Kelle offers tips for sanding the small spots in the trunk of the SS496. Discuss this project at today!


The quarter panels are straightening out, and Kelle offers advice on body filler fire safety! Discuss this project at today!


The vast majority of body filler has been spread all over this car, and now the crew is sanding the filler down to a paper-thin layer of smooth and straight 1969 Chevelle. Nobody likes this part of the game... it's when you lose your fingerprints and get dust in your ears. But it's what it takes to make a car straight. Next comes a layer of spray polyester to fill the final scratches and sanding nicks. Oh yeah, and then more sanding! Discuss this project at today!


Tonight, the crew taped the car and sprayed a coat of sprayable polyester - or "Bodyman In A Can" according to John. It goes on thick, covers all he sanding scratches, and sands like chalk. More sanding tomorrow! Discuss this project at today!


Several months ago, we test assembled our primerred chassis to see if all the new parts fit. Which they did, but now we're doing some detail work on the frame before final paint & assembly. It's amazing how many times you take these things apart and put them back together. Also, body man Mark Poole sheds some light on the theory of high and low spots. Discuss this project at today!


Block sanding is what makes cars straight. The repetitive process of sanding a panel over and over again removes high and low spots in filler or surfacing primer, helping you achieve an arrow-straight panel. The downside is that it really isn't any fun to do. Here, Mark Poole blocks the Chevelle with a Durablock sanding block from Eastwood and some 3M paper to flatten the panels for a mirror finish. Discuss this project at today!


We're beginning the reassembly of the chassis for the last time. It's been stripped, media blasted, primed, test-assembled, disassembled, bodyworked, sanded, re-sprayed, and now it's all going back together again. Hopefully without the need of all the king's horses and all the king's men. Discuss this project at today!


We received an email asking how to convert a bench-seat floor to a bucket seat setup... here's how we did it. You also have to add the console brackets and shifter to make it complete. More on that later! Discuss this project at today!


The block-sanding is complete on our Chevelle's doors and front sheetmetal, so this time, John and the crew removed it to prep the inside of the fenders and inner fenders for paint. The process includes scuffing with scotchbrite pads, sanding, and priming. Then the firewall can be prepped for seam sealing and paint. Discuss this project at


This time, we offer up a tip for not getting a parts-store rental spring compressor stuck in a control arm... (duh)... and then Kevin goes off on a rant about the misleading cheap paint job stories found in magazines. Discuss this project at today!


We're getting closer to spraying paint on the SS496 - the bodywork is done and today we sprayed the last coats of PPG surfacing primer! Tomorrow, the wetsanding begins to prep the primecoat for paint. Discuss this project at today!


Sealing the seams of a car body before paint is not really a glamorous job, but it makes all the difference in the world when it comes to an overall clean and crisp look. This time, we show you the trick John Blandford likes to use to make the seam sealer lines nice and straight, not just globbed on like the originals were. He tapes off the area to be sealed, then uses a pneumatic applicator gun to apply the 3M sealer. This stuff keeps all the moisture out and leaves a finished appearance. Paint is coming soon! Discuss this project at today!


Tonight, we've reached a turning point... there's color on the SS496! John mixed up some PPG sealer to cover the last prime coat, then brewed up a batch of PPG Deltron basecoat in GM Butternut Yellow. The first color application was on the door jambs, the trunk jambs, and on the backside of the fender jambs and doors, hood edges, header panel lip, tail pan, and other areas you can't spray with the car assembled. Then a layer of PPG Concept 2000 clear was applied to bring out the shine. It's bright! Discuss this project at today!


The firewall on the SS496 Chevelle is supposed to appear basically stock, so we welded up all the extra holes that accumulated over the years, straightened out the non-factory wrinkles, and now it was time to turn it black. So out came masking tape, paper, and plastic again for another round. The firewall and dash were shot with PPG DP90 Epoxy black. Comment on today!