Brian's 69 Camaro

[bcampbell2858]

Hey Folks!

New member here! Been lurking for a couple months and finally just bought the car I've always wanted: a 1969 Camaro! I've seen quite a few of these on this site and I'm grateful for the info you guys post. Fun and quick story behind this car. I just bought it locally for $1000 and it is in fairly rough shape. A tree had hit the roof and it was missing the whole front clip besides the subframe. The car was also lacking doors and an interior of any kind. Yesterday, while checking through craigslist, I happened upon a set of doors, hood, and one fender...for $300! After meeting up with the person (different person than I bought car from), I found out that the parts actually came from my car! Except for some surface rust, they appear to be in great condition as well!

As you can see from the pictures below, the car needs quite a bit of work. I've always done mechanics work but never got into body work and have never welded a piece of metal in my life. I am, however, a carpenter, and I have an eye for a finished project with perfect lines, gaps, and smoothness. I learn quick and never shy away from a tool I've yet to use!

Plans:

While I haven't completely decided on suspension/drivetrain, there are some obvious things I need to replace. The lower firewall is rusted through. Floor pan is shot. Trunk is shot. Roof is caved in and may have to replace roof bracing if it can't be straightened out. Rocker panels are pretty decent. Rear quarters are so-so. They have some rot on the wheelwell lip and on sail panel at rear window. Chances are I'll be replacing these as well. With that said...just about all body panels need replacing. I anticipate this being a very long project and I intend to do just about all the work myself. I want to do this project correctly and a hack job just isn't in my nature.

So far:

As mentioned, I've only had the car for about a week. I've removed the subframe. Cut out the rusted dash support. Removed steering column and everything off of firewall. I'm in the process of removing rear suspension and rear end from the car. First thing I will be replacing is the firewall. Should be arriving this week! Also in the process of checking out prices on having the shell sandblasted. Stay Tuned! -Brian

https://www.pro-touring.com/attachment.php?attachmentid=114980&stc=1https://www.pro-touring.com/attachment.php?attachmentid=114981&stc=1https://www.pro-touring.com/attachment.php?attachmentid=114982&stc=1https://www.pro-touring.com/attachment.php?attachmentid=114983&stc=1https://www.pro-touring.com/attachment.php?attachmentid=114984&stc=1https://www.pro-touring.com/attachment.php?attachmentid=114985&stc=1https://www.pro-touring.com/attachment.php?attachmentid=114986&stc=1

[Motown 454]

Welcome to Pro-touring! There's plenty of great information and generous help on how you can use it. I don't see the pictures but looking forward to seeing them.

[bcampbell2858]

Hey Motown, thanks for the welcome! That is unfortunate about the pictures...was having issues uploading. Can anyone else see/not see pics? Lemme know folks and I will re-upload if necessary. Thanks! -Brian

[Motown 454]

I use photobucket.

[minendrews68]

I can't see them either, I also use Photobucket. If you have trouble let me know and ill try to help. and welcome!

[Justin@EntropyRad]

https://www.pro-touring.com/attachment.php?attachmentid=115074&stc=1

[bcampbell2858]

Hey Folks, sorry for the wait! Been much to busy! Here are the photos, hopefully you can see them now.


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[Blown73]

Meh. I have seen worse starting points :)

Welcome to the site, looking forward to seeing your build progress!!

[armourmark]

It's just like eating an elephant, one bite at a time. Break it down into phases so you can have those small moral victories and stay motivated. Good luck and I look forward to your progress!

[Motown 454]

There they are ! I've used that blue handled auto body tool on the transmission tunnel too. Keep them coming!

[bcampbell2858]

Hey everyone,

Been doing some more disassembly. Rough cuts in trunk and driver rear quarter to get at seams better. I am somewhat limited on tool selection...looking to pick up a large air compressor and some air tools soon. Been doing all the cutting with an electric die grinder. One thing of interest...when I cut out the rear quarter, I noticed there was two layers...so it has been skinned at one point in its life. I already picked up a new trunk pan...next on list is new quarters, roof, and tail panel. I plan to tackle floor pan when those are done.

