Patching up my '96 Roadmaster Wagon

Blake442

Blake442

Geezer
Apr 24, 2007
6,736
777
113
Minneapolis
#1
Haven't been too active here for a while... Didn't do much of anything this summer but it was time to finally tackle a project that I had to get done before winter.
The rust spot behind the left rear tire had been getting bigger and bigger since I bought the car in January of 2016.
My degree in auto-body repair and nearly a decade of restoration experience have given me all the skills necessary to repair this properly.
I won't be doing it that way... lol
Sure, I could, and I have all the tools at my disposal... but it would drag out over several days, if not weeks while I did everything.
But this car just isn't worth that kind of treatment, and it's my daily driver, so I was looking to knock this project out in a single day.
For what I'm capable of, I should be ashamed lol, but I'm thrilled with how it turned out.
Follow along as I turn about $100 in materials and about 7 hours of my time into exactly what I was hoping for!
Here's my beloved Road Barge!


And here is the nasty 1/4 panel...


Rust goes up much farther on the inside...


Rusty metal cut out... inner panels rusty too


Made my first template out of plastic cardboard


And made two more templates for the inner parts


Cut out the rusty inner parts


Riveted in the patches I made from my templates.
I used a sheet of aluminum I got at Menards... easier to work with than steel


Goobered it all up with seam-sealer


And riveted in the outer patch


Seam sealed the backside


Undercoated the lower back side


1st smear of fiberglass filler


Buzzed it down with the D.A.


2nd wipe with regular filler


Buzzed down with the D.A.


2 coats of rattle can primer


3 coats of Rustoleum gloss white, with a few runs for good measure...


Ta-Daaaaa!!!!


Good as new!!!


And finally, my helper, Ziggy.
He's the reason some of the pictures are blurry...
Every time I knelt down to take one, he was all over me!
The pics that are good are because I had to throw him in his kennel so I could take them lol


So there you have it...
The low-buck, low-hour, barge patching!
 
joesregalproject

joesregalproject

Royal Smart Person
Nov 4, 2012
2,245
784
113
Pittsburgh, PA
#2
Looks great! I worked in auto body for about 8 years, but I still find it way more fun to do a function-over-form repair, or "inspection sticker specials" as we called them. I've fixed many a rust hole with tiger hair and pop rivets.

Damn I love those 90s b bodies.
 
Blake442

Blake442

Geezer
Apr 24, 2007
6,736
777
113
Minneapolis
#4
That's my buddies dog... out at the same shop I painted my other wagon at.
At least He didn't get any nose prints in the fresh paint lol!
 
8

81cutlass

Royal Smart Person
Feb 16, 2009
1,234
1,090
113
Western MN
#5
That's a pro job right there :p

It's tough to justify driving anything nice in the cities, especially during the winter. For as much salt (and worse the other drivers) a beater that your decently OK with is a better option.

How many miles do you have on it these days? I damn near bought a olds custom cruiser when I was 15 for my first car, it was in worse shape 10 years ago than yours is today though haha. Probably good i didnt end up with that.
 
DRIVEN

DRIVEN

Comic Book Super Hero
Apr 25, 2009
4,721
1,793
113
Owyhee County
#6
Well, the hole is gone.:ROFLMAO:
 
Blake442

Blake442

Geezer
Apr 24, 2007
6,736
777
113
Minneapolis
#8
I'm sure next year I'll be patching the other side again, the band-aid I dropped in the bottom of the spare tire well is looking worse for wear.
Just under 175,000 miles, and yes it's an LT1.
The 4L60E is what I'm worried about, they're typically only good to about 150K or so, so I'm on borrowed time... The one in my Caprice went out at 127K.

The next adventure will be replacing the trans cooler lines, they're all rusty along the bottom of the radiator... yay!
 
DRIVEN

DRIVEN

Comic Book Super Hero
Apr 25, 2009
4,721
1,793
113
Owyhee County
#9
Man, I really feel for you guys in the rust belt.
 
joesregalproject

joesregalproject

Royal Smart Person
Nov 4, 2012
2,245
784
113
Pittsburgh, PA
#10
To try and keep the rust at bay you might try coating the underside or at least parts of it with Fluid Film. Runs about $9 a can at Lowe's or you can buy gallons from Advance Auto for around $50 IIRC.
 
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