Seam sealing

This close-up of the trailing edge of the rear deck lid shows the result of Rick's re-crimping work. Note that both the inner surface of the frame and the inner skin, visible through the drain hole, are coated with Corroless corrosion resistant paint.

He later applied seam sealer between the crimped edges and the frame to prevent moisture from infiltrating the joints and becoming trapped between the metal surfaces. Careful application around the drain hole is a must to prevent the drain's function from being impaired.

Rad cap clearance

The addition of the large capacity radiator to what originally was the Corvair's trunk compartment made it necessary to cut a notch into the front lid frame to provide clearance for the rad cap. After making the initial hole, Rick cut and welded some metal to the ends for a more finished appearance.

Many hot rodders wouldn't bother investing the extra hour or two required to professionally finish an area few people would ever notice, but this type of detail work can set your car apart from the pack.

Repairing door jam rust damage

A careful inspection of the door jam areas revealed solid metal solid metal on the passenger side, but considerable internal rust damage on the driver's side. Due to the complexity of contours in this area and Rick's desire to correctly restore the integrity of the lower door hinge mounting point, Rick saved this job for last, when his metal working skills would be most highly developed. He dreaded working in this area, but tackled it with determination and eventually ground out all the rust and welded new metal pieces into the holes. When he'd finished with the mini die grinder and 2" discs he recommends for this kind of work, he had created several long, ugly gashes to fill. It took a long time to cut the patch panels and get them right. Holding them in place while tacking them wasn't easy, but he persisted and got the job done, as we'll see in other photos.