Pics!

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[Blown73]

Looks great! The worst part is getting all those spot welds drilled out.

One word of note: As you disassemble, I would recommend some form of support on the body. I put a bunch in my car as I did this, I have yet to find out if it works, but it starts to get loose the more body panels you take out. I put it at a point to keep the body from compressing on itself, so it doesnt have to be anything super structural. Door jambs are one spot, i also put one from the dash to the back tray.

Just a thought, keep up the progress!

[oweb2]

So stupid newb question incoming........

Seeing as though he has cut out the quarter and trunk pan, would this be a good time to mini-tub if he were going to do it? Would that be too much body off the car at one time? Would it matter if he braced it up? Or would you weld it all back up and then tub it?

I have been going back and forth on replacing my quarters, and I know I need to do the trunk pan ( unless I want to patch it), but if I cut out as much as he did when is a good time to do it?

[Justin@EntropyRad]

The thought of cutting quarters still sketches me out..even though I've seen it on here a bunch

[oweb2]

The thought of cutting quarters still sketches me out..even though I've seen it on here a bunch

Thats part of the reason I asked my question, at a minimum I am probably going to have to do my trunk pan at the most I might need to reskin my quarter panel. I could probably get away with not doing anything to my quarter since most of the rust is at the bottom and just patch it (granted these would probably be some sizeable patches) but if it makes my life easier to just cut it out, do the tub and reskin, that might be an option.

Especially since I have to cut out the trunk and and my tail panel isn't in the best condition either, though again could probably be saved with some finesse.

[Justin@EntropyRad]

The joys of classic metal

[ICrombie]

I've seen people tub the car with no quarters on and attach them later, it will make it a lot easier to cut up the trunk and fit the tubs with the quarters gone. If you haven't done so already, I'd brace the car really well, with a well braced car (or on a body cart) I don't think you have to worry too much about having to do the metal work in a particular order.

Also just a tip on tools, doing all of the cutting will much easier with a good air hammer and chisel set, if you get a good air compressor that'd be one of the first air tools I'd buy. I can't tell you how many hours I saved using an air hammer to remove the frame rails, I didn't even drill out a single spot weld to remove them and the trunk was completely unharmed in the process.

[TonyV]

Be careful cutting too much out at one time....i did it and getting wheel tubs/quarters/doors and tail panel all lined up was very difficult. I'd suggest doing one at a time at a time so you always have a reference....just my .02

[bcampbell2858]

Hey folks,

Thanks for all the tips! This is definitely my first adventure into this type of structural/body panel replacement. With that said, I am a finish carpenter by trade. I understand a thing or two about perfection...and I will accept nothing less than perfection. As an internet and computer savvy 32 year old, my research has brought me to this forum due to its wealth of information. You folks have provided me with such an expanse of knowledge...and I intend to put it to good use!!!!!

With that said...I present to you the beginnings of the body jig!

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Took this picture yesterday...since then I've done some cutting and prepping of the base structure. I am roughly following these plans: 115755.

Courtesy from the folks at the camaros.net forum at this link: http://www.camaros.net/forums/showthread.php?t=163374

I will be making a few modifications to this jig per Page 5 (post 61) of that link. I like moving the rear casters further towards the back to increase stability. As a side note, I would like to thank the folks at that forum for providing that information! Also, I have cross-referenced and double checked all measurements to the original Fisher Body Manual for a 1969 Camaro. Everything seems to be in check.

I believe I'll have the jig welded up within the next 2 weeks. I will try to get pictures as I can. Looking forward to dropping the body onto the jig! My plan of attack after this will be floor pan, then fixing the very rear of frame rails (leaf spring mounts rotted), then trunk pan.

Here is a current pic:

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Thank you all for your posts! I am not the best at keeping an up to date to blog, but I will do what I can!

