1968 Chevy Bel Air Wagon Project
I got tipped by a forum member that I don't need to leave this forum to make
a new project thread even if it isn't a truck. Thumbs up! This is about my newly acquired '68 Chevy Wagon, originaly manufactured in Tonawanda (New York), April 16th 1968. Well, that might be the date of the manufacture of the engine, but it's pretty close, I assume. Power is provided by a 327 v-8 Turbo Fire, coupled to a Turbo Hydramatic TH-400 transmission. This wagon came from California to Finland (in the north of Europe) in 2014, and has been used as a daily driver by its previous owner, and I bought it the very last days of October 2018. My daily driver is a 1980 Caprice (previously a hearse), and for summer wheels a 1957 Pontiac (not a wagon), and I had been looking to get a sixties wagon for some time and when I happened to get hold on some cash, the result was this gray beauty. http://www.waasadata.com/belair/img/belair001.jpg It drives and runs pretty nicely, and will be a good driver with a bit of service to the carb and ignition. And some other small stuff. This is not a restoration, it's about making an old shabby wagon look (and sound) nice. |
Re: 1968 Chevy Bel Air Wagon Project
The wagon was bought in the middle of a trip to the southern parts of our
country, and I bought it without checking it much. I was in a hurry, and the previous owner seemed nice enough. I drove the wagon about 500 miles the first couple days, and it ran ok, save for a few stalls at stop lights. It runs good, but stalls when it idles for a bit. Might be the fuel level is too high. After driving the ugly wagon for a while, I decided it was time to get it tidied up a bit for next summer, and drove it into my garage. It's always nice to have a new project. http://www.waasadata.com/belair/img/belair002.jpg The idea was to tidy it up a bit, get rid of all the warped side trim, do some kind of patina job, new double exhausts, and a bit of service. When I started checking the body out, it turned up to be rusted and patched badly, in all senses of both words. Also, close to where I live, a young guy has bought a '67 patina wagon, and I prefer not to be mistaken for him *grins*. Actually mostly because I didn't get a wagon to be like everybody else. So, a real paint job is in the plan now. The paint is not the origianl paint, nor color,and it's flaking, so there will be some elbow grease involved in making this problem go away. Oh, and sheesh, those 14" wheels with tiny radials look ridiculously small! A kind of plan or goal for the project was whipped up in photoshop. New wheels, lowering the front for a bit of rake, and a cream colored paint job would make it look a lot nicer. New, suitably loud pipes too. http://www.waasadata.com/belair/img/belairplan.jpg |
Re: 1968 Chevy Bel Air Wagon Project
Cool project and I will be tagging along.
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Re: 1968 Chevy Bel Air Wagon Project
Nice! My parents owned a 67 Belair wagon way back.
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Re: 1968 Chevy Bel Air Wagon Project
I started out with the fun stuff, and ordered some new rubber and a couple
new wheels. Lookwise, the wheels and stance are important factors and can totally make it or break it. I got 225/70-15" tires with white letters for the fronts, and 255s for the rears. New 8" wide aluminum rims, very closely resembliing the widened 10" GM wheels I happened to have in my garage. I tried the tires on the wheels, to be sure they would fit. The rears were a tight fit. http://www.waasadata.com/belair/img/belair003.jpg After checking that they would fit both front and rear, the rear rims were sandblasted, epoxied, and filled. Then epoxied again, painted black, masked off, painted silver, and cleared. A weeks worth of labour. At least they came out costing less than the aluminum ones :) http://www.waasadata.com/belair/img/belair004.jpg Finally, with the tires mounted, we can have a good look. The silver idoesn't exactly look like the polished aluminum, but it's a mile of dirt road before I hit the tarmac, so it'll probably be okay by then. http://www.waasadata.com/belair/img/belair009.jpg Just the little wheel caps to do. The fronts have new ones, but the originals for the rears are missing. Maybe we can invent something that fits... |
Re: 1968 Chevy Bel Air Wagon Project
Thank you Advanced Design for showing interest. I hope to be able to keep you
following this thread. Same goes for you Clyde65. I'm envious of such memories from the past. Not many American cars around when I was a kid, save for a 1967ish Valiant that our neighbour owned in the early seventies. I guess I'm working on providing my surroundings with new memories of old American cars. |
Re: 1968 Chevy Bel Air Wagon Project
Always like those type wheels.
