Re: 1964 Suburban Pics
 

There has been a lot of interest in this repair and the part so I'm going to post my progress and some pics. I pulled apart the eyebrow this morning; made a couple mistakes but for the most part have it figured out now.

The corners are the worst! There are spots welds in the windsheild frame and on the top edge of the frame. In the pic you can see the 4 welds on the inner support(antler looking thing). The piece is then the bottom slice of bread in three pieces at the top. It sandwiches the inner panel with the roof panel; the inner panel is the 'peanut butter':lol:. I drilled down from the top thinking it was only two but soon figured it out when it wouldnt come apart. After drilling up I was able to rip it out by sawzalling the spot welds horizontally working my way to the corner. The corner has an interior bracket that has some more welds which I coulnt see. The reason this area rots is due to the interior not draining and it makes for a small puddle to sit there.

The new re-pop panel has a hole to weld it to the bracket in the corner; mine doesnt line up but I believe I tore a piece out that would have been there. I know Nobby mentioned getting a spot welder to reassemble but I'm going to figure out a way to mig it back together; my only option. I'm still debating about repairing just the ends or doing the whole panel.

PIX...........

Re: 1964 Suburban Pics
 

:lol:What!!!:smoke: Your going in deep.:lol: Good luck. We know u have the skill.:smoke: You have all that metal why not replace the good metal with the cheap china stuff.:lol: Just drill holes in it and weld them.

Re: 1964 Suburban Pics
 

:haha: Dave, you kill me!!!!:lol: Hey, BTW its Taiwanese metal, ok?? Or I could spend the next 5 years trying to learn how to use a stretcher/shinker and make the panel myself?;)

Drilling it is definitely whats happening to it. I'll do a couple down from the top and a few from the bottom; should tie it all back together.

BTW, the first side took an hour, the second side took 15 minutes to tear apart.

Re: 1964 Suburban Pics
 

Are you going to do anything to rust proof the inside? Bet some people would just glue it. I think thats how they do a roof.

Re: 1964 Suburban Pics
 

I have already sprayed a bunch of rust converter in there. The corner support is the worst part and I've cleaned it up. I have the pieces cut and ready to weld. I'm going to start by welding back the welds I shouldnt have drilled, leaving some open to attach the panels. I cut the ends off and used 10'' off each side. Thought about glue, but it's just one more thing to buy; I already own a welder and drill bits.:lol:

Re: 1964 Suburban Pics
 

Well, this is as far as I got....tacked in one side and was tired and started hurrying which isnt good so I packed it in for the night. I have to clearance one end for welds; it's difficult to judge as the piece 'tater chips' into place. I need to push up and clamp it then weld the inside edge. It should be easy to finish, along with the other side, tomorrow.

Re: 1964 Suburban Pics
 

Looks great man!! Don't forget to put a welding blanket over your door glass. You don't want an errant piece of slag to ruin your glass. I put slag in almost every piece of glass in my wife's truck tack-welding the well-nuts for the roof rack to the roof skin. Just tack welding. Grinding will do it too. I'm sure you know this already, but didn't want to see you forget too and ruin glass that is much harder to replace than mine was.

Glad to see you keeping on it. Good progress!!

Re: 1964 Suburban Pics
 

Thanx Nick....I actually didnt know that. I've shot grinding crap all over and not had any issues I'm aware of at the moment. Guess I've been lucky.

You were winning the TOTM earlier.....:metal:

Re: 1964 Suburban Pics
 

Yeah, I opened the thread and thought Hey, I'm eligible. Then I noticed that I had already been nominated. I'm not too quick you know....

I just finished a couple week run of body and paint work today. I still have some more to do, but the big project is done. I really, really, don't like body and paint work. Every once in a while I have to do some project to remind me of WHY I don't like it. It also re-establishes my admiration for those guys who take something we wouldn't buy for a parts truck and turn it into a nice truck.

Re: 1964 Suburban Pics
 

I think I like it.:confused:..............:lol: I go back and forth but right now I'm having fun with it. I've always liked cleaning up parts and giving them a coat of paint. Dont know why.

Re: 1964 Suburban Pics
 

Well, they're in!!!!:metal: Probably wont get me a gig on the latest hot rod TV show, but I'm happy.

