nomadbird
Well-known member
Those of us with the first generation of Thunderbirds are quite fortunate in having the majority of restoration parts readily available to us. A recent post included a reference to an owners satisfaction using patch panels furnished by CASCO.
With the exception of seeing some demonstrations on the TV show titled "Dreamcar Garage", There is very little discussion on the subject of sheet metal replacement. How about us sharing our experiences with metal replacement and the techniques used in the installation? Even though most people sub out their body work, it is worthwhile knowing something about the procedures and tweaking required to get the results you desire.
One of the most common replacement items is the front fender. Just because it is a genuine Ford item that cost you mega bucks is no guarantee it will fit without alterations. Before you or your contractor get too far with metal finishing, mount the headlight bucket and headlight door. Most new fenders are not the same size around the headlight as the outside of the headlight door. The most common "fix" is to split the fender open along the seam from below the headlight opening to the bottom of the front surface of the fender. Perform the necessary metal shaping, then spot weld (or replicate) the flanges back together inside the fender below the headlight bucket.
Because the headlight door is a casting that is not readily re-shaped, this procedure is about the only way to match the size & shape of the new fender with the headlight door. Unfortunately, too many owners don't become aware of this mis-match until they re-assemble their freshly painted car.
Almost everyone has needed metal repair or replacement at one time or another. What's your experience or tip?
Tom
With the exception of seeing some demonstrations on the TV show titled "Dreamcar Garage", There is very little discussion on the subject of sheet metal replacement. How about us sharing our experiences with metal replacement and the techniques used in the installation? Even though most people sub out their body work, it is worthwhile knowing something about the procedures and tweaking required to get the results you desire.
One of the most common replacement items is the front fender. Just because it is a genuine Ford item that cost you mega bucks is no guarantee it will fit without alterations. Before you or your contractor get too far with metal finishing, mount the headlight bucket and headlight door. Most new fenders are not the same size around the headlight as the outside of the headlight door. The most common "fix" is to split the fender open along the seam from below the headlight opening to the bottom of the front surface of the fender. Perform the necessary metal shaping, then spot weld (or replicate) the flanges back together inside the fender below the headlight bucket.
Because the headlight door is a casting that is not readily re-shaped, this procedure is about the only way to match the size & shape of the new fender with the headlight door. Unfortunately, too many owners don't become aware of this mis-match until they re-assemble their freshly painted car.
Almost everyone has needed metal repair or replacement at one time or another. What's your experience or tip?
Tom
