BUILD THREAD “The Juggernaut”

That's some fancy bead rolling you got there- very smooth stuff. I would've wasted multiple pieces trying to get that semicircle right. And you're right about the reverse lights looking better with no gap above them, that's a subtle yet appreciated mod. I've also got a lay down plate mount that needs installed, and now that I know there's room for a "cap hanger" back there I can stop putting it on my trunk!
 
Beautiful work Donovan. That must have been fun and gratifying to fabricate. Thanks for the update! It was a fun read.
 
Wow, awesome work as always Donovan!. Lots of nice little touches there too. The nutserts, the stainless button head screws, and the fuel cap holder. I like it!

Thanks Jeff. Adding those little touches after all that work is the icing on the cake so to speak. I really enjoy that part. It’s gratifying to see it all come together after the weeks of planning, measuring and fabrication.

Yet another instance of really great fabrication work that, for the most part, nobody will ever notice. That's a shame..... Nice work, Donovan! 👍

Appreciate it Mike, thank you. Once again, there’s that double edged sword, if done properly and well no one will be any the wiser, but it’ll likely go unnoticed for the most part. But if it’s poorly executed, well…

That's some fancy bead rolling you got there- very smooth stuff. I would've wasted multiple pieces trying to get that semicircle right. And you're right about the reverse lights looking better with no gap above them, that's a subtle yet appreciated mod. I've also got a lay down plate mount that needs installed, and now that I know there's room for a "cap hanger" back there I can stop putting it on my trunk!

Thanks, the bead rolling is a learned skill like any other. The more I do it however, the better I get but I’m not where I’d like to be just yet. Your feed rate, good lighting where the dies contact the metal, and the correct pressure all play critical roles in how the end result turns out.

The cap bracket was just a nice little convenience feature that I wanted to add after years of frustration owning G bodies.

You're almost good enough to come work on my junk. 😉

*almost.
😅
Noted, and I’ll keep that in mind should I ever feel the need.

Beautiful work Donovan. That must have been fun and gratifying to fabricate. Thanks for the update! It was a fun read.

Thank YOU Jared. It was indeed fun and challenging to build, and every step that turned out successfully was gratifying each time. I’m not quite done yet, there’s still a bit left to do, but it’s 95% there.

I’m glad you enjoyed the update.


Thanks for all the kind words, comments and support guys. As always it’s greatly appreciated.
 
First look!

The fabrication on the rear filler panel is complete, and the bulk of fitting it to the car is also done.

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I still have to weld some tabs, flanges and whatever else to it to help support it, but for a first look I’m extremely happy with it. I did a little more trimming after those pictures were taken, and it’s fitting even better now:

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But now I have a little conundrum. The “bump” on top isn’t really needed anymore as the license plate light I’m using is a lot lower profile. So should I continue to keep it, or eliminate it altogether and make it completely smooth across the top?

As you can see in the following picture, the backside of the bump is open so something will have to be done regardless.

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It’s extremely quick and dirty, but I whipped up a little closeout piece for the backside just to give a rough idea of what it’d look like if I choose to keep it:

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So what says everyone? Skid the bump and make the top of it completely smooth, or keep it because it adds some visual interest in that area?

Keep in mind that the entire panel will be welded to the tail pan making it all one piece, and that gap to the body you see either side of the bump will disappear. It’ll all be completely smooth from the weatherstrip flange to the outer edge of the fabricated panel.

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Let me know your thoughts!

D.
 
I vote to keep the bump. NOBODY will know the bump is not really needed unless you tell them, and the fill piece seems to be already cut for it (You have to weld up patches either way). You went to all that trouble to replicate it, but it also keeps that "stock" look when painted. JMO. But it's your car, your money, your effort.

Nobody sees it unless the trunk is open anyway and it also offsets the slightly angled blend where the lamp goes underneath.

But, with that in mind, and I know how detail-oriented you are, maybe try this to help make up your mind...

Take a flat piece of sheetmetal and hold it up where the filler would be to simulate the flat section. My eyes are old, but I seem to see a slight rise in that pinchweld area where the trunk seal would go. A slight arc upward, if you will. May simply be a visual angle or something, or a slightly sagging center since it's just being held up with magnets and not attached yet.

The pics below should give you an idea of the ability of that bump to distract your eye-line. The bump must work in that regard, since nobody else mentioned it. Unless, of course, you have another plan.

1 and 4 seem lower than points 2 and 3 showing a very slight upward arc from point 1 of the GM side of the rear panel that seems to go back again as you reach point 4. At least in my eyes. And, if I had to bet which one is laser-straight, it wouldn't be GM's side of it. 🙂
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At this angle, it doesn't go away, at least for me. So I don't think it's just a Jedi mind-trick. Area 1 still looks lower than 2.
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This is no way no how a knock on your skills. I think the filler looks unbelievably great. You just out-did GM's structure-work by a mile, so I'm simply pointing out GM's shortcomings on this. I wonder if all of the A/G-bodies are like this?
 
Oh, and I meant to ask this on previous construction thread: The license plate lamp can be removed/replaced through its opening once it's in its final configuration, right? May need that bump for maneuvering the lamp should it ever need replacing. Just a thought for service-ability.
 
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