service CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual

CORVETTE BODY 1B-28

Fig. 63—Spare Tire Mount

1.
Cover

2.
Strap Assembly

3. Strap Assembly

Pivot Bolt
Swivel Bolt Nut

Swivel Lock Bolt

Swivel Bolt

Bracket
7. Swivel Bolt Pin

8. Tray

9. Lock Case

10.
Lock Cover

1.
Panel Roof Trim

2.
Panel Retaining

Screw

3. Washer

4.
Chart Molding

5. Screw - Rear

Quarter Trim

Panel Retaining
Fig.
64—Rear Body Trim

6.
"J"
Nut - Rear

Quarter Trim

Panel Retaining

7. Panel Assembly - Rear

Quarter Trim

8. Cover - Rear Lower

9. Cement - 3M-1711

or Equivalent
plastic body panels. The general area around the welding

operation should be protected with wet asbestos or any

other like method (several thicknesses of aluminum foil

makes an excellent heat shield if out of the way of direct

flame).

Straightening of steel parts while still in body must be

done with care. When applying hydraulic jacks or like

equipment which operates by exerting force, bear in

mind that the part being used to brace the stationary end

of tool must be able to withstand such usage and that

fiber glass parts, though tougher than steel, will not yield

or "take a set" as with steel parts, so naturally they

cannot be "straightened". If poor alignment exists due

to collision or other physical damage, check steel re-

inforcements in cowl, roof and sill areas (fig. 69) with

care.

Tracing line of damaging force and checking body

carefully for broken bonds and cracks before, during

and after repairs will pay off repeatedly.

Small cracks and faults in bonds and panels will usually

grow larger if left unattended.

REPAIR PANELS

Body repair panels are illustrated in Figures 66

through 70. Those shown are typical of panels which are

available through Chevrolet parts sources. Procedures

which may be used for installing panels are explained in

the following pages.

Figure 71 illustrates various bonds which will be en-

countered during repair procedures. The legend for

Figure 71 cites typical applications for bonds shown.

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-29

CUSHION

CUSHION ASNi.^ty** ACCESS

#2 BODY BRACKET

( 67 ONLY)
SHIM

( 37 POSITION).

CUSHION ASM.

( 37)

SHIM

( 67 POSITION)

CUSHION

( 37 ONLY)

#1 BODY BRACKET

Fig.
65—Body Mounts

PRECAUTIONS

Creams are available to protect the skin from a con-

dition known as occupational, or contact dermatitis. This

common type of dermatitis is not contagious. Improved

resin formulas in the approved kits have almost elimi-

nated skin irritation. Cream is supplied with the kit for

men who may have a tendency toward skin irritation

from the resins or dust.

The application of these creams is recommended

whenever the Resin Kit materials are used. Generally,

the cream is not required when the plastic solder kit is

being used. Directions for using the cream is as follows:

a. Wash hands clean. Dry thoroughly.

b.
Squeeze about 1/2 inch (or 1/2 teaspoonful) of

#71 cream into palm of hand.

c. Spread evenly and lightly until cream disappears.

Work cream into cuticle, between fingers and

around wrists.

d. Apply second coat, repeating Steps b and c.

e. Hold hands briefly under cold running water to

set cream.

2.
Remove resin mixture from hands as soon as possi-

ble and imperatively before mixture starts to gel.

This can be observed by the action of the material

being used. Resin may be removed with lacquer

thinner by washing in soap and water.

3.
Respirators are recommended when grinding. Also

some minor skin irritation from glass and powdered

cured resin may be evident. Washing in cold water

will help to minimize.

4.
Use a belt sander with a vacuum attachment for dust

control if possible.
5. Resin mixtures may produce toxic fumes and should

be used in well ventilated areas.

6. Be careful not to get any resin material on clothing.

7. Use the right materials for the job. It is important

to use the approved kits because Chevrolet's rigid

quality standards assure you the right material to

do the job. Other materials available may not meet

the required engineering and safety standards.

8. Keep the materials, utensils and work area clean

and dry. These repairs involve chemical reactions,

and dirt or moisture may upset the chemical bal-

ances and produce unsatisfactory results.

9. Before starting repair operations, look for hidden

damage by applying pressure around the damaged

area, looking for hairline cracks and other breakage.

Check for minor damage at other points in the vehi-

cle such as around exhaust pipes, grille, headlamps

and points of wear or rub. Early repair of this

minor damage may prevent major repair later.

PLASTIC SOLDER
KIT

The Plastic Solder Repair Kit is used for minor re-

pairs on the Corvette body. These materials will produce

an easy, quick and lasting repair in the case of small

cracks, surface imperfections and small holes.

