V8TV Posted January 19, 2016 Author Share Posted January 19, 2016 great metalwork and pics. Thank you Gary! Great work . A friend had a car like that in the late 60's . If you need new parts there is a company in Oakville , Ontario , Canada called Special Interest Cars at 905 844 8063 I guessing they must have 6,000 square feet of parts . They ship all over . Great tip, we'll look them up! Link to comment Share on other sites More sharing options...
V8TV Posted January 19, 2016 Author Share Posted January 19, 2016 The Galaxie’s body was then mounted on the body jig using the original body mount locations. This will keep the body square and true as the crew enters the next phase of sheet metal repairs. The rusty rear wheel tubs were removed in preparation for the installation of our replacement tubs, and eventual quarter panel repairs. The rear tail panel was riddled with rust holes, so Adam removed the piece by way of the factory seams and spot welds. Note the cross brace bolted in to keep the body dimensions intact. Adam begins by forming the inner structure. 1 Link to comment Share on other sites More sharing options...
V8TV Posted January 19, 2016 Author Share Posted January 19, 2016 This is a compound bend, and he used the Mittler Brothers box / pan brake along with some square tube stock to form the piece. Comparing to the original.. If any one of the bends or dimensions is incorrect, the whole panel is useless and a new piece must be made. It’s starting to look like the original… Cleaning the body of rust, scale, and torn welds to accept the new panel. These areas are reconstructed with new steel. 1 Link to comment Share on other sites More sharing options...
V8TV Posted January 19, 2016 Author Share Posted January 19, 2016 Test fitting… When the fit is right, the panel is spot welded with an HTP Versa Spot 7000 to reproduce a factory original appearance. After a little primer, the repair is undetectable, complete with the proper weatherstrip channel. 1 Link to comment Share on other sites More sharing options...
GARY F Posted January 20, 2016 Share Posted January 20, 2016 outstanding progress & workmanship Link to comment Share on other sites More sharing options...
Guest Cajun Ty Posted January 27, 2016 Share Posted January 27, 2016 Awesome metal work and rebuild Link to comment Share on other sites More sharing options...
V8TV Posted January 28, 2016 Author Share Posted January 28, 2016 outstanding progress & workmanship Awesome metal work and rebuild Link to comment Share on other sites More sharing options...
V8TV Posted January 28, 2016 Author Share Posted January 28, 2016 Next up for repair were the quarter panels. The quarters were dented, rusty, and were repaired previously. The crew searched for a decent pair of take-off quarters from a clean donor car, but determined that the available parts were in need of as much repair as the ones already on the car. Some reproduction panels were sourced and purchased. However, the wheel lip contour was not very accurate, so the new panel needed to be re-shaped to match the original. Adam spent time with an air hammer with a soft-edge hammer and a dolley to push the lip into the required shape. After the shape was corrected, the original quarter panel was measured in various locations to ensure that the new panel was installed in the proper location. It was determined easier to install the new panel in two parts rather than one large panel. The original steel was removed, but the original “Galaxie” trim holes were left intact. 1 Link to comment Share on other sites More sharing options...
V8TV Posted January 28, 2016 Author Share Posted January 28, 2016 The new panels were test-fitted and removed for additional tweaking many times. Cleco clamps were used to hold the panels in place during fitting, and the restored wheel tubs were also in place to test the fit. When the fit was acceptable, the panels were held in place with Eastwood panel clamps and it was tack welded together. After tacking and grinding, the panel repair is nearly complete. 1 Link to comment Share on other sites More sharing options...
V8TV Posted January 28, 2016 Author Share Posted January 28, 2016 The wheel tubs were installed next. The door opening edge was finished off: All welds were dressed inside the trunk. 1 Link to comment Share on other sites More sharing options...
GARY F Posted January 28, 2016 Share Posted January 28, 2016 (edited) you guys aer amazing, where are you located? Edited January 28, 2016 by GARY F (see edit history) Link to comment Share on other sites More sharing options...
V8TV Posted February 2, 2016 Author Share Posted February 2, 2016 you guys aer amazing, where are you located? Our shop is located just outside of St. Louis but in Red Bud, Illinois. The address is in the V8 Speed & Resto Shop link in my signature. Thanks Gary! 1 Link to comment Share on other sites More sharing options...
