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'78 Camaro Steel Bumper Conversion typography

Part 2: Buildup and Framerail Mod

BY All Chevy Performance Staff
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elcome back to our multi-part series on our second-gen Camaro conversion. Last time we covered this project we addressed the teardown of our ’78 Camaro that we are converting to a ’71-73 steel-bumper car. It is a pretty straightforward process where we removed the entire back end of the car with the exception of the roof, package tray, and framerails. You can catch that in the June ’22 issue of All Chevy Performance.

This time around, we cover the modifications that you will need to make both framerails, proper location of the trunk floor, prepping the panels for installation, and mocking them up properly to get those gaps nice and tight.

With this conversion there isn’t a ton of fabrication needed, making it a very approachable conversion. We are back with Auto Metal Direct and Craig Hopkins of The Installation Center. We’ll follow along to see how Hopkins tackles that framerail situation and how he aligns the AMD panels to make this conversion a breeze.

Craig Hopkins lays down a coat of Medallion weld-through primer to all the mating services
1. With the car prepared for reassembly, Craig Hopkins lays down a coat of Medallion weld-through primer to all the mating services. You may notice the mods to the framerail at this point.
a template is drawn on the rear framerail to mirror the new trunk floor
2. The ’74-81 cars have a flat rear framerail, so we need to do some modifications. A template is drawn to mirror the new trunk floor to accommodate this. It is cut and bent from heavy-gauge metal.
the framerail ends with added steel plates
3. With the fabricated framerail end welded into place, Hopkins adds steel plate to the inside for added rigidity.
close up of a new framerail matching the contour of the new trunk floor
close up of the other new framerail matching the contour of the new trunk floor
4-5. As you can see here, the new framerail ends match the contour of the new trunk floor just like we need.
mechanic applies weld-through primer to the new AMD trunk floor
6. With the framerails corrected, Hopkins applies weld-through primer to the new AMD trunk floor.
close profile view of the new AMD trunk floor, in place and clamped
7. The new AMD trunk floor slides right in. Hopkins lines it up using the factory locator holes and starts clamping the panel in place.
body clamps and tech screws hold the parts to be welded tightly in place
8. The secret to a good weld is a tight fit. Body clamps and tech screws are your friend here.
the trunk floor, showing welding and metal work completed with a spot welder
9. The Installation Center rebuilds bodies. It’s what they do. Using a spot welder gives you that factory finish. If you’re doing this at home, pre-drill the holes so plug-welding the panel is easier.
mechanic plug welds the harder-to-reach areas with his MIG torch
10. Not all areas can be reached with the spot welder. Hopkins plug welds the harder-to-reach areas with his MIG torch.
mechanic begins mocking up the rear frame crossmember from AMD
mechanic continues mocking up the rear frame crossmember from AMD
11-12. With the trunk floor in, Hopkins can mock up the rear frame crossmember from AMD.
another mechanic assists in the installation of the rear frame crossmember
13. Hopkins gets some help from Brandon Lethiot and the spot welder to install the rear frame crossmember.
panels parts rest on the garage floor during their prep for installation
14. Pro tip! Prep your panels before installing them. AMD panels come EDP coated to prevent rust and corrosion prior to installation. This will need to be removed beforehand at all the points of welding. Take note on each panel where you will be plug welding and predrill your holes prior to installation.
mechanic applies a coat of weld-through primer to a new inner wheelhouse
15. Weld-through primer is a staple at The Installation Center. Hopkins applies a coat to the new inner wheelhouses.
two mechanics mock up the inner wheelhouses, including the upper roof structure
16. Hopkins and Lethiot mock up the inner wheelhouses. The AMD ’70-74 Camaro inner wheelhouses include the upper roof structure just like original, making installation a breeze.
mechanic screws a panel in place
17. The panels are temporarily screwed into place. This is a temporary hold to give us the ability to adjust our gaps as needed.
three quarter rear view of the passenger side of the car
18. The rear of the car is starting to take shape and the outer wheelhouses are clamped into place.
the mechanic mocks up the trunk floor extensions to align with the outer wheelhouse and the rear frame crossmember
19. Hopkins mocks up the trunk floor extensions to align with the outer wheelhouse and the rear frame crossmember.
another mechanic applies weld-through primer on a quarter-panel prior to installation
20. All helping hands on deck with this one, Wesley Kennedy applies weld-through primer on the quarter-panels prior to installation.
with assistance, the mechanic lines up an AMD quarter-panel and mocks up the rear tail panel
21. Hopkins and Kennedy line up the AMD quarter-panels and mock up the rear tail panel.
with the quarter-panels in place, mechanic number three fine-tunes the taillight panel
22. With the quarter-panels in place, Kennedy can fine-tune the taillight panel exactly where he needs it.
two mechanics test fit the decklid
23. With all the new AMD sheetmetal in place, Hopkins and Kennedy can start dialing in the placement of the panels by test-fitting the decklid.
two mechanics adjust the passenger side door
24. Adjusting the doors is a good idea at this point. It’s a lot easier to adjust now as needed before final weld up on the quarter-panel and doorjamb.
rear view of the mechanic test fitting the back glass
25. One last thing we want to check is the back glass. The early second-gen Camaros have the smaller back glass, and we want to make sure it is going to fit with ease. Take into consideration the glass seal and trim when checking this area.
close rear view of the car in preparation for the rear welding
26. With the new AMD panels exactly where he wants them, Hopkinds is ready to move onto welding the rear of this one up. Be sure to check it out in the next issue of All Chevy Performance magazine.
Auto Metal Direct
(833) 404-4777
autometaldirect.com
The Installation Center
(706) 348-6653
amdinstallation.com