1.
Use paint remover or power sander, and remove

finish from damaged area. Carefully inspect for

other areas requiring repair.

2.
Mix the materials (fig. 72).

3.
Apply the material, using a putty knife or rubber

squeegee, Figure 73. Work the material into the

repair and build the material up to the desired

CHEVROLET CHASSIS SERVICE

CORVETTE BODY 1B-30

Fig*
66—Front
Body Construction

6. Panel - Front Fender Lower
1.
Panel - Hood

2.
Panel - Cowl Upper F. Front

3.
Panel - Front Fender Upper 7. Bonding Strip

4.
Bonding Strip - Front Fender 8. Panel - Radiator Grille

Upper to Lower

5.
Panel - Front Fender

Lower Rear
Lower

9. Panel - Radiator Grille Upper

- Lower Half
10.
Bonding Strip - Front

Fender Lower Front

to Rear

11.
Bonding Strip - Front Fender

Upper to Radiator Grille

Upper Panel
12.
Reinforcement - Front

Fender

13.
Bonding Strip - Front Fender

Upper Reinforcement

14.
Panel - Radiator Grille Upper -

Upper Half

contour. For deep filling and on vertical surfaces,

several layers may be used, each about 1/2" thick.

4.
Finish the repair by grinding, sanding and painting

in the usual manner, Figure 74.

RESIN KIT

The Resin Repair Kit, for major repairs, contains

resin, hardener, Thixatrope, fiberglass cloth, protecting

creams and mixing utensils. Repairs such as torn panels
and separated joints require the adhesive qualities of the

resin and the reinforcing qualities of the glass fibers.

The following procedure is basic for repairing any

plastic (fiberglass component or panel).

1.
Look for hidden damage. Apply pressure by hand

around the damaged area.

2.
Use paint remover and remove finish from around

damage area. Inspect area again for signs of other

damage.

3.
Grind or file the damaged area to form a "V" at

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-31

1
^JS^ST**-

Fig.
67—Center Body Construction

1.
Panel—Instrument

2.
Pad Assembly Instrument

Panel - Right

Hand

4.
Reinforcement -. Door

Upper Front

5. Panel - Door Inner

Upper
6. Reinforcement - Upper Rear

7. Cover - Front Access Hole

8. Reinforcement - Door Outer

Panel inner

9. Cover - Rear Access Hole

10.
Pillar Assembly - Door Lock

11.
Panel - Door Lower

Inner
12.
Sill - Door

13.
Molding - Rocker

14.
Panel - Side Door

Outer

15.
Panet - Door Hinge

Reinforcing

16.
Reinforcement Assembly

- Side Door Inner
17.
Bonding Strip - Side

Door Upper Bonding

18.
Pillar Panel - Hinge

19.
Hinge Assembly

20.
Pad Assembly Instrument

Panel - Left Hand

21.
Bracket - Radio Mounting

22.
Bracket - Clock Mounting

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-32

1.
Panel - Underbody

2.
Panel - Wheel Housing

Closing - Right Hand

3. Shield - Right Hand Splash

4.
Nut

5. Panel - Underbody Closing
Fig.
68—Underbody Construction

6. Shield - Left Hand Splash

7. Nut

8. Reinforcement - Body

Mounting

9. Panel - Wheel Housing Closing

- Left Hand
10.
Plate - Seat Belt Mounting

11.
Bracket - Center Cover

Mounting

12.
Plate - Transmission Control

Boot Retaining

the broken or cracked portion. Side of "V" should

have a shallow pitch for maximum bonding surface.

A belt sander with a vacuum attachment will mini-

mize the dust problem, Figure 75.

4.
If rear of damage is accessible, use a button-type

repair. Clean back of area to permit the use of

laminate (resin-saturated glass-cloth) on both sides

of damaged area.

5. Cut fiberglass cloth to size. Make certain a minimum

of five layers is cut for the average repair.

6. Mix resin and hardener, 1 part hardener to 4 parts

resin. Add Thixatrope to the mix to give the mix

body and reduce the "runniness" of the material.

CAUTION: Cleanliness is most important. Be

certain all containers are dry and clean and

the resin and hardener cans are kept closed

when not in use. Do not use waxed cups for

mixing and do not allow resin to enter hardener

can or vice versa.

7. Saturate layers of fiberglass (fig. 76). Place lami-

nate over damage area. Smooth out wrinkles and

make sure general contour of area is maintained,

Figure 77.
8. Apply heat to repair area. Heat lamps are recom-

mended, used at least 12" away from repair. Allow

.15 to 20 minutes curing time. Trim repair to shape

at gel stage.