They look good on that wagon. |
Re: 1968 Chevy Bel Air Wagon Project
Thank you Getter-Done, I think the wagon will look great with those
wheels. To me this is also one of the best wagon body styles by Chevrolet, love the side view. So, the wagon's in the garage, and the grinder is out for some old repair hunting. When I noticed the badly done repairs on the various body panels, I knew I had more work ahead than nagotiated. Sure enough, this is what the repairs look like: http://waasadata.com/belair/img/belair005.jpg Yup. A big enough piece of Sheet metal, in this case also just bent under the front fender, the result being that no panels seem to align whatsoever. All these repairs are being cut off, new patch panels made, and those, in turn, are welded in flush. As you might be able to see in this pic, the bottom of the fender is now in line with the rocker panel, and all of the patch sitting flush, it will need much less filler to look that much better. At least in theory :) http://waasadata.com/belair/img/belair006.jpg Behind the rear wheel, at the bottom of the rear fender, a long piece was done in the same manner. There also was a dent right above the exhaust pipe, so that got tidied up smartly. http://waasadata.com/belair/img/belair007.jpg After taking care of a few more old repairs, all welds ground, the car was turned around, and work can comence on the right hand side of the vehicle. http://waasadata.com/belair/img/belair008.jpg |
Re: 1968 Chevy Bel Air Wagon Project
On the right hand side of the car the problems were a bit worse than expected.
I had noticed something about the shape of the rear pillar, and these patches were a bit worse to get out than the previous ones. The new patches were made a bit smaller than the old ones, and cutting those off left some score marks in the sheetmetal. Some filler will remedy that. Someday I might try lead... http://www.waasadata.com/belair/img/belair008b.jpg A few of these patches have been made, and it still makes me wonder how a California car can be this rotted. It was made in Tonawanda, New York, so it might have spent part of its life there. Funny thing is that the bottoms of the doors are in better shape than the rear pillars. That's new to me. Wonder if it has been sitting under some kind of tarp? The hood was very badly rusted too, and some bright previous owner has sand blasted it from the inside, which has warped the outside skin severely. Good thinking... Duh. |
Re: 1968 Chevy Bel Air Wagon Project
I like your work.
If only cars could talk. Where was it parked? Who? What? I Got some lead smearing Wooden spoons at a garage sale last year. I have thought about filling seams like that also. Keep up the good work. |
Re: 1968 Chevy Bel Air Wagon Project
Nice wagon , you dont waste any time do you ,you dove right in .
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Re: 1968 Chevy Bel Air Wagon Project
I love the wagon. I may be partial as I have owned more wagons than regular cars.
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Re: 1968 Chevy Bel Air Wagon Project
Thanks Getter-Done, and yes, if only...
I didn't want to waste much time, flashed, since the fall was coming fast, and it had this effect on other people: http://waasadata.com/belair/img/belair001b.jpg When we came back to the wagon after shopping, cars on both sides had vanished, and nobody had dared park there again. I like to feel a bit of pride when driving my car, and this wasn't cutting it :) I hear you Warrens69GMC, I've always loved wagons, and had my fair share: 1965 Ford Taunus Turnier 17m 1700 V4 1970 Ford Taunus 17m Turnier V6 2000S Van 1971 Ford Taunus 17m Turnier V6 2000S Van 1972 Ford Taunus estate 1966 Ford Cortina Estate 1982 Oldsmobile Custom Cruiser 1980 Volkswagen Passat Kombi 1970 Toyota Crown Wagon 1984 Ford Crown Victoria Wagon 1980 Chevrolet Caprice Classic 1971 Pontiac Grand Safari 455 1983 Chevrolet Caprice Classic 1980 Chevrolet Caprice Classic 1990 Chevrolet Caprice Classic and 1968 Chevrolet Bel Air Wagon |
Re: 1968 Chevy Bel Air Wagon Project
I've loved wagons ever since I was a kid when we had a 41 Ford woodie. I've had three Dodges along the way but have a Suburban now. I guess you could say it's the follow up to an actual station wagon. I like the way you are going so I'll be following along.
