Marriage: 1980 Grand Am and 2005 GTO Build Thread.

[smed7880]

Lost most of the weekend due to work and then got sick...yesterday was a on the couch day. Today i got 4 hours of car time. Cut up the old GAm frame and loaded it in my f150, removed glass/roof from rusty regal and saved the center section of the roof for patch metal, saved some liitle pieces.

Still need to harvest the rockers, some of the 1/4s, the bucket seat mounts, the console mounts (just cutting out the hump for now), the floor shift column and instrument panel, wiring harness.

Wont get any car time until next weekend.

 

[smed7880]

First day in many that the morning was actually nice. Another 4 or 5 hours of car yesterday.

Behold the power of the sawzall.

I should be able to finish cutting up Rusty Regal today and be able to finally clean up the driveway.

 

[smed7880]

Rusty Regal is cut up, no longer taking space in the driveway, and is loaded on my f150 awaiting delivery to the metal man.

Ive got good factory metal where i need it. Have to make some runs to storage, do some clean up, and do some reorging to get ready for underbody Grand Am repairs. I have enough patch metal. After unloading the metal im into Rusty Regal for $350 and for everything it gave thats a big win.

Finally some decent weather to work in, 80s!

Edit...well ok, 94, but thats a far sight better than its been. Did the storage run but still need to clean up garage and reorg...itll wait. Driveway is cleaned up and thats a win. Near as i can tell i avoided a nasty gram from the hoa by blocking the mess with the cars so it couldnt be seen.

Next weekend i can get back to her Grand Am. Ill get the S10 brakes on it, get the frame on the ground, and build my skate based pillars. Im going to tie in 3 sides for stability while im under it cutting and welding. Need to figure out what underbody stuff im going to do...will probably just clean it, scuff it, prime and epoxy.

 

[smed7880]

Delivered to the metal man. 1500ish pounds of metal in 2 trips. Rusty Regal all in cost $325...frame etc and no long drive to get it made it well bought. Will update project cost list tonight

 

[smed7880]

Thinking about chemical welding vs cut out/weld back in. I havent messed with chem welding but it sounds ideal for the patching i need to do. Maybe tack/spot weld in combo with the chemical weld??? Not sure yet.

Once i cut out the bad metal and treat it, then cut the overlapping patch pieces ill know exactly how much im dealing with.

Adhesive Bonding or Welding? The Answer May Surprise You - Wiley Metal

In fabrication the main way we create permanent joins is by welding. Welding has it’s drawbacks though, some of which we’ve discussed here. Thin materials, dissimilar materials, aluminum, even stainless can present challenges. And then there’s all the prep and clean-up, which takes time and adds...

www.wileymetal.com

An Introduction to Methyl Methacrylate Adhesives (MMAs)

Learn more about what MMAs are as well as their applications and advantages.

www.gluegun.com

 

[smed7880]

Lots of delays due to work and my Torino. The battle with the shop hasnt been fun. I finally got the front clip back on and it went to the shop last tuesday for transmission leak repairs and fixing the crappy paint. Today was clean up the garage from Torinocation and blow the dust off her Grand Am project.

I didnt get much wrenching in but the corvette brakes are off, the dual caliper S10 front brakes are on, and it is sitting on its 14" rally ii fronts and 15" inch rally ii rears with skates.

Ill start reassessing the bottom of the car getting ready for metal repairs. I need to finish researching the chemical welding, and get my replacement pieces cut.

Im supposed to get my Torino back Wednesday...will see what happens. Either way wrenching will be happening

 

[smed7880]

Ordered the mma422.

 

[smed7880]

Work, tore up my back, more work = delays.

Torino still dealing with paint...promises promises from the shop...

Finally getting a little time on her Grand Am. The body is off the frame again and is resting on 6 supports on skates so i can move it if need be.

Exploring rust to get reacquainted

The fronts of the rockers, floor, etc are solid.

Body crossmember and the rocker joint area is shot but drivers is the worst. Some of the floor on both sides rotted too.

Donor section from Rusty Regal is solid.

Im thinking ill cut out the bad and cut the donor to piece to match, to include the rocker section, all as one piece. It will be off a little but should be close enough for the body mount to pick up the slack.

I was going to use the metal glue, but welding is the way to go. I may use both???

Lots of tricky cutting to do.

 

[smed7880]

Not as bad as i envisioned.

Cut about a foot of the crossmember out.

Rocker is 3x6 ish

Floor will have 3 patches....2 softballs and a rectangle where the circles are.

Im trying to leave as much of it in place as i can.

First step will be welding in the flush rocker patch panel so the crossmember sectioning has a flush area to be welded to.

Second welding in the floor.

Third welding in the crossmember section.

So far it looks like Rusty Regal will supply enough metal.

 

[smed7880]

Once all the welding underneath is done ill wire wheel the bottom, eastwood rustproof in the creases i cant get to, primer with some HOK primer ive had for a few years, then paint it black with expoxy marine grade single stage paint via a roller/paintbrush.

Im going to get back to getting the gto drivetrain work done after i get the bottom of the body repaired and painted. But, i plan to join the frame with the drivetrain first, then put the body back on.

Ill need to paint jambs etc so once the body is on the frame its an exterior panel only spray.