Here's a cut-and-paste from my "First-Generation Camaro Assembly Process" paper that describes the original front sheet metal installation, followed by another alternative process from Lordstown:
"Camaro Front Sheet Metal Installation
Both plants used similar processes for front sheet metal installation, although it was done in different locations. At Van Nuys, this was done on the Trim Line with the body in an overhead carrier. At Norwood, this was done on the Final Line after body drop.
Front Sheetmetal Assembly
The "buck-built" front clip was lowered into place with an overhead hoist; two operators guided it into position, pulling the rear of the fenders outboard to clear the side shroud "saddlebags" on the body as the assembly moved rearward. The hook was then released and the hoist went back upstairs to pick up the next assembly. At this point, operator skill became critical as the shim packs were made up and stuffed in place for the top, front, side, and bottom fender-to-body attachments to achieve the correct gap and flush fits between the fenders and the body.
Establishing a perfectly square hood opening was critical, as the hood was "trapped" on all four sides by the header, fenders, and cowl vent grille; a special "
hood squaring fixture" was dropped in place. It had two pins at the rear that went into the two holes in the cowl just inboard of the fenders (the ones with the little black plastic plugs in them), two pins at the front that engaged the two holes in the top of the radiator support just inboard of the diagonal brace attachments, and locator blocks on the sides for the fenders. Once the fender fit points at the rear were properly shimmed and secured, the squaring fixture was removed, and the front end was ready for the hood.
The last step prior to hood installation was to retrieve the antenna body from the R.H. hinge pillar and install it to the fender.
Hood Installation
The hinges were fixtured to the fender reinforcement and torqued, and a hood locating fixture was clamped to the top of each hinge; the hood was removed from the delivery conveyor and positioned to the hinges, where the locator fixtures positioned it fore-aft on each hinge, and the bolts were torqued. Final hood fit was established in the next station by two hood fitters who tweaked the hinges, latch, and bumpers to achieve correct gap and flush on all four sides."
Added:
Lordstown "Piecemeal" Front Sheet Metal ProcessLordstown, like many other Chevrolet plants, installed front sheet metal on the Final Line, after Body Drop, a piece at a time, on the Pontiac Firebird and the Chevrolet Impala and Caprice. The radiator support, header panel, and grille went on first as a complete subassembly, pattern-shimmed to the frame horns, followed by the fenders as complete subassemblies (inner fender, outer fender, seals, plumbing, electrical, etc.). Shimming at the cowl and squaring-fixturing followed, and the hood was installed and fitted last.