9. After the repair is cured, grind, file or sand to

contour. Files other than body files may be more

suitable. A belt sander with a vacuum cleaner at-

tachment will minimize the dust problem. Feather

edge and finish sand.

NOTE:
After Resin Repair, small pits or ir-

• regularities may appear in finished surface.

Imperfections should be repaired using the

Plastic Solder Repair Kit.

SPECIFIC REPAIRS

Scratched Panels, Spot Refinishing

In many instances, a scratched panel will involve only

a paint refinishing job. Figure 78 shows the top of a

fender panel which has been scratched through to the

plastic.

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-33

Fig.
69~Bonding Strips - Roof Reinforcement

1.
Body Hinge Pillar - Right Hand

2.
Roof Panel Side Front - Right Hand

3. Roof Panel Side Rear - Right Hand

4.
Roof Panel Rear
5. Roof Panel Side Front - Left Hand

6. Roof Panel Side Rear - Left Hand

7. Roof Panel Front
8. Body Hinge Pillar - Left Hand

9. Windshield Lower Outer - Left Hand

10.
Windshield Lower Outer - Right Hand

1.
Remove all paint down to the plastic from the area

surrounding the scratch with Lacquer Removing

Solvent.

2.
Featheredge the repair area with No. 220 wet or

dry sandpaper and finish block sand with No. 320

wet or dry paper, Figure 79.

CAUTION: Do not sand too deeply into fiber-

glass mat. Should it be necessary to cut fairly

deep into the glass mat use the repair pro-

cedure suggested for dents and pits in plastic

panels.
3.
Clean up repair area Prep-Sol or its equivalent,

then finish the clean-up with a tack rag.

4.
Protect surrounding panels by masking before per-

forming paint refinishing operations. Use only non-

staining type masking tapes on Corvette plastic body.

5. Refinish panel as described in paint refinishing

portion of this manual.

Dents or Pits in Panels,. Cracks in Glaze Coat

Figure 80 shows a panel which has received a heavy

glancing blow, resulting in an indentation or large pit

in the panel. The following procedure is advised for a

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-34

1.
Panel - Roof

2.
Door Assembly - Fuel Tank Filler

3. Bezel - Fuel Tank Filler Door

4.
Panel - Body Rear Upper

- Right Hand

5. Panel - Body Rear Upper

- Left Hand

6. Frame - Rear Window Inner

7. Panel - Roof Inner Trim

8. Lid Assembly - Folding Top

Compartment

9. Hinge Assembly - Folding top Lid

- Right Hand

10.
Striker Plate Assembly - Right Hand

11.
Hinge Assembly - Folding Top Lid

- Left Hand

12.
Plate - Nut - Right Hand

13.
Extension - Body Rear Upper Panel
Fig.
70—Rear Body Construction

14.
Bonding Strip - Body Rear Upper

Panel to Quarter Panel

- Right Hand

15.
Support - Body Rear Upper Panel

16.
Panel - Body Lock - Right Hand

17.
Pane! - Body Lock Pillar - Right Hand

18.
Panel - Rear Quarter - Right Hand

19.
Shield Rear Quarter Splash

20.
Panel - Body Rear Upper

21.
Extension - Body Rear Upper Panel

Support - Right Hand

and Left Hand

22.
Bonding Strip - Body Rear Upper

Panel at Body Rear Lower

23.
Bonding Strip - Body Lower Panel

to Right Hand Quarter Panel

24.
Bonding Strip - Rear Filler Panel

Lower - Right Hand
25.
Panel - Rear Filler

26.
Bonding Strip - Rear Filler Panel

. Lower - Left Hand

27.
Bonding Strip -Body Lower Panel

to Left Quarter Panel

28.
Shield - Rear Quarter Splash

- Left Hand

29.
Bonding Strip - Body Rear

Upper Panel to Quarter

Panel - Left Hand

30.
Panel - Body Lock

31.
Panel - Body Lock Pillar

32.
Extension - Body Rear Upper Panel

33.
Panel - Rear Quarter - Left Hand

34.
Plate - Nut - Left Hand

35.
Striker Plate Assembly - Left Hand

36.
Body Rear Lower Panel

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-35

Fig.
71-Typical

1.
Door Sill to Underbody

2.
Dash Panel Extension

to Dash Panel

3. Grille Upper Panel to

Upper Panel Reinforce-

ment and Bonding Strip

4.
Rear Quarter Panel to

Underbody (Rocket)

5. Instrument Panel to

Door Hinge Pillar
Body Bonds

6. Rear Upper Panel Rear

Support Extension to

Rear Upper Panel Support

7. Body Rear Upper Extension

Panel and Rear Quarter

Panel to Bonding Strip

8. Body Rear Upper Panel

to Splash Shield

9. Rear Upper Panel Rear

Support Extension to Rear

Upper Panel Support

repair of this type of damage. Cracks in the glaze or

finish coat of plastic and paint may also use this

procedure.