-Brian

P.S. After seeing these pics uploaded...I can't wait to upgrade to a new phone...I have a Galaxy S3 and my buddy's Galaxy S6 Edge is incredibly better.

[TheJDMan]

I would recommend that you don't cut out any more of the body structure until you can get it properly supported to avoid distortion. Do you have a welder? If not take a look at some of the 110v MIG welders from Eastwood. Just make sure what ever MIG you buy can use shielding gas.

[instro84]

I would recommend that you don't cut out any more of the body structure until you can get it properly supported to avoid distortion. Do you have a welder? If not take a look at some of the 110v MIG welders from Eastwood. Just make sure what ever MIG you buy can use shielding gas.

i was thinking the same, don't want ti all twisted after new steel is in.

[bcampbell2858]

I would recommend that you don't cut out any more of the body structure until you can get it properly supported to avoid distortion. Do you have a welder? If not take a look at some of the 110v MIG welders from Eastwood. Just make sure what ever MIG you buy can use shielding gas.

This is exactly my plan. I had initially thought of building a wooden cart, but many of the people I have seen do that eventually opted for building a metal cart. I have the steel in hand and already have the base cut and mocked up level/square. Hoping to start welding it together this weekend.

I was just given a Lincoln weldpak 100 for free. Unfortunately it is not set up for shielding gas but from what I've read I shouldn't have much of an issue welding the 1/8" steel for the cart. As for when I start welding body parts back on, I will be borrowing a friend's 110v Eastwood Mig 135 and I'll be using the shielding gas.

I'll get some more pics up when the cart is made!

Thanks everyone for your tips and suggestions,
Brian

[minendrews68]

I would recommend that you don't cut out any more of the body structure until you can get it properly supported to avoid distortion. Do you have a welder? If not take a look at some of the 110v MIG welders from Eastwood. Just make sure what ever MIG you buy can use shielding gas.

Take Steve's advice on using shielded gas. I used my Hobart with flux wire until i finally switched, night and day! Be sure when you switch to check polarity, I didn't and it has to be done.

[bcampbell2858]

Take Steve's advice on using shielded gas. I used my Hobart with flux wire until i finally switched, night and day! Be sure when you switch to check polarity, I didn't and it has to be done.

Hey, yeah I saw the info on the polarity switch. Looks pretty straight forward. My question would be...is it really all that necessary to use gas on building the cart? Of course I want strong, reliable welds...but they don't have to be pretty. As I had mentioned, soon I will have my hands on a shielding gas-capable mig welder for doing the actual body work...but I'm looking to start welding the cart this weekend and I had figured the flux core would be fine for something like that. If there is something I am not understanding?

-Brian

[minendrews68]

In my opinion, as is others the shielded gas just makes for a cleaner, better weld. Most welders have provisions for the use of the gas, I know mine did, just had to get a gas bottle. I personally wouldn't use anything but the shielded. Again, just my opinion, but I bet I'm not alone..

[bcampbell2858]

Hey All,

Progress on the body cart! Just got all the casters and levelers on and flipped the cart right side up. Gotta weld the tops of the main section and weld the long 2x3 sections on (They are just sitting on there at the moment). Been double and triple checking measurements, I want to make sure I get it right. Very happy with the progress so far. If all goes well, I may have the car on the cart this coming weekend. Quick question for you folks, I plan on painting the cart so I don't have to be dealing with the greasiness of it...did you guys just use an automotive degreaser before priming/painting?

Thanks!
-Brian

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[Justin@EntropyRad]

Dig how it's coming...will definitely be following to see how things develop

[Carl @ Chassisworks]

Hi Brian,
Welcome to the site. I just came across your build. Like Jeff said earlier, I've seen worse starting points. It's good that you're not scared to just jump right in. If you haven't decided on a suspension route, you might consider our gStreet chassis. I'd be willing to bet that once you take a peek inside the rockers they're not too pretty. Since you're gonna have to replace the whole floor anyway, might as well replace it with something that gives you increased strength, more clearance for suspension, and more headroom. Plus, it's designed to accept our latest suspension package.