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Re: 1968 Chevy Bel Air Wagon Project
Count me in for a Bel Air Wagon build!!! I daily drive 'Wanda' my '65 Bel Air Wagon (thread is also here in Alternate Tinkerings).
Repairs are looking great so far - carry on!:chevy: |
Re: 1968 Chevy Bel Air Wagon Project
Welcome aboard, Russell Ashley and BossHogg69! The love for
wagons is something you either have, or you don't. I always drive my wagons with the rear seat down, which to me always has been a cool thing, and it's not often I need to haul more than two passengers anyway. "Wanda" is a nice name for a wagon. Mine was called "Bella" by its previous owner. It didn't stick with me, since A good friend of mine has had a Bella of his own for many years, a '56 BelAir coupe. |
Re: 1968 Chevy Bel Air Wagon Project
So, it's been a bit of a break here, with Christmas, New Years and everything.
Happy New Year all! Back to business: This wagon has been in Finland for some four years, and from the relatively fresh look of the paint, the hood was sand blasted from the inside by the previous owner. If you ever thought of sand blasting a car: Don't! The '68 Chevy hood has a substantial inner structure, with two big triangle shaped holes. When blasting, the sand has thumped the sheet metal in these areas so hard, that it stretched considerably. I trailered the hood to a good friend's body shop, and he showed me how to shrink the stretched metal. Here's how I did it with an electric spot welder of sorts, equipped with a graphite rod. http://waasadata.com/belair/img/belair010.jpg The metal is heated in a slow circular motion, and when the center of the area is reached, the middle has a dull glow to it, and the area is rapidly cooled with a long blast of compressed air. It's slow work, and gives you an urge, and an itch to go faster and... Well it's time consuming. One of those circular thingys takes quite some time to do, so this is the result of a few hours of work, counting in some hammer and dolly work and lots of planning, and hesitating. This shrinking is all new to me http://waasadata.com/belair/img/belair011.jpg After all this work, the hood seemed about as crooked as it was to begin with, only it looked a lot worse. Luckily my pal came to the rescue, and did his magic with hammers and dollies, and the result is so good, that it seems like an awesome amount of body filler might make the hood like a hood again. The hood is back in my own shop (just a heated garage, really), and put aside for now. This kind of work really makes it feel the project is at a standstill. |
Re: 1968 Chevy Bel Air Wagon Project
As this car is so badly rusted, you'd think the wheel arches would be really bad,
but surprisingly enough, they're not. Only one spot was rusted, and it was here, in to the front of the right hand side rear wheelwell. http://waasadata.com/belair/img/belair015.jpg The holes are for rosette welds, to make it sit and look like the original spot welds. It's functional too. I like to drill the holes pretty big, to get a good weld to the inner fender. This is all welded by now, but I don't have any pics of it at this time. Notice the smart ground lead from the welder in the previous post of mine. A powerful magnet does the grounding, I really like the idea, and might use it some day. |
Re: 1968 Chevy Bel Air Wagon Project
Never seen a shrinking method like you used...I thought I researched it all...a shrinking disc turned out to be the best method for me...its works amazing...
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Re: 1968 Chevy Bel Air Wagon Project
Hi, mongocanfly, I've read about those shrinking discs, but never seen
one in use. When I built a rod in the early two thousands, I didn't know that I could attach a graphite rod to my mig welder, and shrunk sheet metal by welding on the inside, and cooling it off with water from the outside. It works, but it's pretty unpredictable. |
Re: 1968 Chevy Bel Air Wagon Project
Nice work Flatbed. That shrinking process is one I haven’t used and it looks like it did the job. Mostly I’ve been exposed to a shrinking disc use. Here is an overview.