If I had the truck torn apart and could stand in the engine area I would change the whole panel. I have created some work by sectioning them in place, but I needed to prep for paint any way. If I was to install the whole panel, one thing I would do before cutting out the original would be measuring the original gap for the windshield(the space that it fits in from top to bottom). This panel may try to re-establish a new line and I dont know if it would cause trouble re-installing the windshield or not. The corners are the hardest to deal with and the rest of the panel is a breeze. If you drill down thru or up thru the panel you can lay the heat in pretty well as you have a double lip to weld against; it doesnt move! One problem with sectioning is the joint against the original metal; welding on to the old stuff blew some holes but I just kept at it and got it done.

I will fill in some small places with weld and then it's on to the fiberglass and seam sealer, prime it and sand, sand, sand.

The end gaps down low are no worse than the factory, BTW.

Re: 1964 Suburban Pics
 

Ok... I gotta ask.. Are the very ends at the seams welded inside--so to say "hidden"?? I'll be replacing the whole panel and have been curious about this part... Looks great BTW
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Re: 1964 Suburban Pics
 

No they aren't, that would suck taking them apart!! There are one or two spot welds on the tab inside straight up thru the panel; in the area of the hole in the new panel. I considered welding it myself for a smooth look. It's hard to see but the factory filled in the gaps with some type of body filler which will fall out as you start cleaning.

I'm glad to have this done!!!

Re: 1964 Suburban Pics
 

Hey there Pro,
You seemed kinda nervous doing this patching .... if you were then that is how I am every time I cut and weld something.
Looks good from here though !!

Keep us posted, want to see how you finish this up, and what you move on to next!

Re: 1964 Suburban Pics
 

:lol: not nervous about the patches, just the result!!! I wasn't sure if I was opening a can of worms when I got in there. Turns out it's not too bad. Using the entire piece would be easier; I had to trim the drip edge to transition evenly.

I will hit these pieces and then primer the roof and windshield area...then I havent decided:smoke:.

Re: 1964 Suburban Pics
 

I am with you on doing the whole part, I am surprised you didnt throw a 2x6 or two across your fenders as a scaffolding and just do it... ??

But before I start critiquing other peoples work, I better get out of my bath robe and get some work done on my own !! LOL

Still looks good man !

Re: 1964 Suburban Pics
 

Did'nt look all that bad. Good for another 40 years. I'll be doing mine some day. BTW its easy to mess up your glass with a welder or a grinder. It doesn't like hot stuff.

Re: 1964 Suburban Pics
 

Protrash... Thanks a bunch for getting those pictures up. I'll be doing the exact same repair--and I'll also do photos as I have the sincere pleasure of replacing the whole thing.. Buuuuuttttt--mine will come from the '65 Truck cab that I dissected. So, it should be fun taking the area apart twice.. One thing I was considering aside from welding the end seams--was welding the entire top rain gutter edge. I know that is how water had gotten inside of mine as that part is separating allowing water to get in. Right now--this is only a consideration--don't know if I'll do it yet..

Re: 1964 Suburban Pics
 

Since your all set up why not just weld the end gaps shut.:sumo::smoke:

Re: 1964 Suburban Pics
 

If you're taking the piece out, you mite just sawzall straight down the gap and then clean the tab off the back later(on the donor panel). Welding that rusted metal is going to be a real bear. As the seam sealer gets old in the gutter it lets in the water and gets in everywhere; it happens on all these trucks. I'm planning on adding fiberglass under the seam sealer. It's water proof and recommended for boats. There is also no good drain in there and the water must puddle up against the seam and eats its way down thru.


I'm considering this, Dave. I was almost out of gas and needed to get the pieces done. Next weekend I'll get more gas and be able to make some filler pieces so the gap is easy to bridge. I could do it with fiberglass easily!!:lol:
I've had some stuck on my garage floor for 5 years now!!

Re: 1964 Suburban Pics
 

Could weld it easier. Then do your hood and your bed.Then get more gas.

Re: 1964 Suburban Pics
 

any updates

Re: 1964 Suburban Pics
 

Protrash--where'd ya go?? You hibernating still?? (you're in arizonahhh--you have no excuse!!)

Re: 1964 Suburban Pics
 

^^
i second that.......