file 1966 Ford Galaxie 7-Litre Complete Restoration at V8 Speed & Resto Shop

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20 Jan 2016 13:40 #2138 by TopBlissGT
looks like its coming along nicely

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07 Mar 2016 22:01 #2376 by oestek
Thanks guys!

These, like many cars from this era, allowed water to pool up in the lower window channels. This eventually rusted through and allowed water to enter the trunk and rust the inner structure and the trunk floor. Here, we removed the rear deck lid filler panel to begin repairs.



The original led was removed from the seam, and the spot welds were drilled out.



Note the holes along the lower window channel ledge.



Once the spot welds were drilled, a cut-off wheel was used to separate the panel.



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07 Mar 2016 22:06 #2377 by oestek
Once the deck filler panel is removed, Adam sizes up the repairs needed. Several new channels will be made and attached.





Note how the trunk hinge supports were braced before the panel was removed.





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07 Mar 2016 22:07 #2378 by oestek
The filler panel poses some challenges, but they pale compared to the lower support panel. This piece is loaded with complex ribbed holes… and rusted areas with missing material. This is not a panel that can be bought, so Adam will use the Mittler Brothers bead roller, Box Pan Brake, and hand tools to make a new replacement panel.





The part is cut from sheet steel, and the basic shape is formed.





The irregular shapes were introduced into the panel one-by-one.



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07 Mar 2016 22:09 #2379 by oestek
The old panel didn’t give up her secrets easily.



In addition to the bead roller, there was much hammer and dolly work to form the ridges and shapes.



The process was repeated across the panel.



Overlaid, the new piece matches the profile perfectly.



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07 Mar 2016 22:11 #2380 by oestek
Next, the forward ridge was made and added to the new panel.



The bottom side reveals the folded edges, and the machinist’s blue dye used for marking the steel panel during fabrication.



The finished panel was protected with weld-through primer, and the HTP welders were again used to install the new panel in place.



Panel clamps hold the part in place for welding.

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