https://youtu.be/X8cruauERmI |
Re: 1968 Chevy Bel Air Wagon Project
Thank you Advanced Design, for the link. The shrinking disc seems to
work very nicely, and I'll get one some day. Seems like it's a fast way to do it too. In this very case, though, it would have been a bit harder to do with the disc, since the sheet metal had stretched in a way that had made it buckle down. No high spots to "grind" with the disc. You could also heat the sheet metal with a welding torch, but I think that might require some expertise to get it right. Another problem in this case was, that you couldn't work the sheet metal in any place you wanted or needed, because of the hood's inner structure. |
Re: 1968 Chevy Bel Air Wagon Project
Hey BossHogg69, did you see what I wrote in your '65 wagon thread
about the tail lights? I always liked the way the tail light are close to eachother to Chevrolets from 1965 and older. When Chevrolet came back to separate lights in 1968, they put them farther away from eachother. On the Kingswood this was further exaggerated. This is illustrated in this pic: http://www.waasadata.com/belair/img/belair016.jpg My wagon has been hit in the rear left corner, and the tail light lenses are all in dire need of getting changed for new ones. It's not really easy to find tail light lenses for the 1968 wagon, so I came up with the idea of costomizing my ride by mounting three pairs of 1950 Pontiac tail lights with sequential turn signals. Ever since I was a kid, I have dreamed of having that kind of turn signals on my car. This would also let me tuck the tail lights a little bit closer to eachother, than they're originally on an impala or caprice wagon. I tried to photoshop Pontiac lights onto the tail of a '68 wagon, and I think this would look so okay, that people who don't know classic cars probably wouldn't notice that it's not an original look. http://www.waasadata.com/belair/img/belair014.jpg Yup, I pasted in my own register plate too . |
Re: 1968 Chevy Bel Air Wagon Project
In my last post I mentioned that my wagon has been hit in the rear left hand
corner. Somebody apparently backed into something, Should be a pretty straightforward repair. First the bumper came off. Not an easy task, as some nutcase had welded the bumper brackets to the frame! Anyway, this is what it looks like to start with: http://www.waasadata.com/belair/img/belair017.jpg The outer part of the rear should follow the same line as the tail gate, so it's almost in inch too far in. I have borrowed a slide hammer with a claw that grips thin sheet metal. Just spot weld in a piece of scrap cheet metal, and start hammering (pulling) away. Well, first the paint has to come off. http://www.waasadata.com/belair/img/belair019.jpg Oh shoot! Not something I had expected. The fender bender was actually repaired to this state! My flabber was trulyly gasted. I heated the parts with lots of lead on, and let it run to the floor. I did a few releif cuts where the sheet metal was badly wrinkled and started pulling from different pieces that i had spot welded to the car. Looks much better already, but the outer corner is still a bit too far to the right, and nothing happens when I pull to the side. I called it a day, and will continue on tuesday night. http://www.waasadata.com/belair/img/belair018.jpg |
Re: 1968 Chevy Bel Air Wagon Project
Those round Pontiac taillights you photoshopped in would look bada$$!!!! And then if you made them with sequential turn signals??? YES! I say go for it. :metal:
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Re: 1968 Chevy Bel Air Wagon Project
I'm in! I owned a 68 396 4 speed wagon 35 years ago lol.
Looking forward to how this one turns out. |
Re: 1968 Chevy Bel Air Wagon Project
Thank you BossHogg69 for the encouraging words :)
Nice to have you on board, mingoman, I hope you won't be disappointed. Once again, this is a repair project, not a restoration. I work on a budget, and am an amateur just trying to make do with my limited tools and skills. So, on with it. I worked some with the tail en since my last post. First i welded some scrap pieces to the outermost corner of the tail, and tried pulling to the side. No matter how hard I hammered away with the heavy slide hammer, nothing gave. In the end I gave up, and cut it all away: http://www.waasadata.com/belair/img/belair020.jpg Then I drew a template from the right hand side, and welded in the new tail strip. After a few spot welds I chacked the fit, and all was good, so I welded it all and ground the welds. Now it looked good, and I called it a night. The next day, when showing the pics to a buddy, I noticed that it really didn't look that good, so when I got home I checked with the template I had made before. http://www.waasadata.com/belair/img/belair023.jpg I was right. Apparently the whole thing had warped badly as I was welding it. The green part shows how far off the curve was and the white arrow shows where the little sharpie V should point at. Luckily it was pretty pliable,and i got it sorted. I cut out som pieces for the bottom part to fix it all. After I had welded a four or five spots I chacked again, and... Rats! it had moved again. I was close to giving up for the night, but hated the thought of being at work knowing I hadn't figured this one out yet, and started over. Cut out the few spot welds, and hammered away until I was satisified with the fit. Then lying under the rear of the car, cut pieces to fit, and slowly spotwelded them in, checking the alignment and all after almost every spot was welded. http://www.waasadata.com/belair/img/belair022.jpg Rear corner seen from below. Also visible in this shot is the scrap pieces of sheet metal spotwelded to the corner, that I pulled with the slide hammer and used for grounding the welder. This rear corner is welded now,and just waits for grinding. As usual, this dented corner took a lot more work than anticipated to get it done. About four times. I should remember that ;) |
Re: 1968 Chevy Bel Air Wagon Project
I am impressed with the dedication to get the shape correct. Well done!