NOTE:
This repair may be used wherever the

damage is not extensive and the plastic is not

pierced, but the damage area does require a

plastic build-up.

1.
Remove paint down to the plastic form area sur-

rounding the damage with Lacquer Removing Solvent,

or its equivalent.

2.
Scuff area surrounding damaged area to provide a

good bonding surface.

3.
Clean up work area with Prep-Sol then use tack

rag for finish clean-up.

4.
Use the Plastic Solder Repair (previously described)

to fill the imperfections.

5. Feather sand damaged area with No. 220 sandpaper

and finish sand with No. 320.

6. Prepare repair area for paint refinishing operatiou
Fig.
72—Mixing Plastic Solder Material

Cracked Panels

NOTE:
For best results, temperature should be

at least 70o-75°F.

1.
In the case of a cracked panel, such as shown in

Figure 81 cut along the break line with a hacksaw

blade and remove broken portion of the panel.

2.
Remove the paint down to the plastic from both

portions of the panel with a Lacquer Remover or

its equivalent.

3.
Remove dirt and deadener thoroughly, back ap-

proximately 2 to 3 inches from the fracture, on

Fig.
73—Applying Plastic Solder

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-36

Fig.
74-Finishing Plastic Solder Repair
Fig.
77—Applying Laminate to Body

Fig.
75—Grinding "V" at Damaged Area

pig.
76—Applying Resin Mixture to Fiber Glass

the under side of both portions of the panel. Also,

remove paint and scuff area clean to provide a

good bonding surface.

Remove all cracked and fractured material along

the break: Bevel the attaching edges of the panels

at approximately a 30° angle with a file or grinder

and scuff plastic surfaces along edges of break.
Fig.
78—Typical Scratched Panel

Fig. 79—Repair Area Finish Sanded

NOTE:
Mask surrounding panels using a non-

staining masking tape.

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-37

Fig.
80—Typical Pitted Panel

5. Use "C" clamps to align panel portions allowing

approximately 1/8" between the panels or as neces-

sary to provide proper alignment of panels, Figure

82.

6. Cut two pieces of woven glass fiber cloth for backup

of sufficient size to overlap the fracture by approxi-

mately two inches.

7. Clean up repair area with Prep-Sol, then use tack

rag for finish cleanup.

8. Use the Resin Repair Procedure previously

described.

NOTE:
In some cases it may be desirous to

provide additional reinforcements along a frac-

Fig.
81—Typical Cracked Panel
Fig.
82—Cracked Panel Preparation

ture. This may be accomplished by placing

glass cloth strips in the panel break before

applying the plastic mixture.

Fractured Panels

Sometimes damage will occur to panels where the

underside is inaccessible or for reasons of panel con-

tour it is impractical to use back plies of fiberglass

cloth. The following repair operations are typical of

this type of damage.

1.
Prepare the damaged area by grinding or filing all

cracked and splintered material away from the

fracture.

2.
Bevel the edge of the fracture at approximately a

20° angle.

3.
Remove paint from area surrounding fracture with

Lacquer Solvent, or its equivalent.

4.
Scuff surface to provide a good bonding surface.

Then, clean up area with Prep-Sol and wipe dry.

5. Protect adjacent panels by masking, use non-staining

masking tape.

6. Cut a strip of fiberglass cloth of sufficient size, so

the fracture will be lapped from 1 to 2 inches on all

sides.

7. Prepare plastic mixture in an unwaxed paper cup.

(See Resin Repair Kit procedure.)

8. Impregnate glass fiber cloth by brushing or dipping

in plastic mixture. Squeeze excess mixture from

cloth.

NOTE:
Avoid over-rich plastic areas in the

glass cloth, as the strength of the patch is

directly proportional to the glass content of

the patch.

9. Position plastic impregnated fiberglass over the

fracture on the exterior of the panel, lap the break

by 1 to 2 inches, and depress into fracture.

10.
Carefully work excess plastic out of woven glass

by "squeegeeing" from the center of the break

outward.

NOTE:
Hold woven glass in place until plastic

resin "gels" with Saranwrap or some similar

material.

CHEVROLET CHASSIS SERVICE MANUAL