The Build – Patch Panel Repair on ’65 Malibu SS

Have you ever seen a smashed classic car in the junk yard and thought to yourself: “That Chevy’s got potential, I wonder what I could do to bring that beauty back to its prime?” We also know that it’s difficult to part ways with your classic ride, so the associates here at American Modern have decided to document the collector car restomod process with a 1965 Chevy Malibu SS. We’ve started a weekly online show – The Build – with a Chevy that took a detour into a brick wall. The series takes you step-by-step into the complete resto-mod project of this American classic.

Fast forward to present day, and we have observed The Build tear down, straighten up, and sand blast the ’65 Malibu. Everything from an engine overhaul to interior updates, dent and rust removal, frame adjustments and body work, American Modern is now working on patching the quarter panel.

Rick Drewry, senior claims specialist for American Modern Insurance Group and host of The Build, finds some rust on the right quarter panel that needs attention. In order to repair it properly, the crew cuts out the affected area to get a better look at the inner wheel well. Rick says “less is more”, as the collector car still has some good metal, they will only be using a piece of the patch panel and not the entire sheet.

The inner wheel well of the classic car has a small region that needs removed before adding the exterior panel. The crew cuts out the trouble spot, then cuts out a piece of metal to patch and weld. The best part is the weld will never be seen as it will be covered by the exterior patch panel. The patch panel is mocked in place and the rivets are installed to keep it flush with the metal before welding it in.

Piece-by-piece we continue to watch the American classic appear as if it never even touched a brick wall. Make sure you watch us next week to see what else is restored on the’65 Chevy Malibu collector car on The Build! You can get a full list of episodes on our YouTube Channel.

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Rick Drewry

Collector Car Senior Specialist at American Modern Insurance Group
Rick Drewry is the senior claims specialist, Collector Vehicle & Motorcycle, at American Modern Insurance Group. He has been passionate about collector cars since he was a kid. He has owned and restored collector cars for 30 years.

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