When it came time to mend the inner wheel house to the body I decided to take a different route than would normally be done on a street car. I decided instead of steel tubs that I would crush panel it with .040 aluminum. This provides an easy custom closure.
First I installed a 1"x 1" flange on the spot weld flange of the inner wheel house. ( the pictures are looking rearward in the driver side rear wheel house)
Next I made up a steel pattern base with pre drilled rivet holes to provide a rigid base.
To this base I added my paper patterns out to the body to get the contour  over the curve.
The last picture in this series shows the completed pattern out of the car ready to transfer to the aluminum.

Copying the pattern on to a piece of .040 pre painted satin aluminum I made the finish crush panel.

While the pattern was taken tight to the body I turned the outer lip down to help the panel gap slightly away from the body and provide an area for a silicone bead.

Next I installed the crush panel applying silicone behind all riveted areas to prevent the panels from loosening  and  finally applying a bead between the panel and the outer body to secure it and provide a cushion between the panel and the body.

I repeated the process for the forward section of the wheel housing.

The LX chassis has plastic inner wheel house covers that protect the fuel lines and other things mounted in the wheel house from road debris. I wanted to adapt and reuse these covers so after slightly modifying them to pop inside of the 68 body I had to create an attachment to the outer body. I first made up an inner rim to fit the wheel opening. I bent a piece of .040  90 degrees and shaped it to fit inside the wheel opening. After it was shaped I put a 1/4" step in it to receive a flat vertical flange. Temporarily installing the plastic inner cover I made a paper pattern for the vertical flange. The last picture is of the completed 2 piece flange.

With the vertical flange temporarily installed I bent some sheet metal 90 degrees and made a pattern that would help me make a flange for the outer rim of the plastic cover to bolt to. The second picture is of the completed flange with 1/4 20 aluminum threaded inserts  in it to receive the bolts. The last two pictures are of the plastic wheel house cover installed. Instead of using the one way push in plastic clips I installed threaded aluminum inserts at the attachment points so that I could bolt this piece in.

Well I hope everyone here had a wonderful Christmas. I had some other pics pertaining to the recently remounted gas filler but I figured I would wait till after Christmas to post.
In moving the gas fill to the top of the quarter I had to compromise the trunk space in order to re route the fill tube to the forward mounted tank. I did this by first drilling my destination hole through the side wall of the inner wheel tub. I then took a wooden dowel and torqued the hole over so that the hose would not have to bend to get through. The silicone hose I used does not like bending at all. Tends to flatten out. I cut the steel fill tube as far down as I could so the silicone hose would gently arc into it.

Finally here is a picture of the complete hook up to the fill inlet. I had to segment the a curve in the existing steel fill tube because like I said the silicone tube did not want to bend very well. I ran the vapor recovery line up and over and through a rubber grommet into the vent line coming out of the tank. Right now with cutting the fill up as high as I could and getting the hose through the wheel tub as low as I could to transition into the tank tube everything is about level. One more reason to put a lot of front to rear rake in this car.

There is a neat piece that finishes out the trunk that will now have to be modified to make room for all of this stuff in the trunk.

Well I can stop pretending that the gas hole in the side of the car didn't bother me as much as it bothered everybody else. Never let it be said that peer pressure can't be a positive thing. I got to looking at it this morning and a gas line route dawned on me. Not ideal but better than a gas hole in the side of quarter panel. I decided to move it to the top of the quarter where it will be less offensive. To do this I will have to cut the filler neck as high as possible and run the fuel line through the inside of the trunk an back out the side of the wheel hole in front of the shock location. I had to cut out a mount for some electronic doohickey that was mounted right below the gas hole so I will have to relocate that and then come up with a removable shield to protect the gas filler line from anything that might get thrown into the trunk.

Well I looked at relocating the fuel filler behind it's present location but mounting it in the top of the quarter would cause the fuel line to have to dip way down and then up over the wheel housing to get to the tank. That would cause gas to be always laying in the bottom of the fuel line gully. Looking at the side of the quarter further back would mean I would have to loop the fuel line around in the trunk and it wouldn't look much better than it does right now so I decided to try to remodel the door to make it smaller and flow a little better with the side of the car. I took about 2 1/4 inched out of the over all height and  sloped the top  to better match the quarter panel. I went ahead and rough bondo'd it in and hit it with some flat black to see what it would look like. I am not nearly as unhappy with it as I was. Bottom line is I am committed to this location now and I am moving on.

Decided to get back to mending the body and the chassis together. I started with  making extensions to go from the frame to the 1/8" plate installed in the body to support the rear bumper. I made a plate to bolt to the existing bumper studs in the frame. I then pieced the 1 1/2" .120 wall tube to create a kick up style outrigger. Hopefully if anyone runs into the back of me  Undecided these will give before the frame is damaged.  Finally I welded the outriggers to the body at the bumper location.

Well this is all going to look a little odd until it is all painted one color but I installed the 06 fuel filler door in the side of the quarter panel. The upper contour of the door was beveled in  so I had to do a little modification to get it to be the same as the quarter. I am no 100% happy with this and I might have to move it to a more appealing location.

To build the final piece of the upper dash I started out shaping a piece of steel to create a rim over the gauge cluster. I put some 1/16" double face tape on the bottom side to space it off to allow for the vinyl to be applied to this piece later.
The second picture shows the rim in place.
The third picture is of the paper pattern for the steel piece to fit into this area.
The last picture in this series shows the clips I formed and welded to the under front side of the panel. These will grab the piece of the forward permanent dash section providing for a blind fastened front edge. You will notice that I am simply using velcro to hold down the front of the dash pod section to the dash pod.

The first picture here shows the cover for the dash pod area installed.

After that I built the rest of the top dash that extends over to cover the climate control and passenger area. Two small offset flanges were welded to the bottom so that I could secure this section with screws from underneath the dash.

The third picture shows the upper dash removed from the car. I will bondo it so that irregularities in the surface won't telegraph through the vinyl.

The last picture shows a side view . You will notice that I cut a piece of 3/8 tube in halve and welded it to the front edge to create a bull nose or rounded front edge.

Well you all are probably as sick of looking at pictures of my cowl as much as I am sick of working on this tedious area but here are a few more as I close in on the finish of this area.  The first is of the last of the HVAC ducts installed over the gauge cluster area.
Major pain trying protect wiring and plastic parts and route everything. Just hope I get a little bit of air out of these when all is said and done.
Second picture is of the sub cowl finally sealed and painted.
The third picture is the cowl with the seams sealed with epoxy, bondoed and primed.
Finally I am moving on to the dash. The last picture is of the part of the dash that will be permanently attached to the car. There will be a removable padded section to transition from this assembly to the removable dash assembly.

This picture is of the finished cowl piece which I coated with spray on bed liner to give it a textured appearance.