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pbrown
January 9th, 2007, 08:12 PM
It's been slow so I thought I would share what I've been up to.

The trunk lid is getting radiused.
The seams are welded up.
The backup lights are shaved.
The gas filler is gone.

Elliot is doing at his shop in the Capitol Hill area of Seattle.

The fenders and hood have been sent out for media blasting. Elliot will do rust repair and then coat them inside and out with PPG DPLF epoxy primer.
Alsprint
January 14th, 2007, 10:14 AM
I like the radious! How are you going to make sure the water flows out and not under the radious so it wont rust? Are you going to use body sealant? I think the look is unigue. Where did you come come up that idea. Do you ever sleep? (LOL) Al
pbrown
January 14th, 2007, 10:41 AM
The filler panel will be fully welded and ground smooth. The curve follows the factory body seal perfectly. Water will not be a problem.

I took this from someone on TFFN. They had a 63 Falcon done this way and it looked good. The doors are also getting this treatment.
redfalken
January 15th, 2007, 08:42 AM
Pat was helping me install a manual choke this Sunday (in his nice, warm garage :) ) and I mentioned we should have a gathering in a few weeks at Elliot's shop to check out the progress on his bird.

Not a formal meeting but just a few hours to check out the progress and see the techniques involved in custom metal fabrication. It's hard to get in the car club mood when it's 30 degrees outside but it would be nice to see everyone again and I'm sure the Elhot Fab batcave is kept toasty!

Anyone up for that? I'll have to confirm it with Elliot, pick a date (maybe Feb. 3 or 4), and then I can send out an email invite to everyone on the forum.
Jeff W
January 15th, 2007, 11:02 PM
Elliots! I'm in.
MacDee
January 16th, 2007, 11:48 AM
I'd be there!
pbrown
January 16th, 2007, 07:01 PM
I visited Elliot's shop today. Here are some more photos.
pbrown
January 16th, 2007, 07:08 PM
A couple more. The green car is not mine. These are just to show the look I'm going for. Elliot does mostly restoration work so this is a fun one.
Dan
January 19th, 2007, 10:29 PM
Planning to be there, If I don't work. Need the extra $$ fer my Falcon. Thanx for the invite :)
Dano
pbrown
January 24th, 2007, 05:00 PM
A little update for those interested.

This is the drivers door radius work. The door gap is set. It's coming along nicely.

I bit of bad news. There is rust in both lower quarters. I ordered new panels from Autokrafters.
redfalken
January 24th, 2007, 09:38 PM
Yikes! If YOU'VE got rusted quarters I'd really hate to see mine...

Well there's no time like the present to get it outta there. When I look back on my paint job I was more interested in getting it shiney and fresh looking and probably should have had a better job done on the rust repair.
Dan
January 25th, 2007, 09:09 PM
A little update for those interested.

This is the drivers door radius work. The door gap is set. It's coming along nicely.

I bit of bad news. There is rust in both lower quarters. I ordered new panels from Autokrafters.

Lookin' goodhttp://rainierfalcons.com/forums/images/icons/icon7.gif
Can't wait to see it in person.
Are the panels you ordered aftermarket or OEM FORD? If aftermarket they are NOT the same size and are major pain in the U know what!!---weather you do or someone else does--they are not the same.
Dan
January 25th, 2007, 09:23 PM
If not properly gotten rid of, rust will come back(under your nice new paint). It may take awhile but will show as bubbles in your paint only it's not your paint(METAL ZITS). God forbid you have any Bondo on top of such areas because it will pop the entire piece of bondo off car.
Primer is not a sealer either. At least as far a H2o is concerned. It is right before painting, but in my case, I have primed parts (on my car) in September and use car every day(rain or shine). I will have to re-work those parts before I get the 'killer' paint.
pbrown
January 25th, 2007, 09:52 PM
They are aftermarket panels. They won't be exact but will still be easier than fabricating them by hand. I can asure you that nobody will every be able to tell it was repaired.

Primer is a sealer. I think you are referring to 1K or 2K surfacer. Surfacer is the sandable stuff and is not water proof. Moisture will go right through and rust from underneith.

Once the rust and remaining metal work is done, I will be laying down the products in the following order:

Epoxy Primer (PPG DPLF/DP401LF)
body filler where required (Evercoat Z-Grip and Metal Glaze)
2K Sanding Primer (PPG K36 Primer Surfacer)
Sealer (PPG DPLF/DP401LF)
Basecoat/Color
Clearcoat (2 coats)
pbrown
February 6th, 2007, 08:36 PM
I stopped by the shop and got a few photos.
BillP 98201
February 12th, 2007, 12:13 AM
Wow! Looks like you are making good progress. Cant wait to see the finished bird.
pbrown
February 12th, 2007, 09:14 AM
Bad news guys. The trunk is trash. I can't go into great detail but there was a problem during the media blasting that wasn't noticed until the epoxy primer was applied. Anyway, I need to find a new trunk lid and start over.
Alsprint
February 12th, 2007, 07:16 PM
I have one that had a little damage to the area by the trunk lock (wasnt bad) but some one drilled about 4 holes and pilled the dent. Thea holes need to be welded but its a pretty good deck. Al
pbrown
February 12th, 2007, 09:26 PM
Al,

Can you send me a photo?
pbrown
February 14th, 2007, 08:21 PM
More bad news. The hood is also warped. I was able to get a replacement trunk and hood from Jake today. I'll drop them off at Elliot's shop in the morning and do this thing all over again.
Luva65wagon
February 21st, 2007, 10:11 PM
Patrick,

Was the warpage due to the sand blasting? I'm curious what your problem was since I now have a couple of fenders to finally rework.
pbrown
February 22nd, 2007, 08:49 AM
Was the warpage due to the sand blasting?

Yes it was. They did a good job with the fenders. I don't know who the shop was. They were a sub to Elliot.
Luva65wagon
February 22nd, 2007, 09:09 AM
Fenders, due to the compound curves, can handle a lot of abuse, but flat panels are another story. They heat up and work harden to such a degree that it's very easy for these to just move all over the place, as I guess was the case here. You have to be very gentle and have a very light touch. Anyway, thanks for clueing us in on what not to do.

I've been going to contact a company in Canada about their process. This is their site:

http://gemblasting.com/index.php
pbrown
March 23rd, 2007, 04:58 PM
Here is an update. The car is mostly done. The cutting and welding phase is done. It just needs some priming and assembly to get home.

Here are some shots of the new fuel filler.
pbrown
March 23rd, 2007, 05:01 PM
A few more shots.
redfalken
March 23rd, 2007, 07:28 PM
Looking good! I see a spring sanding party in our future...

Have you set a goal for your first car show with the new paint job???
new_falcon_owner
July 7th, 2007, 04:02 PM
question about your fuel filler location...

arent you afraid of the gas fumes entering your car (its vented inside the trunk now?) if you have stuff in your trunk arent you nervous it will hit the filler tube and bust it? Looks nice and clean, but id be abit nervous.

rick
pbrown
July 8th, 2007, 02:07 AM
question about your fuel filler location...

arent you afraid of the gas fumes entering your car (its vented inside the trunk now?) if you have stuff in your trunk arent you nervous it will hit the filler tube and bust it? Looks nice and clean, but id be abit nervous.

rick

The cap is sealed and the tank vents to the outside through the trunk floor. I don't store anything in the trunk so I'm not worried about things sliding around.