BUILD THREAD “The Juggernaut”

Quick proof of life/current status/direction change and future plans update.

Officially, as of tonight, both rear floor pans are now fully welded in, metal finished out, and complete.

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With this small milestone, the future direction is going to take a slight detour from continuing on with the floor pieces for a bit. Now that the new rear pans are solid, have added the much needed structural strength to the floor, and able to tolerate some load, I’m going to be working on finally finishing off the poor rear firewall.

The firewall has sat unfinished and stagnant for the last 5+ years, and it eats at me every time I look at it. The package tray section of it is good, just needs a good cleaning and scuffing of the bare metal areas to be ready for epoxy primer. The vertical and focal point area however needs finishing. I’m in a kind of “X needs to be done before I can proceed with Y and Z” type scenario here. My real focus is to be able to bead roll the new side panels and get them welded in permanently, but I have to address and finish the center section first.

The center section needs a little hammer and dolly work to get it nice, and the side panels need to be out to have access to the backside with the dolly. I started on it tonight, removed the panels…

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…then stripped off the old putty from the face and did some profiling of the metal to clean it and get it ready to accept some fresh filler.

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I still have some more profiling to do, but it’s a start for now. Actually, I’ll likely get the hammer and dolly work done first, then profile the worked and remaining areas. Once that’s done, it’ll be dust city as the filler work will commence in earnest on it. When the center feature is straight, right, and looking good, then I’ll cover it up and switch to bead rolling the side panels and getting them welded in. Then most likely shoot the entire rear firewall in epoxy to finish and protect it until such time as I need to worry about upholstering it.

Just a quick recap on the center feature of the rear firewall, for those new members and for those who might’ve forgotten what it is.
It’s not just a random design, although it looks decent and could be dismissed as such, it actually has some historical significance to it.

When Cutlass was first introduced to the motoring public, it actually wasn’t even its own model yet. It was an slightly upscale OPTION on the base model F85, one of Oldsmobile’s more popular cars at the time. The original F85 emblem looked like this…

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…and so now you can see the resemblance. This is my small and subtle way of paying homage to the car that started the Cutlass bloodline and marque that we all know and love today. Should be interesting to see if anyone will pick up on this once this car gets revealed to the world.

Anyways, enough for now, let me know what y’all think about the progress and the direction it’s headed. I’m still really happy with it.

D.
 
Very nice! I remember when you first did that rear wall, doesn't seem like its been so long ago. Looking forward to seeing the finished result.
 
Had no idea the back wall was based on that F85 emblem, very clever and interesting reference. Are you planning to color the back wall like the badge to make it really stand out and tie in with your new interior design and color scheme?

Great work and progress!

Thanks Mike.
No, the color won’t be the same, it’ll likely be wrapped in black leather to match the rest of the black interior I have planned for the car. Screaming bright red in an otherwise black interior would look odd to say the least. Nope, subtlety will be the name of the game here, well as far as a 3’ tall F85 emblem where the back seat used to reside can be!
😅

Resemblance is spot on and your artistic skills nailed it.

Thanks Tony, it was as close as I could possibly get it, without having an actual emblem to work from and only using pictures I found online. I especially like the 3D aspect to it, makes it that much more visually appealing that way IMO.

Very nice! I remember when you first did that rear wall, doesn't seem like its been so long ago. Looking forward to seeing the finished result.

Yeah, it doesn’t seem like that long ago to me either Josh, but the calendar doesn’t lie. The years seem to be ticking by faster and faster every year now, and I’m really feeling the need to complete this car before I’m too old to do this anymore, and still have time to actually enjoy it too.
Expect to see some long term increased devotion to it from now on.
 
Borrowed a spare 4’ LED shop light my buddy Mike had tonight for doing the filler work on the rear firewall center section, and zip tied it to the inside of the roof.

Man, was that just the ticket! Illuminates EVERYTHING beautifully, and will make working on it soooo much easier.

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Should’ve done this from the beginning!!
 
Borrowed a spare 4’ LED shop light my buddy Mike had tonight for doing the filler work on the rear firewall center section, and zip tied it to the inside of the roof.

Man, was that just the ticket! Illuminates EVERYTHING beautifully, and will make working on it soooo much easier.

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Should’ve done this from the beginning!!

Yup, got one hanging inside the Monte. Helps with the cataracts. 😉
 
Let there be light ✨
Question about rear package tray. Will there be an addition of speakers.... somewhere?

Definitely, possibly, maybe.

I purposely made the package tray solid with no holes for speakers because it’s always easier to make holes after the fact than try to fill them in when you realize things don’t fit, or that decisions have been changed. I’ve actually got these sitting in my cart as we speak…

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…as I will probably mount speakers in these areas for sure. But there’s always still the possibility that I’ll mount some in the package tray as well, it’s just too soon to finalize that decision yet.
There’s also the possibility that I might mount a pair of 12” subs in the firewall side panels firing forward as well, that’s why I’m purposely leaving the middles of them blank with the bead rolling features closer to the perimeter.
 
Just for shjts and giggles I looked up the actual definition of the word “suck” in the dictionary today, and sure enough, there it was:

suck:
verb
\ ˈsək \
sucked; sucking; sucks

“To attempt to apply or sand body filler in a 1 3/4” x 1 3/4” inside recess. To attempt to sand any body filler in any inside corner. Attempting to apply or sand body filler in a spot so tight so as to subvert any attempt to access it with any sort of spreading tool or sanding block, or reasonable facsimile thereof.
See images attached”

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So it’s true. Look up “suck” in the dictionary, and there really are pictures of what I’m attempting.
Better bring your “A” game and every trick in your book son. This ain’t no picnic.
Makes me wish I had’ve been more careful grinding the plug welds inside here back when I did it.
 

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