1966 Ford Mustang Hardtop Dynacorn Sheetmetal Replacement

Our new Dynacorn #2117 quarter-panel is measured and a cutting guideline taped to it to achieve a perfect fit.

Ted does a fit check, trimming and adjusting as he goes. It all has to fit together.

Ted fit-checks the rear valance as well.

Once the quarter-panel and valance are properly fitted, Ted checks the end cap fit, which also requires adjustment. The quarter-panel radius must follow the end cap radius. Otherwise, you have sloppy fit. Adjustment takes place at the bottom by moving that attachment point up or down to control radius before welding.

Ted uses sheetmetal screws as temporary fastening points prior to welding. This secures the quarter-panel exactly where it is supposed to be. When there are adjustments, Ted removes screws and makes adjustments.

Here, the quarter-panel is secured with screws and ready for welding.

Ted clamps areas between screws as he welds. The clamp flattens the steel between screws to remove waves and provide a solid bond.

Ted lightly stitch-welds small 1/4-inch beads, then cools the surface immediately with a wet towel to prevent warping. He does this with one-inch spacing; he will come back to stitch-weld a second time between welds, cooling each weld along the way.

The B-pillar is handled the same way in a process of rosette welding and cooling. Ted has punched 3/8-inch holes in the B-pillar lip for this purpose. Each is plug- and fill-welded, which is also known as rosette welding.

Ted ultimately winds up with a succession of small stitch welds. Screws are then removed in preparation for grinding.

Ted uses a small grinder to smooth each weld before going to a larger grinder for surface blending.

A larger sander is used to blend stitch welds into the quarter-panel.

Ted has punched holes inside the original quarter-panel where it joins the rocker panel, which will be rosette welded. The factory spot-welded this location, which cannot be done here.

B-pillar rosette welds are ready for finish work and filler.

Rosette welds are finished off with a course 40-grit sanding disc.

When using filler, follow the manufacturer's directions to the letter. Fillers fail when they aren't mixed properly. Too much hardener and they cure quickly. Not enough hardener and they never cure. Filler needs to cure at exactly the rate set by knowledgeable chemists and manufacturers.

Apply filler in thin coats, one at a time.

Ted doesn't like excessive body filler dust created by sanding. He uses graters to get it down to final finish mode, then he sands and refills as necessary.

Our installed Dynacorn quarter-panel from Mustangs Plus is ready for final finish work.