2018 12:42PM

Fourth one (in progress...but tacked in place and the seam is straight and will look great).

Darrin Hartzler
Bethesda, MD

Corvairs in two states of the Union and varying states of disarray.

Northern Virginia Corvairs & Group Corvair

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Re: Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: Darrin ()
Date: January 11, 2018 12:50PM

Will, the hardest part for me on this particular project was taking the cutting tools to the rusty corner. Once all the bad was cut out the next steps were easier to figure out. So...I would change the title of this thread to "Cut, ponder, measure....etc....

Darrin Hartzler
Bethesda, MD

Corvairs in two states of the Union and varying states of disarray.

Northern Virginia Corvairs & Group Corvair

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Re: Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: Frank DuVal ()
Date: January 11, 2018 01:55PM

Is this the tool you used?

[www.eastwood.com]



Frank DuVal

Fredericksburg, VA



Edited 1 time(s). Last edit at 01/11/2018 02:14PM by MattNall.

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Re: Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: Darrin ()
Date: January 11, 2018 02:00PM

Hey Frank,

Yes, that is it. Works pretty well. I can bring it by for a test drive if you want. Need to come visit you one of these weekends I am out in Catlett.

Darrin Hartzler
Bethesda, MD

Corvairs in two states of the Union and varying states of disarray.

Northern Virginia Corvairs & Group Corvair

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Re: Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: TerribleTed ()
Date: January 11, 2018 04:08PM

Clark's has always sold a nice usable outer fender patch panel...the rest is certainly fab city

---------------------------------------------------------------------------------------------------------

Avid Corvair hobbiest since 1984.
I have personally performed ground up restoration on over 20 Corvairs.
I currently work full time at restoring and repairing Corvairs.
Located in the Atlanta Georgia area.
[www.facebook.com]

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Re: Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: corventure Dave ()
Date: January 11, 2018 04:28PM

Ay Darrin,

looks good and your doing fine.thumbs up

I have always took pride in the fact that with a little practice and patience, I can do a lot of these things every bit as BAD as the so called professionals!
The more I have done over the years, the better my skills.

Great work!smileys with beer Please keep us posted.

Corventure Dave

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Re: Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: Darrin ()
Date: January 12, 2018 06:31AM

Thanks Dave...that is my new mantra...at least I am not paying someone else big bucks to do just as bad a job!

I was visiting a Corvair friend a couple of weeks ago and he had a beautiful non-Corvair that he had painted a few years ago. He pointed out the only small run in the whole paint job first thing! The car was huge and beautiful. Thankfully I am not a perfectionist of that sort. He did such good work overall, but saw that flaw every time he looked at the car.

Luckily, I will have multiple flaws to point to so will not be fixated on only one! Life is good.

Darrin Hartzler
Bethesda, MD

Corvairs in two states of the Union and varying states of disarray.

Northern Virginia Corvairs & Group Corvair

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Re: Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: SkidRo ()
Date: January 12, 2018 08:33AM

Darrin, great job. I can't wait to get my MIG welder. It's on my list. I am going to practice on my 86 C10, which are notorious for rusting everywhere. I am going to try using magnets to hold the pieces in position when I tack the patch panels in place.

Rory
66 Corsa
Silver Spring, MD

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Re: Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: viewmaster ()
Date: January 12, 2018 09:08AM

Imagination + metal + hammer = success!!

-m



Mike
'65 '500' Sedan 110 PG
'65 Monza Sedan turbo'd 110 SU conversion
Fresno, CA

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Re: Measure, model, fabricate, weld, grind, weld, grind, weld...
Posted by: Darrin ()
Date: January 12, 2018 11:52AM

Rory, I use magnets and c-clamps both. I find it really helpful to back the weld area with copper plate if it is accessible. Less burn through and can fill slightly larger gaps this way. Also helpful on thinner metal due to rust.

Darrin Hartzler
Bethesda, MD

Corvairs in two states of the Union and varying states of disarray.

Northern Virginia Corvairs & Group Corvair

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