After "noodling" around (as Sven says) in my mind on how to go about proceeding on this part of the car, I came to some conclusions I've mentioned before. The "semi-full" quarter replacement is always an option. It's not the cheapest option, especially when you add shipping to the overall cost. It's still on the table if I can't get this panel sorted. I'm not sure when Gregg Cly will make it back home from the tornado disaster claims in Oklahoma. And then I don't know what panels would be available. Again, shipping could be steep. So, with all this being said, and with some of the suggestions from some of my blog followers, I decided to see what I could do. Like I said before, the worst that could happen is that I would gain some metal working skills and replace the panel. So off we go...
First off, as of this writing, I got home from Vacation Bible School prep that starts tomorrow. My loving wife had the NASCAR Sprint cup race on TV and a bottle of Woodford Reserve Kentucky Bourbon on tap for me. I am thrilled that Greg Biffle won at Michigan today on father's day. He's a great guy and drives a Ford! He's a family guy and is holding his daughter in victory lane! I'm a avid member of the ABJ club...Anyone But Jimmy (Johnson). But I digress, as usual.
I got a late start on the fastback yesterday since I had some castoff kitchen cabinets I hung in the garage to get more organized. My hayfield needed to be cut and I got that done. My wife was weaving a blanket on her loom. So there's no guilt involved in working on the Mustang. But in all honesty, my wife encourages me to work on the fastback. I think there's an alternative motive though. She want's her set of keys to it when it's done. I say, go for it baby! Dang! I digress twice in one post? Oh boy!
Now on to the business at hand....
How would I approach the metal work on this cantankerous quarter panel? It was definitely distorted on the bottom edge where I cut the lower section from the quarter panel due to all the stress induced from the previous metal work. RJ made the suggestion about using a horizontal template as a guide for the metal work. I did that...sort of. I took my big 24" carpenter's square and put in along the horizontal station line I have been using throughout this process. I then compared it to the right side station ling. No comparison. The decision I made was to take a piece of square tubing and clamp it to the cut edge on of the panel...
What the idea behind this was to provide some sort of stability while trying to perform the metal work. The next step was to run my sanding board across the primered panel to determine the high and low spots. The high and low spots were quite noticable. I started working the high spots with the shrinking disc. That is evident by the dark spots...
I dug out every tool in my arsenal. Literally. Full set of dollys and hammers. Slapping spoon (my new best friend!) Wood bucks. No air tools since this is detailed body work. The one decision I made soon after starting was removing the square bar stock I had C clamped in place . Otherwise, I would not be able to check how straight that edge would be in its natural state. With the lower end of the quarter panel open, it also made it easier to access the upper panel with all the body tools necessary to straighten the mess of dents. After working the highs and the lows from the top down, I used my sanding board on the panel to be able to keep track of the progress. Then I would continue my massaging until the bare metal was more prevalent...
I saw improvement after a half hour of working the panel. The change that's most notable is that the cut edge is getting straighter. This is a lesson in how fluid metal is. The stress that was causing the warping of the panel is slowly disappearing! Notice how the cut edge is now becoming straight.
Here's a wider view of the panel. There is more shiny metal present and less primer, an indication that the panel is returning to its original contour...
Another an hour and a half later, here are the results. There is more shiny metal from the sanding that indicates the panel is becoming straighter...
It's interesting how the metal moves through the panel. Once again, this is a lesson in fluid mechanics.
It's obvious that the upper quarter is getting closer to the original contour and in the process, the cut edge is also getting closer to it's contour. At this point, there is literally no oil canning in the panel!!!
There is no more than 1/32" of variation between the bare metal and the remaining primer in some of the low spots. I'll work those places out to get them closer since I'm a believer of less filler is more. But as it stand right now, my decision is to go ahead and put the aftermarket panel in that I've been cutting to shape. I just may be OK with this when I'm done. And that is good news!
So with the cut edge straight, the next step in the process will be to trim the patch to the quarter panel. After welding it in, I'll use the templates I made to check the contour of the quarter panel. If there are any adjustments to make, I'll do it then.
Right now, I would say things are looking up. My main desire is to retain as much of the original sheet metal as I can. Lord willing, it looks like that is a viable reality. Of course, after all the metal work is done, I'll check it with the templates I made earlier from the left rear quarter panel.
More news at 11.....
First off, as of this writing, I got home from Vacation Bible School prep that starts tomorrow. My loving wife had the NASCAR Sprint cup race on TV and a bottle of Woodford Reserve Kentucky Bourbon on tap for me. I am thrilled that Greg Biffle won at Michigan today on father's day. He's a great guy and drives a Ford! He's a family guy and is holding his daughter in victory lane! I'm a avid member of the ABJ club...Anyone But Jimmy (Johnson). But I digress, as usual.
I got a late start on the fastback yesterday since I had some castoff kitchen cabinets I hung in the garage to get more organized. My hayfield needed to be cut and I got that done. My wife was weaving a blanket on her loom. So there's no guilt involved in working on the Mustang. But in all honesty, my wife encourages me to work on the fastback. I think there's an alternative motive though. She want's her set of keys to it when it's done. I say, go for it baby! Dang! I digress twice in one post? Oh boy!
Now on to the business at hand....
