I knew this project was going to have some rust, but cutting into it today revealed an absolute nightmare.  In this episode, we get the car up on the rotisserie to start stripping the underside down to bare metal. Everything seemed standard until I reached the rear chassis rail. There was an old repair patch covering up some previous work—but once I cut it away, I uncovered the absolute worst-case scenario. The original metal underneath was completely destroyed by rust. With the chassis rail structurally compromised, there was only one option: build a new one from scratch. Watch as I template, cut, and fabricate one half of a brand-new chassis rail using hand tools, custom patterns, the Pullmax, and the English Wheel to turn the edges and match the factory lines. If you enjoy old-school metal shaping, rust repair, and classic car restoration, make sure to hit that Subscribe button to follow the full build!📌

CHAPTERS:

0:00 - The Hidden Nightmare
2:14 - Stripping to Bare Metal
4:17 - Cutting Off the Old Repair Patch
4:46 - Inspecting the Destroyed Chassis Rail
5:28 - Making the Patterns by Hand
10:42 - Shaping Metal on the Pullmax
24:19 - Fine Tuning with the English Wheel
31:09 - The Finished Chassis Half

🛠️ TOOLS & GEAR USED IN THIS VIDEO:• Pullmax Machine• English Wheel• Hand Dollies & Hammers• Shrinker Stretcher.

#CarRestoration #MetalShaping #RustRepair #Fabrication #EnglishWheel #Pullmax #ClassicCar