Click for Details
https://static1.pt-content.com/images/pt/2015/08/CamaroFloor_seatmount_ID-1.jpghttps://static1.pt-content.com/images/pt/2015/08/CamaroFloor_rearfloor_ID-1.jpghttps://static1.pt-content.com/images/pt/2015/08/CamaroTrunk_angle_ID-1.jpghttps://static1.pt-content.com/images/pt/2015/08/CamaroFrontSuspension_front_ID-1.jpghttps://static1.pt-content.com/images/pt/2015/08/CamaroFrontSuspension_shock_ID-1.jpghttps://static1.pt-content.com/images/pt/2015/08/5737SM12_witharms_ID-1.jpg

https://static1.pt-content.com/images/noimg.gif
https://static1.pt-content.com/images/pt/2015/08/CamaroFrame_AT-1.jpg (https://www.cachassisworks.com/cac_press_67-69Camaro.html)

[bcampbell2858]

Hi Carl! I will be giving serious consideration to your products. This is the first car I have ever restored and I have never dived into a project like this....but my goal has always been to mend the old with the new. At this stage of the project, I am not yet sure what direction I will take (money and time of course), but your website is saved for when the time comes to make the decision. In the meantime...a couple more pictures of the jig cart!

Keep in mind folks, I have never welded a thing in my life before this...I'm a wood guy! I'm a finish carpenter! So I understand what it should look like, and what a good product looks like, and I believe that is a good start. Welding this jig up has been extremely fun! I've loved the learning experience!

Welding uprights etc:

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Everything is on track to get this jig finished up saturday morning and have the car on it by the end of the weekend...excellent!

-Brian

[minendrews68]

Is it just me or does it look like the kineption pin fell out of the konozilator valve on the last picture?

[minendrews68]

Ok, just messin' with ya'.. Looks good so far.

[bcampbell2858]

Ok, just messin' with ya'.. Looks good so far.

Haha! All good...back to the garage, gotta go lube up that muffler bearing!

[bcampbell2858]

Jig Cart is done for now! I will be waiting to put the rear frame support on since my existing frame rails are so rotted at the leaf spring mount. Barring any unforeseen problems, I should have the car on the jig this weekend. Going to get some friends over, grab some 2x4s, slip them under and pick up the car and have another buddy slide the cart underneath...going to be fun! Once the car is on, I still need to weld on the rocker panel supports since I have to replace the floor pan.

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[1969fbird]

Good story on how you picked up parts from Craigslist and they actually belonged to your car. Haha

[bcampbell2858]

Car is on cart! Also, got a new phone...so better quality pics!

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Next up, rocker panel supports so I can replace floor pan and frame rails!

-Brian

[bcampbell2858]

Progress Update:

Still in heavy dissassembly mode. I got some supports in for the rocker panels for when I go to replace floor pan and frame rails. I fastened these directly to rocker with two self tapping screws on each side to prevent movement. Also welding in a support for the frame rails themselves roughly above where the rear end would be. I temporarily tack welded the existing frame rails to this support for future location purposes of new frame rails. Tonight, I did a rough cut into the floor pan so I can sit inside. Next step is to do some metal clean up and find all the spot welds in the floor pan, inner/outer wheel wells, and trunk pan. I'm sure it will take me some time to get these all drilled out and metal removed....but slow and steady will keep me from getting worn out!

My current plan of attack is to get the new floor pan in, then trunk pan along with outer wheel wells and inner DSE tubs. I'll be doing the frame rails as I go with the trunk pan since modification is necessary from I've seen. Once I get to that point, I'm going to rough cut the passenger rear quarter out, and have the car media blasted and epoxied. I feel that'll put me in a good spot to really see some of the other repairs that I may have to do. If anyone has a better order I should be doing this in, let me know!

