By Brian Brennan Photography by The Author

e’re back! Our ’69 Ford Torino Fastback Q-code continues to have its “skin” refurbished. This time we take a look at the wheelhouse and trunk floor extension. It should be noted that while we are working on a ’69 Ford Torino Fastback the parts and the work required will be the same for ’66-’69 Ford Fairlanes and Torinos and other years and models … but more on that later.

We find ourselves once again back at The Installation Center (TIC) in Cleveland, Georgia, watching Craig Hopkins continue the resurrection of our Torino while using Auto Metal Direct (AMD) sheetmetal. In the past two articles we have looked at replacing entire rear quarter-panels and the core support. Both of those projects required a good bit of effort and expertise. This time we are looking at patch panels; it’s been our experience this is something virtually any rodder who has dabbled in sheetmetal work has done some patch panel work.

Let us first familiarize ourselves with the parts at hand.

The Outer Wheelhouse patch panel is available in two different part numbers to accommodate the left- and righthand sides. We are working specifically with the lefthand (PN 770-8468-L, driver side) outer wheelhouse patch panel for ’68-’69 Fairlanes and Torinos (these parts won’t work on similar-year wagons). There is also a patch panel for the righthand (passenger side) outer wheelhouse
(PN 770-8468-R).

These pieces are stamped for AMD out of a high-quality heavy-gauge steel on AMD-exclusive tooling. It should be noted that AMD went to great lengths to make sure that their replicated parts feature correct-as-original shape, size, bends, tabs, and holes. This AMD component replaces Ford PN C8OZ-5427895-B. The wheelhouse will come to you with an EPD coating to protect against rust and corrosion. We have spoken about EPD, as it stands for electrophoretic deposition. E-coating, as it is commonly referred to, is an immersion wet paint process that uses electrical current to attract material (paint) to the metal surface. It’s great for protecting metal during the build process right up and until the body- and paintwork begins.

The second patch panel that we will be working on within this story is the Trunk Floor Side (PN 840-8468-L, extension). It will work on ’68 and ’69 Torinos, Mercury Cyclones, and Montegos and ’69 Fairlanes and Mercury Comets (except wagon or Ranchero). There’s also a Trunk Floor Side for the righthand (passenger) side, PN 840-8468-R. 

This component is stamped from the same high-quality heavy-gauge steel and each of these pieces features the same correct shape, size, bends, ribs, holes, and tabs like the factory. It arrives EPD coated to help protect against rust and corrosion. This AMD component also replaces Ford PN D0OZ-65112A23-A and comes with the same EPD coating.

Follow along with the photos as it will pretty much be a step-by-step process on how to remove the tired and rusted-out sheetmetal and replace it with the fresh sheetmetal from AMD.

3. Once Craig at the Installation Center has figured out what metal needs to be replaced, he will gather the correct sheetmetal pieces from Auto Metal Direct (AMD). The labor it would take to replace both the outer wheelhouse and the trunk floor extension isn’t warranted as most of the metal is in good condition. Craig starts by taping a cutline on the car and also taping off a line to cut both the outer wheelhouse and the trunk floor extension.

4-5. Butt welding is the proper method for this repair. TIC starts by cutting out the old damaged metal. Using a cut-off wheel, both rusted areas are removed. An air chisel is used to separate the wheelhouse from the trunk floor extension.

6. Follow the same procedure on the new panels to create your patches.

8. Reproduction trunk floor side, extension (PNs 840-8468-L and 840-8468-R) for the ’68 and ’69 Ford Fairlane and Torino.

9. Clean the surfaces that will be welded, both on your patch panels and on your car. A sanding disc works great for this.

10-11. Test-fitting your panel is key to great results. TIC uses mockup panels with self-tapping screws and clamps. They will scribe the backside of the patch panels and cut the excess off to ensure a flush fit. A grinder will allow you to fine-tune it from there.

12-13. TIC will be spot-welding the quarter-panel on the car, so prep the wheelhouse patch on both sides for a proper weld. Here a media blast cabinet was used but a wire wheel will do the job as well.

15. There’s a lot of undercoating that needs to be removed at the repair site. A hand torch and scraper work best.

17. Using 0.023 wire for ease of control on thinner metal, TIC tacks the trunk floor extension in place. They also start with the inner edge and manipulate the patch in and out for that flush fit. Often a thin screwdriver helps. Continue tacking the patch flush across the panel.

19. Small welds, cool it down. All in one direction.

21. Start cleaning up the welds with a grinding disc. Finish sanding using a sanding disc to bring the two parts into one.

22. Don’t forget to plug weld any area that your spot welder will not reach later on.

23-24. Craig will be welding the wheelhouse patch the same way. He leaves the patch loose from the trunk floor extension so he can make any final adjustments before going for the final weld up. A clamp will hold it in place until that time comes.

25. Tack the patch and check alignment. Using your flathead screwdriver, flush the patch and continue tacking as before. A hammer and dolly will be helpful to get the perfect alignment.

26-27. Continue to weld the panel just like the trunk floor extension. One direct, small weld and then cool the weld.

29. Craig (left) test-fits the patch to make sure he’s happy with the alignment before proceeding.

31. After testing a final time, TIC is happy with the alignment on the quarter-panel and we weld up the relief cut. Follow the same steps in cleaning up this area.

33. The rust is repaired and the car is ready for its other repairs.