How To Trunk Repair; Part 3

Trunk Repair, Part 3

In the first two parts of this How To Trunk Repair article we showed you how Mike Bowers cut up his trunk and installed patch panels from Dr. Cyclone, Tom Wilson to bring a 1969 Talladega trunk back to life. This Part 3 story will guide you through the finish work to make the repair invisible. If you would like to start with Part 1, Click Here.

I use a 24 grit disk to remove slag and flatten the welds down. This will let you find any holes in the welds and make it easier to keep the next grinding step flat.

Fill any holes in the welds.

Use 3/16 grinding wheel to grind the welds down. Pay attention to how deep you cut, make multiple passes removing a little at a time. If you go too deep the metal will be too thin and crack.

I didn’t take any photo but now you finish hammering in the 180 degree bend at the bottom use a hammer and dolly. Lightly hammer against the dolly making multiple passes, Putting the dolly on the outside and hammering from the inside as much as possible. There will be some places that you will have to hammer from the outside. On the ends I used a pair of Lyman pliers to fold and align. Some relief cuts will have to be made to the flange in order to fold the flange under in the radius bend. If you have an alignment problem with the existing trunk side (which usually will be to short from bending the flange under) you can build that part up with welds then grind to match.

Finish sand with a 100 grit disk over the hammered areas.

NOTE: The disks I use are important. I prefer to use 3M green disks in 0.03-0.04 and 0.06 for cutting. I prefer the o.03 to cut with but the 0.04-0.06 will work. In my opinion the thin Chinese disks are prone to coming apart and wear out fast. I have never had a green 3M disk come apart, this is more of a safety issue for me. If you also prefer the green disks, you can likely find them at your local Reilly Auto Parts Store but they may have to order them from their warehouse.

Filed Under: FeaturedFord TalladegaMercury SpoilerMercury Spoiler IIRestoration

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About the Author: Some of my first and strongest memories from my childhood relate to cars. I still remember when things happened based on what car I was driving at the time. I grew up and lived in Iowa for nearly 40 years before moving to Southern California and now live in Tennessee. I was a Corvette fanatic for years but then re-discovered vintage American Muscle. My wife, Katrina, and I decided we wanted to focus on unique and rare muscle cars. After a lot of research we fell in love with the Ford Blue Oval Aero Cars. These were only built in 1969 and and aerodynamics became an important part of winning races. The only purpose of these limited production cars was to win NASCAR races using the Boss 429 and 427 power plants complimented with a special, wind cheating, aerodynamic body. The Ford Talladega and Mercury Cyclone Spoiler II are terrific and historic cars. This site is devoted to these car and their owners past and present. We provide an Online Registry for recording the long term history and ownership of every remaining Talladega, Spoiler and Spoiler II.

Comments (2)

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  1. Alan Miller says:

    Nice job . I had no doubt that it would fit . Everything Tom makes fits well or he won’t make it .

  2. tom wilson says:

    Really beautiful job Mike.Cant wait to see the car finished.

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