Here are the latest pics.

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-Brian

[bcampbell2858]

Hey Everyone,

Quick question for you folks....first off though, here is a picture of where I am currently at:

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The whole floor section has been removed. The car is supported/secured at rear outer rocker panel right before wheel well, and at the front subframe mount on the firewall as seen in these two pictures:

Rocker Support:
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Firewall Support:
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My question now is: I would like to replace the inner rocker panels and I need to know if I should try to brace the car up more in the front? The inner rocker panels continue THRU the firewall, past the toe boards, and stick out near where I have my firewall/subframe support. Seperating all this metal seems a little sketchy to me....but its the only way to slide the new inner rocker in. Here are some more pictures, including the new rockers.

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And for giggles, I have the new frame rails just kinda hanging out in the back at the moment. I bought the ones that are already modified to accept the wider wheel tubs. The trunk floor that I bought is modified as well. These 3 parts are from dynacorn and are meant to work together and take some of the trickier fitment work out of the process.

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Thanks for looking and if anyone has replaced inner rockers, lend me some advice and pics!

-Brian

[kirt70camaro]

Cool to see the step by step please keep doing it. What state are you from?

[bcampbell2858]

Progress Update:

Moving along slowly but surely. Was able to remove passenger inner rocker panel. Was happy to see that the inside of the outer rocker panel was in pretty good shape. Need to do a small patch towards the front, but no big deal. Here's a pic:

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Previously, I was planning on replacing each of the toe boards as separate pieces. Now that I see that the inner rockers actually extend thru the firewall, I've decided to replace the entire firewall. The replacement has the firewall with toeboards as one unit, much like factory. Plus, it will make installation of full inner rocker panels much easier. Only thing I need to do first is to create a new support structure for the front end, as I will temporarily lose the subframe mounting points. I found some good reference pictures and will be adding a support that fastens to door hinge area per this pic:

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Plenty of work to do in meantime, still need to remove driver side inner rocker. I can also remove the inner/outer wheelhouse pieces on both sides of car. It's a grind drilling spot welds but I've made good progress I think.

I'll keep the pictures coming,
-Brian

[bcampbell2858]

Kirt70camaro,

Sorry I didn't see your question earlier. I live in Connecticut.

-Brian

[minendrews68]

Dang Son! why don't you just build it from scratch?..... Just kidding, you seem to be doing a great job. Lot's of work being done here.

[Blown73]

Looks great Brian! Good progress! A project like this is all about baby steps!

keep it up!
-jeff

[bcampbell2858]

Thanks guys!

Overall it has been a pretty fun project so far. Spot weld drilling is tedious but its coming along smoothly. I'm excited to start putting things back together!

-Brian

[cbpldc]

Super impressive! Keep up the good work!

[bcampbell2858]

Update...

Haven't worked on the car since the fall. Wanted to get going on it again since weather has been nice! Removed firewall and have most of driver side inner rocker off except a few strips of metal. Next step will be removing the inner rocker panel brackets that surround the (heater duct hole?). New inner rockers have these pieces already attached. Once that is done...have a little bit of metal repair on inside of driver rocker. After that, I'll be looking to have the car sandblasted and start reassembly.

Pictures:

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-Brian

[rohrt]

Holy *****

Nice work on the cart. I admire your determination too. Looks like your building a car around the VIN plate:)

Just wondering about cost of a new shell verses what you will pay in sheet metal?

[bcampbell2858]

Thanks! I think I recall a new shell being around 15k or so. Think I'll come in at less than half that with new sheet metal....doing the work myself. Don't have that type of cash saved up. Plus, I like the idea of bringing the car back to life...piece by piece! Looking forward to sandblasting and reassembly

-Brian

[bcampbell2858]

update:

Finished removing rest of inner rocker brackets. Next up is grinding down welds, doing a few small patches in outer rockers...then sandblast the car.

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-Brian