Rusted package tray corner, trunk hinge support. Need help.

[cwmiller]

Hey guys,
Need some help. I'm in the process of replacing all the cancer in a 1970 GTO. Today, while I was cutting out the truck pan I noticed that the support metal underneath the rear window panel is trashed. I already knew that the package tray corners were bad, but I didn't know that the support for the trunk hinges and rear window panel was. I took some pictures, 'cause it's kind of hard to explain.

I wasn't sure how to repair the package tray to begin, but now that I came across this I'm really not sure. Any advice is much appreciated!!

Package tray corner (right, passenger side)


Rear window support/Trunk hinge support (right, passenger side)

Trunk hinge is on the far left of the picture. The piece to the right of the hinge is part of the support metal that I pulled away, pretty rotted.

[Judas]

Hey, I am working on this area of my '69 GTO. I'll offer some tips, but I am not a pro. I have a bunch of pics as well, if you're interested.

There are a lot of pieces coming together in this one area, so you have to slice it down into multiple small repairs. It is a difficult repair due to all the curves around the window, both on the outer skin, and the window channel itself due to the curved glass PLUS the number of seperate parts coming together (tray, hinge, filler panel, quarter panel, roof pillar). If the rest of the quarter panel needs repair as well, I would very seriously consider a full quarter due to the complexity of the repair here on top the other work (and if I had a time machine, I would have done so with car). This will repair the outer area all at once, and in replacing the whole quarter, you would have good access to the hinge and tray areas once the old quarter is off.

If you are repairing what is there, I would peel it like an onion, one layer after another. First there is the outer skin, which must be removed because it's rusty, and it's in the way. Starting at the corner of the window, I'd make a posterboard template first, then trace around the template to create a cut line. Making a template first seems to be doing it in reverse, but the reason I go this way is that the area is curved and that makes it more difficult after the part is removed. Even if it's rusted solid, I would leave the horizontal 'flange' where the quarter meets the upper lip of the tray for the moment (cut the vertical wall of the window channel), because you need to see the angles at the corner; where the glass 'dishes'.

Next would be the package tray's rusted parts. Unfortunately, what you'll likely find is the roof support pillar has corroded/rusted out along the lip where the tray meets the pillar. Yours doesnt look too bad, except at the rear corner so you might get lucky. I'd start patching the pillar since it's a structural component. After that, I would repair the trunk hinge support since it is somewhat structural too. Then, repair/replace the package tray, paying special attention to get the angle correct at the upper lip of the tray where it meets the quarter (this is critical since the glass goes back in here.) The finale is the curved corner of the window hole (the quarter panel).

Without a stretcher/shrinker or more exotic metal fab tools, this alone requires 3 seperate parts. First is a curved strip to make the lip (or base) of the channel. Then you'll need a strip for the vertical wall (relatively easy), and then a piece for the outer skin, with the cut out and the curve (I used the area just below the cutout to *tap the curve into the new piece, trying not to dent the car). This is as far as I have gotten, but my plan is to weld these three together then install them as one part. We'll see how it goes.

Good luck. My only word of advice: look at this as multiple small repairs leading to one big repair. Helps cut down on the dissapointment.

PS: Try googling this repair on other GM A-Bodies, especially Chevelles. This rust out is a common problem on these cars.

[garickman]

If yours is too far gone to repair, you might want to give these guys a call. They have alot of cars and can usually cut off what you need. Here is a link to their website. http://gmsportssalvage.com/

[AintQik]

We did what Greg is suggesting on my car. In the end there was no piece aftermarket, and it was far easier locating a good donor than fabbing all those complex curves and supports. Welded in a good majority and fabbed the rest.

I'm not a Pontiac guy so you may have better luck finding aftermaket than I did.

[Judas]

I've dealt with GmSports and was very pleased. They supplied the drivers side quarter for my current project.

[cwmiller]

Thanks for all the advice guys, I've decided to replace both quarters so that will take care of the support areas of the rear window. Right now I am looking for a good donor to cut the package tray out of. I will be checking with gmsports on the tray as well.

[mikes2nd]

good luck finding a clean package tray. Gmsports is okay, just expensive and cranky on the phone if they even have anything.

I would just build it and save the hassles or keep any eye on craigslist/racingjunk/claz.org...

I actually found a full quarter for 150$ (OEM cutoff), if your not in a hurry things will show up.