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Re: 1968 Chevy Bel Air Wagon Project
Now that's what I call dedication!!!
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Re: 1968 Chevy Bel Air Wagon Project
Thank you Advanced Design and BossHogg69, I aim to do it
right. No use botching this job as it's going to get painted afterwards, and it's not fun if it looks all crooked when painted. Got some time to finish the work on the rear of the wagon this weekend. I was going to start grinding the welds saturday, when I discovered two huge rust holes in the tail gate. A deep sigh, and a thought that this will take me a couple weeks to do hit me. On with it. I measured the big patch inte middle, and cut it out. Then made a bend on the sheet metal brake. Some persuasion later, I had a part that fit nicely. I cut away the rust, and adjusted until I could start welding. A few tacks in this pic. On the other side the sheet metal was hammered and dollied flush with the original folded skin, and rosette welded through holes that I had drilled previously. The green arrow points at some more rust. http://www.waasadata.com/belair/img/belair024b.jpg It was a busy saturday, so I only got this patch welded and partly ground. I barely looked at the other rust hole, and even thought of using fiberglass filler, it was in such an awkward place behind the hinge. Sunday I looked at the problematic hole, and decided to give it a try. I cut as much as I could with my small angle grinder with a worn down cutting wheel, and then cut the rest with a rotating file. It worked perfectly, albeit a bit slowly. I measured and cut a patch piece for it, again hammered to a nice shape, and welded it in. Grinding the welds was as hard as cutting the hole, but the same grinder with another file made grinding the welds pretty easy. I sanded the coarse-ish surface with my not-a-dremel and a sanding flap wheel of sorts. Those are toys when it comes to this kind of work, but it made a difference, and my hourly rate is very low :) http://www.waasadata.com/belair/img/belair025.jpg Here the welds are ground. There's also a little patch on the rear quarter, partly behind the hinge. This all was time consuming, but the result is okay, and I'm very happy to have it done. |
Re: 1968 Chevy Bel Air Wagon Project
Some time has passed since I last posted any progress. I'm doing this project in real time, so sometimes less happen.
After the tail gate had been welded and ground, it was time to turn to the bumper. It too was a bit deforemed, the drivers side outer part was bent forward. The inner structure is pretty sturdy, so I cut it to have an easier job bending the end part backwards. This worked, as the bumper wasn't too hard to bend now. After test mounting the bumper on the car, it looked much better, but was too far to the left. Moving it over to the right forced me to move the left hand side bumper mount about 1/4" to the left. The arrow points at the most ovious place to see this. http://www.waasadata.com/belair/img/belair026.jpg With the mount welded, the bumper fit much better to the rear of the wagon. After this pic was taken, the bumper has been slightly straightened as it's a bit crooked in the middle here. http://www.waasadata.com/belair/img/belair027.jpg The ends also fit very nicely to the indentations in the rear quarters, so I consider this repair a success so far. http://www.waasadata.com/belair/img/belair028.jpg |
Re: 1968 Chevy Bel Air Wagon Project
Since it's colder at the door, and also because my garage is a bit too short, the
car was turned around for working on the front. The front of this car is all askew, the lower part of the grille is almost an inch too far to the driver's side, and the lights of that side are too far set back by about 3/4". This car has had more than its fair share of fender benders and mishaps. The result is not nice, and it's hard to tell where to start. So I just took a deep breath and dived right in. http://www.waasadata.com/belair/img/belair029.jpg The front bumper came off pretty easily. The bottom part of the grille is attached to the bumper, some hammering remedied it not being centered. Funny enough, this was all but impossible to accomplish with the bumper mounted on the car, but with everthing unbolted it was a cinch. With things hammered and adjusted, I was almost chocked at how off the left hand side bumper end looked. It wasn't like this before.... Was it? http://www.waasadata.com/belair/img/belair031.jpg At this time measures were taken, and the whole thing removed again. A few tries later the bumper fits much better. http://www.waasadata.com/belair/img/belair032.jpg |
