Does anyone know if the headlamp reinforcement bar (metal) is actaully riveted to the fiberglass on the nose of my '72? I have the dreaded lumps on the fiberglass right above the bar and I was told it was due to the rivets rusting under the fiberglass. From underneath I can see the bar is really rusted, but how did they finish the exterior with rivets sticking out? Are the rivets fastened to some other support structure under the fiberglass? II'm trying to determine if I can replace the bar without major exterior bodywork. Signed confused! Thanks!

Here's how they done it...
They couldn't bond the metal reinforcement bar directly to the 'glass, so what they did was:
Riveted a "bonding strip" to the bar first. A bonding strip is simply a strip of fiberglass about 3"-4" wide. (These are used in several places on Corvettes of our era. The front fenders, and rear quarters are held together with bonding strips and "glue".)
Then, they bonded the strip to the nose of the car. What happens over time, is the rivets corrode, and push up thru the bodywork on the nose, causing the dreaded pimples, or "bumps".
The only way to fix this correctly is to remove the reinforcing bar, drill out what is left of the rivets, re-rivet the bonding strip, and re-bond the bar back to the nose....not exactly a week-end project. Most of the time, the bonding strip itself will need to be replaced, and some times even the bar needs to be replaced. This is really a job for an experienced Corvette body person, IMHO...

Some people have taken the short-cut, and simply drilled down thru the body, made the hole in the bodywork larger, and then re-riveted the bar to the strip, and filled in the holes...this never really works. It ALWAYS shows...it's just about as bad as the original problem...

So...in answer to your question, is this something you can do yourself? If you are really good with fiberglass, and can get the bar/bonding strip off without cutting the front-end off the car,.....sure! Otherwise, I'd seriously suggest a trip to a Corvette Paint/Body shop for advise, and estimates...
Just my opinion

Adam has described the process.  The newer bonding compounds make it possible to bond metal to fiberglass without the use of rivets.  You may not necessarily have to re-rivet the bonding strip to the bar, but you will have to use bonding compound which is compatible with the older press molded fiberglass.  The fact that the rivets are beginning to show indicates your fiberglass and your bar are almost certainly original and nearly forty years old. 6880Mike2008-08-05 06:33:26

That is a great description of the problem.  One final word:  Aftermarket front clips don't use rivets or a bonding strip.  They just bond the bar directly to the new panel.  So obviously the fix doesn't need to involve new rivets.  And yes, it is a big job, and the new bar has to be in just the right position or the headlights won't fit properly.

Larry

Thanks (I guess) everyone! I knew you guys would have the answers! Based upon my experience so far with fiberglass, limited to interior or underbody repairs, I'll leave this one to the experts. Any recommendations for shops in Central Jersey?

Contact Kevin(Kebo)...he's got his fingers on the Joisey Corvette repair pulse...


and there are some other C3VR members up there, too! Adams' Apple2008-08-12 19:01:49