V8TV Posted February 2, 2016 Author Share Posted February 2, 2016 On to the driver side… second verse, same as the first! Make the panel shape corrections on the bench… Roll-out the shape in the English Wheel… Secure the panel with Cleco clamps and see what’s up. 1 Link to comment Share on other sites More sharing options...
V8TV Posted February 2, 2016 Author Share Posted February 2, 2016 Behind the scenes, trimming away the remaining rusty steel. The panels are further worked on the bench to remove the low areas, hammer dings, and to refine the shape. The restored wheel tub is installed, and a straight-edge steel support bar is tack-welded to the car to minimize warping when the new quarter panel is installed. 1 Link to comment Share on other sites More sharing options...
V8TV Posted February 2, 2016 Author Share Posted February 2, 2016 Adam welded the panels together on the bench so he could hammer them straight and finish the welds with better access to both sides of the panels. This time, a small overlap was used to prevent warpage. When finished, both sides of the panels are fully welded and finished smooth. After the tedious welding process and metal finishing. 2 Link to comment Share on other sites More sharing options...
V8TV Posted February 2, 2016 Author Share Posted February 2, 2016 The wheel lip edges are welded to the tub. [ig]https://lh3.googleusercontent.com/-nswmir51f2w/Vnh0D1urpXI/AAAAAAAA2ic/5DgaEeqYWlw/s1600/1966_Ford_7L_GT_02.19.15_015.JPG 1 Link to comment Share on other sites More sharing options...
40phil41 Posted February 2, 2016 Share Posted February 2, 2016 This is very interesting. I recently put quarters on a '64 Tempest (now sold) and had a horizontal seam at about the same position as yours. I crimped the body side along the seam and laid the new panel into it. The problem that I had was I TIG welded the seam (4 in. lengths of weld) and ended up with it sucking in along the full length. Obviously too much heat. I then spent many hours hammering out the seam to get it as straight as possible. You guys obviously know what you are doing. Great work. Phil Link to comment Share on other sites More sharing options...
Luv2Wrench Posted February 2, 2016 Share Posted February 2, 2016 Amazing!! Reminds me of Flop. You guys should track him down and hire him. 1 Link to comment Share on other sites More sharing options...
V8TV Posted February 3, 2016 Author Share Posted February 3, 2016 This is very interesting. I recently put quarters on a '64 Tempest (now sold) and had a horizontal seam at about the same position as yours. I crimped the body side along the seam and laid the new panel into it. The problem that I had was I TIG welded the seam (4 in. lengths of weld) and ended up with it sucking in along the full length. Obviously too much heat. I then spent many hours hammering out the seam to get it as straight as possible. You guys obviously know what you are doing. Great work. Phil It is a tricky task to weld in the middle of panels like this. Typically, we only like to remove / replace quarters at the factory seams in the sail panel, tail, and along the perimeter so that there is no seam and everything goes smoothly. However, sometimes you gotta do what you gotta do. These jobs can go frustratingly slow in an effort to keep the heat out of the panels, but we still had hammer / dolly work to do after the welding. Thanks for the positive feedback! Link to comment Share on other sites More sharing options...
V8TV Posted March 8, 2016 Author Share Posted March 8, 2016 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. Link to comment Share on other sites More sharing options...
V8TV Posted March 8, 2016 Author Share Posted March 8, 2016 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. Link to comment Share on other sites More sharing options...
V8TV Posted March 8, 2016 Author Share Posted March 8, 2016 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. Link to comment Share on other sites More sharing options...
V8TV Posted March 8, 2016 Author Share Posted March 8, 2016 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. Link to comment Share on other sites More sharing options...
V8TV Posted March 8, 2016 Author Share Posted March 8, 2016 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. Link to comment Share on other sites More sharing options...
V8TV Posted March 8, 2016 Author Share Posted March 8, 2016 Adam uses an HTP Versa Spot 7000 resistance spot welder to install the new panel in the same fashion used by the Ford factory back in 1966. Once welded, the repaired deck filler panel was installed over the brace and the complex panel was once again hidden from view. It’s kind of sad, really, to hide such a beautiful piece, but these are the details that make an overall car build stand out. (It is still visible through the trunk opening if you look up.) 1 Link to comment Share on other sites More sharing options...
keiser31 Posted March 8, 2016 Share Posted March 8, 2016 WOW! Just WOW!! Link to comment Share on other sites More sharing options...
