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1963 Ford Falcon Restoration

The right side top and front of the quarter panel, that would be the passenger side. You can see those patches have been finished and the metal work has been done.
Here is the driver's side quarter panel, the top of the wheel lip and in front of the driver's side rear wheel; and you can see the rust in that area is outlined in chalk and it appears to be about the same as the passenger side.
Again the cutout area of rust that was previously noted a few pictures ago; and it's the driver's side lower rear quarter panel that had some previous damage and we've cut that rusty metal away; and you can see the inner panel to the wheel house and the trunk extension has a lot of surface rust; and that must be cleaned before that new patch can be installed, to ensure that it won't rust later and cause us more problems.
This is of the craftsmen at Muscle Car Restorations putting a rust patch on the driver's side, front fender. You can see the lower part of the fender had some rust in it, and we're actually -- had cut out the bad metal; and we fabricated a patch; and he's actually spot welding that patch into position. Note that he tack welds it many, many times around the outside edge of the patch to prevent warpage. He will tack it and tack it about three-eighths of an inch apart and continue tack welding until the entire patch has been completely welded. We butt-weld each and every patch we make. We don't do any lap welding at all.
The driver's side door. This picture was taken to show the most serious rust on the car; and this particular door, the bottom inner panel was too bad to save so we snapped some pictures of this particular problem to show you how bad it was.
That same door with the rusted area removed, and it has been made ready for a replacement bottom from a donor door.
This shows the replacement lower inner door structure that we got from a Ford Ranchero, which that section of the door is interchangeable with the Falcon; and you can see the lower portion of the removed part of the blue door bottom is in the picture as well; and we subsequently welded in the new bottom of the door, did the bodywork, and it's virtually undetectable.

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