Trunk Weatherstrip Gutter

The trunk weatherstrip channel is not reproduced, leaving us 66-67 Chevelle owners to fabricate something to replace the often rotted out channel.  The area is 48" wide and I found some sheetmetal locally that is 24" wide - so making the 2 sides will add up.

What's left of the trunk weather strip channel that is any good was minimal - as you can see here - the rest was rotted and chopped out already. A small piece of original is still there in the picture on the left...

The replacement pieces. 2 pieces bent, pretty close to the originals.  Though these are 90 degree bends, the original channel had curves in the bends.  Not exact, but close enough for this purpose

The measurements for the bends are 3/16" from the edge, then 1/2" from that bend.  I used 22ga weldable sheetmetal that I found at a local ACE hardware store.

Next step is to cut along the "red" line in the pictures on the left.  This is the piece that will be welded under the rear window to trunk filler panel and then welded to the remaining under side (which was removed from the old weatherstrip channel) to make a seemless original looking piece.  I do not look forward to all the welding in the trunk on my back...........

Since there is a slight bend - over the 48" trink weatherstrip gutter it's 1" - but since I'm putting in 2 pieces, I have to get at least a 1/2" bend out of them.  I put relief cuts every 3" which will allow the metal to bend.  Like this....

I'm ready to weld these in after a test fit or 2.  I drilled holes into these pieces so that I can weld then through this piece into the rear window to trunk filler panel, then weld the onder side to this piece and it'll be good as new.

Here's the final pictures.  Looks better than I expected.  A little primer and it'll be ready for paint.

From the passenger side

Top down and rear view