I adapted the pontiac wiper motor to the buick linkage. I modified the buick linkage to fit the pontiac splined motor. I welded brackets inside the wiper cowl and articulated the linkage to check for clearance. It touched at the very bottom of the cowl, but since it's angled, I shimmed it with a few washers until it cleared. Josh
I welded in the lower windshield channel and both pillar channels. I was welding the underside of the passenger channel when the welder stopped working again. I think the wire melted to the sheath inside the Stinger. So now that's on order Josh
So my new welder stinger came in today so I finished welding the windshield channel in place. Then I patched a few holes behind the dash and then mixed up some all-metal filler to seal up the pin holes around the windshield channel and below the dash to keep water out of the interior. I need to pick up more all-metal tomorrow, but she's coming along Josh
I've been body working around the windshield. First, a layer of all-metal, then duraglas, followed by featherlight filler. I also did my best to seal any possible pinholes in the wiper cowl to prevent problems later of any leaks behind the dashboard Josh
I ordered a new wiper transmission because the original was seized with rust. I finished body working the a-pillars. I made block off plates for inside the ends of the wiper cowl. I'm waiting on epoxy paint to come in to coat the inside of the cowl so I can install the new transmission and seal the cowl to prevent water and debris from getting inside behind the dash. I took the tail gate apart because everything's rusted shut. I soaked all the mechanicals in pb blaster. The left side tailgate release rod corroded into a few unusable pieces, so I'll have to find new ones Josh
I lowered the wagon down to weld up the holes for the luggage rack. Knowing about where the car will sit on the pontiac, I rolled an extra wheel under to see about what the stance will be After I welded the holes up, I sprayed the wiper cowl, a-pillars and the ceiling in satin black epoxy paint Josh
I installed the new wiper transmission and sealed the wiper cowl. I'm using a spreader bar because the wagon floor is 59 inches wide and the pontiac is 61. Break out the neosporin! The cutting wheel kicked back and hit the floor and bounced into my knee as the fiber disc came apart Josh
Well I was wrong. I thought I could spread the wagon body 2 inches to straddle the pontiac floor pan. But as I pushed on the b-pillar, things just got worse. The front doors wouldn't close and the rocker panels bowed in the middle. I even made relief cuts on either side of the wiper cowl, but the front under the windshield wouldn't budge. So the new plan is to cut off the rockers that I just put that solid plate on and recess each side one inch and weld it back together. Josh
It looks like the cowl area underneath the A pillar is a lot wider than your new rockers? Are you suggesting you are removing an inch from each side of the frame to accommodate the new shell? Of course I am just looking at the photos. So feel free to ignore me.
When I inserted the load spreader bar, the front end didn't budge. The back by the rear wheel openings was at 62.5 inches, but the front was still 59 inches. So now I plan to cut the rockers off the pontiac and recess them in one inch on each side. The pocket I welded the plates to is about 2.5 inches deep, so if I cut them at the mark I made, I should be able to overlap the metal and weld it back together Josh
Keep chipping away! Details are slow but worth it in the end. It's fun watching this project progress
I removed both front seats. I used a length of scrap 1 inch square tubing to mark my cut line and I removed the passenger rocker panel. I cleaned it up and mocked it in place with clamps and measured to make sure it was exactly an inch shorter, then I welded the top back on. I still have to weld the bottom and make a plate to fill in a gap at the rear, but at least there was enough material and space behind the rocker to make it possible. I also measured front to back to make sure the floor didn't flex when I removed the rocker. Josh
I cut off and recessed the driver's rocker panel. To get the front below the a-pillar to clear the pontiac, I had to trim the hinge pockets off. Now I can set the wagon body down enough until the wiper cowl hits the dash. I need to measure and cut off enough to set the wiper motor just above the brake booster. With the side picture, the body has to drop 7 more inches up front and 6 inches in the rear. Then i can start welding things together. Josh
I got back to cutting away at the dash to get the front to sit as far down as it'll go Then I used an old beat up fender to test fit. I think I'm gonna have to flare the fenders, but I'm loving how it looks Josh
I had staggered wheels on the 65 wagon I just sold. 17x7s up front and 20x8s out back. I would like to go to a 17 up front if I can find something that works. My plan for "flares" would be to cut the fender around the chrome trim and pull it out until it clears the wheels and then weld in a filler piece. Something subtle, not 4x4 flares. I like the shape of the wheel openings and would like to keep the trim pieces Josh
