I am REALLY not looking forward to cutting the channels out!!
How is everyone removing the channels? Spot weld cutter? Run the car into nearest river? Match in the fuel fill neck? Lol

 

It can be done. It sucks, but it can be done. I've done it 3 times. I now charge $5,000.00 labor to do it and that doesn't include paint, just primer. That's the "I don't want to to do it, don't call me" price! My 82 has a set of donor channels I drilled out of an 87 Trans Am in the junk yard back in 2007 LONG before repros were available. I also replaced a set on a 91 GTA for a buddy using those new reproduction channels. Spot weld cutter is the best way to get them out and it will take you a while and best get a few spare spot weld cutter bits. Keep the bit oiled while using it. Clean the inside of the channels with a scotchbrite pad to expose all of the spot welds. Makes them easier to find. Also, best to use a cordless/battery drill. Best advice I can give you, take your time go slow. Be mindful of the ledge under the rails. Try not to drill all the way through it if you can avoid it.

When you go to weld the new ones back on, get a bunch of clamps to hold them in place. Be sure to use weld-through primer on the entire ledge before you weld them on. After welding, carefully grind the welds down, but don't try to flush them perfectly, it doesn't matter. Then get you some panel bond adhesive and coat the entire inside of the tracks over every weld and fill in the gaps where the channels rest against the body (front and back). Make sure you don't get the panel bond inside the weatherstrip grooves.

 

So just use weld through primer on the ledge but don't paint? I just want to make sure I don't have future issues with it.

 

https://www.thirdgen.org/forums/memb...-trans-am.html post #46 & #47 to give you a rough idea of this process.

We used the weld-thru on the ledge and back side of rails., then welded them on. The whole car along with channels was painted together. There is no paint on the ledge or bottom side of rails, just primer.

 

Got it.
You have a serious amount of work into your car. Looks great!!

 

Hmm... Spot weld cutter and an air chisel would probably make short and grizzly work of it. I'd run down the channel with a small sanding disc on a detail sander or 90* air grinder, that should highlight the spot welds. Then cut as many as possible with the cutter, then follow up with a chisel to break the remaining welds.

Disclaimer, I haven't done it, I'm not a body guy professionally, and if I did the above I might potentially create a bigger mess than the flame in the filler neck. BTW, you need to use a rag, preferably soaked in gasoline, a match will go out too quickly.

 

if you are not saving the panel- just use either a mini belt sander (can buy from Harbor freight for cheap) or use a cutoff wheel and just move it back and forth over the spot weld until you are through the first layer of metal. Easy to control and it will save you from accidentally drilling a big hole through multiple layers.

 

https://www.harborfreight.com/38-in-...ter-63657.html

get a few of these. Honestly it doesn’t look like a bad job unless there’s rot behind the rail

 

the rusted channels are gone and so is my will to live..... lol jk
In all honesty it wasnt as bad as I thought it was going to be. Used the Harbor Freight spot weld cutter at first but I'm not a fan. Ended up using a carbide bit in a die grinder to just grind through the channel and then used an air chisel to knock it off. Still need to clean everything up but I'm done for the day. Had a few mistakes but nothing the Hobart cant fix. Lol

 

Looking good so far!

 

Thanks!! Wondering if I should use some rust preventer before shooting the weld thru primer?

 

I’d use epoxy primer on as much bare metal as I could. Use the weld through where you’re going to weld, then top it all off with epoxy when it’s welded up.

 

Got it! Thanks!