What should I build this flat body panel out of?

[aggressive male]

I have this decklid between the trunk and rear window of my car I want to replace with something else. The one I have now is rotting mainly because it is at the edge of where a vinyl roof starts, not to mention it has a major dent in it. It is flat with just a slight curve across the car. I wanted to use plexiglass but that will sag in the sun wont it? I thought of using a piece of stainless steel but how would I make a curved lip to go under the trunk? I was also thinking fiberglass but I don't want to have to make a mold of the piece I have just to make one part. Does anyone know where I can maybe find a flat piece of fiberglass big enough to be able to just cut to size? Or does anyone have an idea of something else I can use? Thanks

[oestek]

What kind of car? The do make repros for many, and you can always source a replacement from a salvage yard. We just replaced 2 of those - one on our '71 Olds from a donor car, and the other on our '65 Chevelle - the panel was from OPGI.

[aggressive male]

What kind of car? The do make repros for many, and you can always source a replacement from a salvage yard. We just replaced 2 of those - one on our '71 Olds from a donor car, and the other on our '65 Chevelle - the panel was from OPGI.

It's for a 77 Deville. I'm very sure they don't make repros and if that place that makes cadillac parts does it would probably be absurdly expensive. It would be very difficult to find another one of those cars in a salvage yard around here and if I did maybe it wouldn't have the dent but would probably have just as much rust because all of them have vinyl roofs that end on it. That's why I want a different material because it's going to see a lot of moisture. However I am lucky it's a flat piece that may be easy to fab.

[SaturnVUEguy]

I would suggest aluminum, but if you are worried about it rusting, I'd say to go with something synthetic, like fiberglass

[aggressive male]

I would suggest aluminum, but if you are worried about it rusting, I'd say to go with something synthetic, like fiberglass

Yeah, being that aluminum and steel corrode faster where you put rivets and screws I think fiberglass would be the better way to go. Now since I really only have to cut a piece to size and add angle pieces to it does anyone know where I can get a flat piece of fiberglass that big so I don't have to buy all the fiberglass cloth and resin just to make something that's already flat? Like cut it out of a trailer at a salvage yard or something?

[toxicz28]

77-79 devilles are the same, might help you widen your search

[aggressive male]

77-79 devilles are the same, might help you widen your search

Yup I knew that. I'm wondering if the ones from oldsmobiles that size and era are the same? It's easier to get new parts for an olds isn't it?

[toxicz28]

Try giving this guy a call. He's near me and all he does is Cadillacs.
http://www.fenenterprises.com/

[justasquid]

would a piece of stainless work?

If you have a dump or junk yard nearby.. look for an old shower.. they are made from fiberglass and I'm sure you could hack a piece long and straight enough from one if thats the way you want to go.

But, if it were me, I would probably just weld in some new steel. It'd be the easiest and it will still hold up well. Just make sure you use a good weld through primer on the bottom of the steel and it shouldn't as fast as the original.... but keep in mind.. the original one lasted 30 years....

[aggressive male]

would a piece of stainless work?

If you have a dump or junk yard nearby.. look for an old shower.. they are made from fiberglass and I'm sure you could hack a piece long and straight enough from one if thats the way you want to go.

But, if it were me, I would probably just weld in some new steel. It'd be the easiest and it will still hold up well. Just make sure you use a good weld through primer on the bottom of the steel and it shouldn't as fast as the original.... but keep in mind.. the original one lasted 30 years....

Yes a piece of stainless would work but bending the edge of it at 90 degrees in a curve to go along with the trunk would be a problem.
Do you mean a shower in a trailer home?

Yes it has lasted 30 years but it didn't look perfect for all of them because it had rust for so many of those years. It's very hard to keep up with rust in new england.

[indyjps]

a shower stall like what would be in a house, the fiberglass wall unit has large flat sections.
Id still do steel, powder coat it and grind back the edges for welding or just por 15 the area after welding.

[Bullett]

What about FRP (fiberglass reinforced panel)? We use them in restaurant kitchens all the time. Comes in 4'x8' sheets, about an 1/8" thick, you can get it at home depot or similar home improvement stores. It would give you your flat panel, you would still have to fab any rolls or angles.