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Discussion Starter · #22 ·
And the body was mounted on the rotisserie for paint removal.



The chassis was disassembled for media blasting.



We elected to use a dustless media blasting technique for paint removal. In this process, crushed recycled glass bead is the cutting media, and it is blasted at the subject with high-pressure water. The water contains a rust inhibitor, so the clean panels do not immediately start corroding. The benefit is that the water keeps the temperature down to prevent the friction of the glass bead impact from heating and warping the panels. The other benefit is that the glass bead does not harm the environment, as the dust simply integrates with the gravel in our lot.

Go Green Dustless Blasting brought their mobile unit to our shop to do the work.





 

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Discussion Starter · #25 ·
Numerous pinholes and previously damaged areas were revealed after paint stripping.



The Go Green crew rinsed the body shell and we rolled the body shell into the paint booth for epoxy primer.



There are numerous areas that will require repairs.



This is below the rear package tray.



Quarter panel:



Other quarter panel:

 

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This is great. Thanks for sharing all the pictures.
 

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Emberglow is probably the best color for a '66 7 Litre.

Guess I should have bought a '66 7 Litre in emberglow! Oh well.
 

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Great to see another 66 being brought back to life! Those rust areas are typical for the 66 but still stink to have to fix. Looking forward to seeing the progress!
 

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Hello,

Great progress, please keep the pics coming. If you don't mind me asking, but what are your plans with the frame? The reason I ask is even though the holes are the obvious spots, there must be large sections of paper thin steel that also will need to be replaced. Are you going to remake large sections? Or just look for a better used chassis?

Keep up the good work!
 

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Discussion Starter · #34 ·
Hello,

Great progress, please keep the pics coming. If you don't mind me asking, but what are your plans with the frame? The reason I ask is even though the holes are the obvious spots, there must be large sections of paper thin steel that also will need to be replaced. Are you going to remake large sections? Or just look for a better used chassis?

Keep up the good work!
We will be repairing the frame... pics in a minute.
 

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Discussion Starter · #37 ·
The body was primed, save for the areas we knew we were removing.








The frame on this car had some obvious repairs over the years. We noticed that these large sections of angle iron steel were added to “fix” something… wonder what it is?



After a little cutting with a wheel on both sides of the frame…



… these giant holes were revealed on the driver’s and passenger side of the frame! Yucko.



 

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Discussion Starter · #38 ·
Obviously, the correct way to repair this stuff is not to just hide it under a patch. The top side of the frame was still intact. Out comes the rusty metal.



We measured the rails and determined that 2” x 2” box channel is a perfect fit inside the stock rails. We elected to leave all 4 sides of the box tube intact to add a little more rigidity to the stock frame. The reinforcements were MIG welded in place, and ground flush.









It’s hard to tell the repair ever occurred.



 

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Discussion Starter · #40 ·
Next, the crew mounted the body on a fixture to begin the sheetmetal repairs. These cars are cool and have a following, but parts are not as plentiful we’d like, so restorers are faced with some decisions to make.

The wheel tubs were very rusty on this car, and replacements are not made for it. The good thing is that the tubs interchange with regular Galaxies, and there were many thousands of those made. We obtained a clean replacement set of wheel tubs removed from a car at Desert Valley Auto Parts (Desert Valley Auto Parts) in Arizona. They cut them from a car and shipped them to us.

Upon arrival, we trimmed off the excess rough edges. The DVAP crew cut them oversize so we could do the finish work in-house.







Our crew drilled and ground away the original spot welds in the car and removed the original wheel tubs.





Original tub removed.



 
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