1951 Ford Sedan - Box Cutter

The new panel was carefully fitted to the opening. Panel clamps and Vice Grips hold it in place while a MIG welder tack welds the panel in 1-inch gaps.

The panel has just enough radius to provide a pleasing transition from the stock panel up the lower window. The added metal also gives the car the illusion of having longer quarter-panels since the roof is moved forward.

Before the area alongside the rear window is filled, the lower rear corner of the quarter window must be completed.

The original corner of the window was given two relief cuts and it was then reshaped by bending it gently around a piece of 2-inch pipe. Bend a bit, test-fit, and bend some more until the radius is just right.

After the proper radius is achieved the piece is cut and fit to the body lines and tack welded in place.

The side panels on either side of the rear window were filled with two triangle shaped pieces of sheetmetal. Welding is simplified by taking extra time to carefully fit all the filler panels.

After finish-welding the filler seams with a TIG welder, Larry Shoaf used a grinder to smooth the welds. A lighter grit grinder will provide more metal finishing before primer is applied.

With the external skin all put back together it was time to connect all the internal body braces. Shoebox Fords are built stout and here we can see the inside corners of the quarter windows are fitted perfectly back in place.

The canted B-pillar was the last remaining fabrication and the post is reinstalled with the front line meeting the bottom and the top of the cut. The pillar is on a pleasing angle.