Ok, was feeling a little under the weather this weekend, but still wanted to get by the shop and get something done. So I thought I would work on somethiing not real physically demanding. I would take a shot at starting to remove the cancer areas of the Eyebrow Grill I had picked up. The passenger side end had some pretty bad rust. I had picked up a donor grill to use for the repairs. I was very nervous about taking on this project. Except for cutting out my rear quarter panels, I have never done sheet metal body work in my life. Here was my plan. I decided what I wanted to remove from the Eyebrow grill. I market it and cut it out using a right angle cutting wheel and a jig saw. I then took the removed piece and cut it down to a more managable size to be used as a template. I then attatched the template to the donor grill using sheet metal screws. I marked the cut edge onto the donor grill. I cut out the donor again using a cutting wheel and jig saw. I had to do a little light trimming and shaping, but the fit was really good. So far every measurement I have taken off the pristine grill that my 66 came with are all very close. Maybe an 1/8 of an inch here or there, but I think I can work with that. The light buckets have some rust through. I plan on doing the same process to replace those. The bottom lip of the grill is also rusted, but I am planning on having a piece of sheet metal cut anyway to lower the bottom lip to cover the 2" body lift gap. I also have plans to make a custom grill section made out of stainless also.
Scott
Scott
