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Old 10-01-2012, 05:33 PM
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trunk lid lip repair.

I thought some of the beginers on here may like to see how I'am going about the lower lip and trunk lid repair on my hawk. Frist I ground off the outer lid pinch weld as if I was going to reskin it. Then I cut off the innerstructure down about a 1 1/2"-2". I took a peice of 20 gague mild steel cut long enough to go end to end and 2 1/2" wide. Primed the back side so it wouldnt rust once welded on. Fit it in behind where I had cut the innerstruture so I had about a 1/4 to 3/8" lap. Made sure my new patch and bottom of deck lid was as even as I could get it all the way across. Now I spot welded all the way across the innerstructure moveing around enough not to wrap anything. I will weld soild with small spot welds and grind down so all it needs is a thin coat of filler to be invisable. Then I will build a new outer lower panel and made a 90% lip to hammer and dollie over for the new pinch weld. I will weld the upper panel and glue the pinch weld area before I hammer it over. will post pictures of that tomorrow.
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  #2 (permalink)  
Old 10-01-2012, 05:35 PM
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last pictures of innerstructure repair.
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Old 10-01-2012, 06:21 PM
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Great stuff but you need to get better photos. Turning off the flash may help as these are washed out. It's such great auto body stuff but it needs to be seen better.

Brian
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Old 10-02-2012, 12:35 PM
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more lip repair

Brain. I tryed to do better with my photo's. Camara is a little old and does well out side but not so good indoors. Wife's new one is better but {Your not taking that out in that dusty body shop}. The frist shot is where I started at today. Finished welding the inside patch on. It doesn't really need to be welded soild as I will seam seal and reprime when I cut off the out side rust area of the trunk. I put a coat of mud over the weld just to hide the fact that a peice has been put on. I finished off with 40 on my 6" da. In a spot like this you dont have to worry much about a few waves by time its done you can't get at the right angle to see them even if they are there. Then I coated it with some SPI epoxy. I just used a brush as I didnt want to clean a gun for a small spot like this. It'll be scuffed and reshot with a gun when I do the rest of the bottom side of the trunk. I also coated the inside of my exterrior patch and the inner side of this patch while I was at it.
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Old 10-02-2012, 12:54 PM
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I cut off the rusted area on the outside of the lid and sealed innerstucture patch where it was laped and reprimed with epoxy. This should hopefully keep any water from coming though. I don't think water is a real issue on this trunk design anyway with the way the butcher job that was on it held up. I think it rusted do to the fact this was a daily driver for the frist 9 yrs of its life by a sales man. That means it saw a lot of mn road salt and snow. Then I put the outer patch on and glued the bottom lip this should seal it and hold it in place. This way I dont have to put any seam sealer on the lip and it should look just like factory when done. Now all i have left is to finish welding on the out side patch. Put it back on the car to check my side gaps and fill and epoxy it. I will have about 10-12 hours in it when done. Which may sound like a lot of time to put into a trunk lid but this is a one year only lid and only 1200 of these where built in 64 so good luck finding a nice one today. This should look just as good as new when I get done with it.
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Old 10-02-2012, 12:58 PM
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Here is the rest of the photos. Hope this helps anyone trying to rebuild a trunk lip.
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Old 10-02-2012, 01:32 PM
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MUCH better photos!

Brian
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Old 10-05-2012, 11:11 AM
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Now all thats left is to block one more time and paint.
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Old 10-06-2012, 07:15 AM
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Looks like someone is havin some fun..If I could I would do nothing but rust repair and metalwork every day,I love it...
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Old 10-06-2012, 11:50 AM
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Deadbodyman. More fun than normal because for once I'am working on mine and not a customers. I've will have about 20 hrs in it by the time I have it painted and maybe $200. in supplies. At my shop rate of $35 thats about a $1000. A lot for a trunk lid but with a one year only part and only 1200 built I didn't have many options.
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Old 10-06-2012, 01:27 PM
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Fit the lid to the car. Off by maybe a 32th of a in. On my side gap. There's more than that in hinge adjustment. I'll just make sure my gaps at the inner 1/4 panel where it meets the trunk and bumper has a good gap when I rework that on both sides. Then I epoxyed the bottom side and painted to match the car. I've been wanting to see what the color should look like.
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Old 10-06-2012, 06:26 PM
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Looking good. 1000 dollars may be a lot for a deck lid repair but aren't you glad you didn't have to write the check?

John L
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Old 10-09-2012, 09:44 AM
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final pictures

well got the lid done and installed. Wanted to paint it to see if myself and the wife both liked the color before I did the restoration. Kind of a blood red. Factory color and I think Its going to work. Three coats of omni base and three good wet coats of spi production clear. Wet sanded with 2000 and buffed. Now if only the rest of the car looked this good.
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