ChuckMcChuckles Posted March 8, 2016 Share Posted March 8, 2016 Outstanding work guys! Link to comment Share on other sites More sharing options...
GARY F Posted March 8, 2016 Share Posted March 8, 2016 Just outstanding Link to comment Share on other sites More sharing options...
Luv2Wrench Posted March 18, 2016 Share Posted March 18, 2016 Thanks for sharing, looks amazing! Link to comment Share on other sites More sharing options...
V8TV Posted April 22, 2016 Author Share Posted April 22, 2016 The doors had various spots where they had rusted. These areas were on the skin as well as on the inner door structure. Adam repaired the skin by removing the rusty material and TIG welding new sections in place. He also created new lower corners for the door structure to fix the rust holes. Link to comment Share on other sites More sharing options...
V8TV Posted April 22, 2016 Author Share Posted April 22, 2016 Meanwhile, the restored chassis was being reassembled. The frame had been sprayed with an epoxy primer, and then top coated with Axalta Imron industrial satin black paint. This offers a factory style sheen but with the added corrosion protection of a base layer of epoxy. New suspension bushings were installed in the control arms, new springs, ball joints, tie rod ends, bearings, and seals were also installed. 1 Link to comment Share on other sites More sharing options...
V8TV Posted April 22, 2016 Author Share Posted April 22, 2016 As the chassis was being built, the body was installed on the rotisserie for final bottom side details. This included finishing grinding some areas that were now easier to access. Once the grinding was complete, The bottom of the car was seam sealed with various 3M sealers to protect the repaired panels from moisture. Any bare steel areas were spot primed with epoxy. Link to comment Share on other sites More sharing options...
V8TV Posted April 22, 2016 Author Share Posted April 22, 2016 (edited) After the Epoxy had cured, the top of the car was masked, and several coats of 3M Body Defender were applied. This is a black coating which will protect the body from rock chips, provide some sound deadener, and still is easy to wipe clean. Edited April 22, 2016 by V8TV (see edit history) Link to comment Share on other sites More sharing options...
V8TV Posted April 22, 2016 Author Share Posted April 22, 2016 Soon, the steering and rear axle assemblies were completed, but one with new shock absorbers and our chassis was once again a roller. Our body shop team took advantage of the rotisserie for better access. Here, Craig sands Evercoat filler on the roof of the car while it is easier to reach. Now that the bottom of the body show was finished and our chassis was reassembled, it was time to make the body to the chassis for the last time. 1 Link to comment Share on other sites More sharing options...
GARY F Posted April 22, 2016 Share Posted April 22, 2016 Outstanding. I enjoy watching the progress. Link to comment Share on other sites More sharing options...
keiser31 Posted April 22, 2016 Share Posted April 22, 2016 Fantastic looking!! Link to comment Share on other sites More sharing options...
95Cardinal Posted April 24, 2016 Share Posted April 24, 2016 Beautiful work! Link to comment Share on other sites More sharing options...
Ted "Wildcat65" Nagel Posted April 26, 2016 Share Posted April 26, 2016 Beauty work. I just purchased a project 7 Litre off ebay, hope it is not hiding all those problems! If it is, well now I know where to send it. Cheers, Link to comment Share on other sites More sharing options...
V8TV Posted April 26, 2016 Author Share Posted April 26, 2016 On 4/22/2016 at 10:45 AM, GARY F said: Outstanding. I enjoy watching the progress. Thank you! We're glad you enjoy the story, it's slower in real life, but fun to share! On 4/22/2016 at 11:13 AM, keiser31 said: Fantastic looking!! On 4/24/2016 at 7:14 PM, 95Cardinal said: Beautiful work! Thank you for the kind words! 4 hours ago, Wildcat65 said: Beauty work. I just purchased a project 7 Litre off ebay, hope it is not hiding all those problems! If it is, well now I know where to send it. Cheers, Ha, hopefully yours is clean! They are very cool cars. We wish you the best of luck with it... parts can be tricky to find! 1 Link to comment Share on other sites More sharing options...
V8TV Posted May 18, 2016 Author Share Posted May 18, 2016 (edited) This one started to look like a car again once the body was mounted back on the frame. New bushings and hardware were used to ensure a safe car, and also to restore proper panel alignment. Edited May 18, 2016 by V8TV (see edit history) 1 Link to comment Share on other sites More sharing options...
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