Re: 1968 Chevy Bel Air Wagon Project
Some little tinkering was done along with the bumper work. I tried polishing the lower grille,
and the results look pretty promising. Not good by a far cry, but better than rattle can silver for sure. I can always paint the bright stuff later if I get tired of it, but it's harder to unpaint bumpers and grille once it's done. http://www.waasadata.com/belair/img/belair030.jpg Having a real bad "before" situation helps :) Most of the trim and emblems are removed for polishing or sanding. Some new bits have been clicked home off the net, like new front turn lights, pedals, arm rests, window cranks etc. Those bits will make the car look well maintained, even if the bright work is a bit on the shabby side. |
Re: 1968 Chevy Bel Air Wagon Project
As the gray paint is flaking off petty badly in places, most of it will be removed. I
was going to have the body soda blasted, but I'm too cheap, and am paying in elbow grease now. The roof and pillars are done, as is the right hand side front and rear fenders. Still just scratching the surface... Pun intended. http://www.waasadata.com/belair/img/belair033.jpg |
Re: 1968 Chevy Bel Air Wagon Project
1 Attachment(s)
Looking good flatbed....if your removing all your paint have you tried a 3M bristle disc...they're not cheap, but they sure do remove paint good...almost like just wiping the paint off....and no metal damage..they make them in the roloks and for hand grinders...sure beats hand sanding
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Re: 1968 Chevy Bel Air Wagon Project
Nice work Flatbed. How did you polish the grill?
Handy recommendation Greg. I’ve never used one though would be handy. |
Re: 1968 Chevy Bel Air Wagon Project
only downside to the bristle brush is cost and life of use...but it works like magic...
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Re: 1968 Chevy Bel Air Wagon Project
Thank you mongocanfly, for the tip. The paint is chipping badly on this
car, and is coming off pretty easily. I just sand it off with an oscillating grinder with 80 grit sanding discs. I tried 40 grit too, but it doesn't help much, as any paint left is so deeply scratched that a lot of sanding has to go into getting those scratches out. I then sand it all smooth with 180, so that the epoxy primer will adhere, and hopfully not shrink into the scratches. The roof seems to be pretty good, so it was mostly just sanded for adhesion. I plan to spray on a nice coat of epoxy first, then block it and fill as needed with poyester filler ( much like bondo I guess), block and fill, block and fill, then epoxy again, block it down and then final paint and clear. I'll paint the final paint in a nearby paintshop, where I worked for a year a few years ago. It's well worth the cost to get the car painted in a dust free environment, with a good spray gun, mine is cheap, and not good for finer work. Thank you Advanced Design, I have an abrasive nylong bristle bruch like this one... https://sc02.alicdn.com/kf/HTB1xPDZH...pg_350x350.jpg ... to knock off the worst pitting, and then I polish with a buffer on a powerdrill using Autosol polish. Speaking of which, Autosol for Aluminum works pretty well on chrome, and doesn't dull it as coarser versions will. |
Re: 1968 Chevy Bel Air Wagon Project
Slow work, this paint stripping. It took some time to make a hole in the garage
wall and build a system for evacuating the dust too. The drivers side is done when it comes to paint stripping. Most is sanded down to the bare metal, and finished with 180 grit for perfect paint adhesion without risk of shrinkage into the gritgrooves. http://www.waasadata.com/belair/img/belair034.jpg The front fender is dented, and this will be adressed before the epoxy goes on. The severely dented, shrunk and hammered hood is also ready for epoxy. http://www.waasadata.com/belair/img/belair036.jpg I'm assuming a lot of filler will have to be used in order to make the hood look like it's supposed to... Detail work is done according to inspiration. My aim to make the wagon look a bit nicer than just your usual respray, so details like nice paint inside the filler door feels important. The chrome is pretty much shot on this car, but I hope to be able make it look tidy anyway. http://www.waasadata.com/belair/img/belair035.jpg |
Re: 1968 Chevy Bel Air Wagon Project
Subscribing to watch....I love the wagons....
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