How would I approach the metal work on this cantankerous quarter panel? It was definitely distorted on the bottom edge where I cut the lower section from the quarter panel due to all the stress induced from the previous metal work. RJ made the suggestion about using a horizontal template as a guide for the metal work. I did that...sort of. I took my big 24" carpenter's square and put in along the horizontal station line I have been using throughout this process. I then compared it to the right side station ling. No comparison. The decision I made was to take a piece of square tubing and clamp it to the cut edge on of the panel...
What the idea behind this was to provide some sort of stability while trying to perform the metal work. The next step was to run my sanding board across the primered panel to determine the high and low spots. The high and low spots were quite noticable. I started working the high spots with the shrinking disc. That is evident by the dark spots...
I dug out every tool in my arsenal. Literally. Full set of dollys and hammers. Slapping spoon (my new best friend!) Wood bucks. No air tools since this is detailed body work. The one decision I made soon after starting was removing the square bar stock I had C clamped in place . Otherwise, I would not be able to check how straight that edge would be in its natural state. With the lower end of the quarter panel open, it also made it easier to access the upper panel with all the body tools necessary to straighten the mess of dents. After working the highs and the lows from the top down, I used my sanding board on the panel to be able to keep track of the progress. Then I would continue my massaging until the bare metal was more prevalent...
I saw improvement after a half hour of working the panel. The change that's most notable is that the cut edge is getting straighter. This is a lesson in how fluid metal is. The stress that was causing the warping of the panel is slowly disappearing! Notice how the cut edge is now becoming straight.
Here's a wider view of the panel. There is more shiny metal present and less primer, an indication that the panel is returning to its original contour...
Another an hour and a half later, here are the results. There is more shiny metal from the sanding that indicates the panel is becoming straighter...
It's interesting how the metal moves through the panel. Once again, this is a lesson in fluid mechanics.
It's obvious that the upper quarter is getting closer to the original contour and in the process, the cut edge is also getting closer to it's contour. At this point, there is literally no oil canning in the panel!!!
There is no more than 1/32" of variation between the bare metal and the remaining primer in some of the low spots. I'll work those places out to get them closer since I'm a believer of less filler is more. But as it stand right now, my decision is to go ahead and put the aftermarket panel in that I've been cutting to shape. I just may be OK with this when I'm done. And that is good news!
So with the cut edge straight, the next step in the process will be to trim the patch to the quarter panel. After welding it in, I'll use the templates I made to check the contour of the quarter panel. If there are any adjustments to make, I'll do it then.
Right now, I would say things are looking up. My main desire is to retain as much of the original sheet metal as I can. Lord willing, it looks like that is a viable reality. Of course, after all the metal work is done, I'll check it with the templates I made earlier from the left rear quarter panel.
More news at 11.....
It's definitely a lot of work, but it will mean that in the end there will be very little filler needed to smooth out what's left. It is very interesting how a dent up top affects an area below it. Great work as always!
ReplyDeleteThanks Grant. I've learned how an impact moves through metal like a wave across a lake. The hard part is trying to think of the damage in reverse and go at it that way. Unfortunately this quarter looked like it had multiple impacts or was hit by something that had a lot of contours to it. When you get to fixing dents, I highly recommend getting a slapping spoon. It's so versatile. You can use it as a dolly or hammer or to spread a hammer blow over a wider area. And it makes tackling a panel like this possible to repair. :-)
DeleteGreat work and write-up as usual Dennis! I might suggest a slapping file would be a good addition to your arsenal. It works on the same pricipal as the slapping spoon, but is heavier and has the tooth of a file in the surface to help shrink the highs a bit when slapping. I am coming to believe that almost 90% of all panel massaging can be done with slapping spoons/files and an good assortment of dollies. Looking forward ton the next installment!
ReplyDeleteI've seen the slapping file and wondered how well it would work. I think I'll get one and give it a whirl since this part of the car would be an ideal candidate for it. I am flat-out amazed at how well the slapping spoon and shrinking disc work. They have been my two tools of choice. The stud weld gun works great when I can't get behind a panel. I'm going to have to go through metal working withdrawal after I get done with the quarter panel!
DeleteNice work Dennis! Glad you found a solution.
ReplyDeleteThanks Alex. I think the jury is still out on the solution. I'll be satisfied when the new patch is in and the templates line up!
DeleteExcellent work. It shows really good in Photo #7 (one before last). That must have been at least a good 2 hours of banging away, eh? I agree with you in preserving as much original metal as possible, since it is thicker gauge than any replacement panel.
ReplyDeleteAs far as NASCAR, I also belong to the ABJ Club. But I went to the Party at the Poconos Race the weekend before last and guess who won? Yes. So, I'm glat the Biff won this last one. Hey, he own and flies a Cessna.
Thanks for your gracious comment. It was at least two hours of "massaging" as I like to call it.
DeleteGreg Biffle and Carl Edwards are both pilots. Mark Martin has his own Cessna Citation Jet. I'm still waiting for mine!
hello Dennis! Nice job on the blog! Car looks great. I happen to be the owner of the engineering car that is mentioned in your blog by Gregg Cly. I would very much enjoy speaking with Gregg or making contact with him. If you could afford us an introduction, it would be greatly appreciated. Thanks! Jose
ReplyDeleteJose, I sent you Gregg's contact information to your email. Hopefully you got it.
Delete