Before you reassembled cars together, you must first replace the window glass and interior parts. If the window was riveted in, a dab of JB Weld will hold it in place again. Always test-fit your components before reassembly begins. Often times a bit too much JB Weld on that axle can cause clearance problems when you install the interior. It may be necessary to grind down the JB Weld with your Dremel, or perhaps trim the interior carefully with an X-Acto knife.

The photo above shows a Custom Firebird ready for final reassembly. You may recall from the Disassembly Section that the posts were first drilled with a 5/64th bit before switching to a larger 5/32nd bit for rivet head removal. The reason for the smaller hole, other than as a guide for the larger drill bit, is to aid in reassembly. The small, deep hole gives extra holding power for JB Weld, epoxy, rivets, or screws.


Here’s a car from Jim’s Custom Rod Shop that has been reassembled with screws: The best screws for 5/64th holes are #3-48 x 3/16th, flathead, phillips screws. Walther’s #2 Self tapping train screws (part # 947-1189) in 3/8″ or 1/4″ can also be used these screws should be proceed down the rivet shaft with a #50 drill bit to create the appropriate hole. Or you may have success at your local hardware store.

Pop-Rivets may also be used – it is recommended that a #40 or equivalent size be used the coordinating drill bit must also be used to ensure the appropriate fit.  Rivets can be great but sometimes hard to use – many customizers end up damaging their customs while using.

The fail-safe method, tried true and true, is the use of JB Weld or JB Kwik as discussed in our Adhesives section. After test-fitting, and assuming your paint job is completely cured, you can apply thin masking tape around the assembled vehicle to hold the parts together while the JB Weld or epoxy dries.  with the previous methods you simply rivet the chassis and body together, or begin screwing. For the adhesives method, you want to be sure the parts are properly aligned and fit snugly against each other. Sometimes drilling a slightly larger hole through the base post holes will help the chassis slide down snug against the body. Next you just mix your JB Weld or epoxy and apply to the post/base with a toothpick, being careful not to get the adhesive all over the base. Additionally, David Elliott recommends putting some JB Weld on the post itself before attaching the chassis. The more holding power the better.

There you have it. The most important thing to remember is that your custom is very near completion at this point… certainly too far along to get in a rush now and smear epoxy across that great paint job! And too far along to squeeze the car together and discover fingerprints in the finish because the paint wasn’t completely dry!

Be careful and be patient.

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