68 camaro - rust holes along front window

[BuddyP]

Just got my shell blasted and primed, and the area at the bottom of the front window, that I once thought was solid, now has a bunch of pin holes about 8"-10" long. What is the best method of fixing these? Can I just weld a bead along them and grind it smooth? I also found a couple up by the pass. toe panel, I really don't want to get into replacing the whole toe panel or floor.

This really chaps my ass.... Please help!

[qwik1320]

How does the top of the cowl look under the dash? I have the same problem with my 67. I was going to just fix the few spots along the bottom of the windshield but the more I looked the more I found so I ended up pulling off the whole upper dash panel for replacement. I'm glad I did, the top of the cowl underneath was rusted big time. The foam strip GM used between the top of the cowl and dash must have gotten saturated from a water leak over the years...

The floor/toe panel is easy, just clean back to good metal and fill them in. Use a copper block to back the hole and fill in the hole then grind smooth.

[MuscleRodz]

If they are small enough, they could be brazed, or you may have to cut and patch.

mike

[BuddyP]

How does the top of the cowl look under the dash? I have the same problem with my 67. I was going to just fix the few spots along the bottom of the windshield but the more I looked the more I found so I ended up pulling off the whole upper dash panel for replacement. I'm glad I did, the top of the cowl underneath was rusted big time. The foam strip GM used between the top of the cowl and dash must have gotten saturated from a water leak over the years...

The floor/toe panel is easy, just clean back to good metal and fill them in. Use a copper block to back the hole and fill in the hole then grind smooth.
I'll have to check under the dash... what's the deal with the copper block? I'm unfamiliar with that??

[mikey]

It gives your weld some backing and it won't stick to it. In short it allows you to weld easier without burning through. Post some pics of the area I have apretty solid 69 coupe parts car might be able to get you some good patch parts cheap.

[qwik1320]

It sucks the heat away faster than if you just tried to weld without a backing, plus the weld doesn't stick to it. Aluminum works too. I find it extremely helpful since I'm just learning to weld.

[BuddyP]

mikey, I'll get some pics posted, but won't be able to until Sunday eveneing

Thanks for the info on the blocks, where's the best place to buy these things?

[qwik1320]

I've seen them for sale but just find a hunk of copper/aluminum. I have some .125" thick pieces from work but even taking a piece of copper pipe and flattening it out will work.

[BuddyP]

I have lots of copper tubing at home (3/8"), so your saying that I just hammer it out and start rubbing it on the metal where I'm going to weld? What about weld thru primer? I have some of that already.

[Mike Holleman]

BP, Just hold the copper behind the hole while you weld. A helper is good. The copper absorbs heat and prevents the sheet metal from burning up and making the hole larger. Works really well. Brazing is a better method if the area around the hole is very thin due to rust. You will figure out real quick whether or not the metal will allow weld.
Mike Holleman

[BuddyP]

Ok, of the pics I currently have, here's one of the pits up front. I'll be able to get some better one's when I get back home.

https://static1.pt-content.com/images/noimg.gif

[69TAPoser]

I echo what qwik1320 said...Mine was the same deal. Some rot along the upper dash panel edge and when we pulled that off, the rot below was worse. Like qwik1320, I also replaced the top cowl and upper dash (actually, I ended up replacing my entire shell due to major rot in most areas...but that's a whole other story!!!) :scared:

I don't want to be an alarmist, but you have your car down so far, you don't want to leave rot on the upper cowl if there is any there. You may or may not be able to see it from the interior, mine was worse than it looked from the inside.

It's hard to tell from the pics how rough the upper dash is. One thing to keep in mind, you can replace the upper dash panel for $75. It may be good insurance just to remove it and see what lies below as you have the car stripped down this far anyway and that area is prone to rot.

Phil

[mikey]

Sorry I can't help you that area on my parts car is worse. The previous owner made it into a drag car. You know how they try to save every ounce well they were real busy.