This is the second in a three part series showing how Mike Bowers used Dr. Cyclone’s patch panels to repair his rusty Talladega trunk lid. This will work on Cyclones which share their trunk with the Talladega, Fairlane and Torino. If you want to start with Part 1, Click Here.
Now cut the scribe line above the radius bend, taking the line.
Place the new outer panel in place and using a sharpie draw a line at the bottom 90 degree bend to against the new lower flange. This is to rough in the lower flange cut. Cut leaving the line.
Take the new panel; at the 90 degree bend at the bottom and start roughing it to a 180 degree bend. Rough in using a hand flanger a little at a time with several passes until you bottom out the flanger. Make sure to take the flanger to the same depth each time.
Then place the panel on your leg, take a flat body hammer and lightly hit the bend to bring it in. DO NOT FOLD ALL THE WAY IN, this is a rough in.
Put the new panel in place checking the alignment. Now you fit the panel by trimming the inner flange enough to allow the outer panel to come up into place. Be careful not to remove to much. If too much is removed it will cause a wrinkle when you finish hammering in the 180 degree bend at the bottom. Take your time the better you fit the panel the better the final product will look.
Once the panel is fit, tack weld the panel in place using the same process as the inner flange. On the outer panel I do no more than 2 spot welds before cooling.