Bob’s 356A project

[robert moglia]

“Regrets, I had a few...”
Finishing the rear fender edge was a lot harder on this side due to the severe rust at the top all the way to the trunk edge.

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After cutting it open and out to repair the upper A post

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I thought using the standard repair panel would fit well.
And at first glance it did.
This is where the “regrets”come in, I trimmed it to fit nicely but once I started to hammer over the rear edge the panel buckled like asphalt in Arizona.
Previously the door surface alignment was perfect now not so much. Disheartened, I quit for the day to fume over a cocktail. The next day drastic surgery was required in an attempt to salvage the panel, so I cut out the buckled middle section. The mis alignment is evident at the front edge of the patch, no way was I gonna get that to line up.

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You can see how far off the crown has become.
I fabricated a new compound curved insert....

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And tacked it in place, it fit!!

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Some minor tweaking to the vertical section was uneventful.

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My harlequin repair ain’t pretty but...
“I did it my way”

[Adam Wright]

Bob, I've never been happier I didn't buy a car, watching you put this back together is great to watch!

[robert moglia]

Adam, that statement can be interpreted in 2 ways!
Just kidding, thank for the encouragement.
Things are moving along, but it’s getting too warm to put in long days, my heart goes out to our west coast friends.
I fabricated the front edge of the quarter panel, the dreaded “Z” piece, fortunately it was not long.
I’ll weld it up tomorrow.

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To change it up, I worked on the rear fender braces, curiously the left side bolts into place, reason unknown to me. My right original was cobbled together rather poorly.
The left was missing.

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Right side:

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Left side:

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Note the added captive nut plate add on.
Both needed modifications as they were too splayed to fit.
Here’s the finished result on the right

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Improvement, don’t ya think?!

[robert moglia]

While I got your attention, any idea as to how to finish this up? The confluence of rear closing panel, outer longitudinal and rear longitudinal just looks a mess with flanges and free edges. Anyone have an idea as to how I should finish this off.

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A picture would be great!
Thanks

[Justin Rio]

Hi Robert, Here is how it was originally finished:

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That flap gets a seam weld.

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My replication of it. I have been blessed to have original reference cars and/or sections to copy or reverse engineer from. I've said on many occasions that I'd be lost without them. Hope this helps.
Justin

[robert moglia]

Perfect! Thanks Justin.

[robert moglia]

How’s this Justin!
Thanks again

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Right front fender support repair too rusty to save
Rust into the bumper support like the other side.
First patch the bumper support

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Of course getting 4 points of attachment line up is impossible (for me) so I cut out the battery box side to allow a “floating” patch that was scribed and cut to size once final position was decided.

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[robert moglia]

While the support is out time to fix this headlight rust through its worse than it looks but I was tempted to just slather it with seam seal!

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Fabricated a new edge, my shrinker has really paid it’s way!

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Rot cut back to clean metal.

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Patch positioned, scribed in place and cut to size.

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Including plug welds from the bucket

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Then the support can be welded in.

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[robert moglia]

Back to work after 3 weeks in the camper!
Hood seal channel repair.

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Rust extended to inner fender panel.
Cut back to solid material.

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Inner repair first

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Then the seal surface.

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Then spotweld the two together and finish.

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Next up left sill install.
Thanks for watching.

[Justin Rio]

Hey Bob, those small peripheral rust repairs can be tough to dredge through and can seem almost endless. I admire your staying power. Keep chipping away at it. Justin

[robert moglia]

Left sill install: it required modifications front and rear to set the door gaps.
First off sill edge 1” running beads every 6”.

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Front

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Rear; including the fabricated B pillar fender Z flange.

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The front drain panel required a lot of adjustments, if I were to do it again I would buy an unassembled sill set.

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Then plug and spot welded in place.

[robert moglia]

As Justin pointed out the little patches require persistence.
Engine bay rust repair.

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Replacement fabricated.

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Tacked in place.

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Finished repair.

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Also finished up the front fender welding on the harlequin patch job.

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And with that the major welding repairs are DONE!
I’ll give it the once over looking for pinholes and the final grinding. Hopefully next week I’ll get the bottom primered, seam sealed and under coated.

[robert moglia]

With the panel replacement done I couldn’t resist.
These are what I replaced.
Prior incorrect floor and longitudinal repair.

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Major pieces still identifiable.....

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All the other trimmings.

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The long and winding road that leads to...the dump!

[Justin Rio]

That was quite the metal journey Bob. All of those bits and pieces in arrangement really tells the tale. The front pan section in olive green almost makes me shutter to think that it might be an actual NOS floor section that is now just wasted metal from a previous repair attempt. BTW: Did you mock up your seat mounts and tracks to confirm that both seats are able to slide back and fourth without binding? Being these are all new reproduction parts installed without jigs makes their alignment side to side an iffy proposition at best. I was reminded about this by Bruce Baker a few years back; just passing along some hard learned lessons from an old expert. You can imagine having your car all painted beautifully with your new carpet set installed then only to find out that your seats won't slide. Best of luck on the next phase of your restoration. Justin

[robert moglia]

Thanks Justin, right now I’m in grinding mode.
I’m good for about 2 hours before my hands go numb!
Even with those gel palm gloves, but I’m plugging along.
Thanks for the tip about the seat mounts, I checked and they worked, phew!
Don’t feel bad about that floor pan, even though green primered it was a lousy reproduction, look at the stamping, about as crisp and sharp as a butter knife!
I should have done the grinding as I progressed, I’m paying the price for my laziness! Once that is done I can paint.