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Trunk floor cut out.

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First test fit of the tail panel.

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I made a quick and ugly t-post dolly to help straighten the c-channel sections.

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Passenger side c-channel straightened:

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I started on the filler neck cover while I'm waiting on new bead roller dies to dimple the trunk floor. They should be here tomorrow.

To start, I made "tucks" in the edge using a set of modified Vice-Grips that "MP&C" posted about in the Garage/Tool section on 67-72chevytrucks.com awhile back. Hammering these out will cause the edge to shrink. The middle was stretched with a mallet and sand bag.

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First quick pass through the planishing hammer to see the rough shape. Needs more stretching to raise the top still.

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Another round of stretching/plannishing. Getting closer.

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Once the bowl shape was where I wanted it I blacked out the area to fold and scribed an line.

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Started the fold using the makeshift tipping die. Had to alternate between stretching the flange and making passes in the bead roller. Once the edge was bent about 45* I finished folding it over with a hammer/dolly.

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Finished piece.

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This is like a religious experience. And I am not religious.

(o{}o)

I started the right section of the trunk floor by laying out the bead pattern and rolling them. Not a fun piece to make; all of the beads in a tight area and at different angles made for some interesting distortion. Pre-stretching helped a ton but I still had some straightening to do after each bead.

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Before rolling the beads I "tuned up" the edges of the dies. The sharp outer edges would sometimes leave a slight bend beside the bead. I made a mandrel out of 3/4" OD tubing with a hex nut JB welded inside and a tack weld to set the depth of the die on the mandrel. This let me chuck the male die in the lathe and slightly rounded off the outer edges.

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With the beads done I laid out where the bends for the "ramp" would be.

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I made a fork to form tucks that will allow me to shrink deep into the panel.


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And started forming tucks and hammering them back flat. I made a few passes then started working out towards the edge making shorter tucks to curl the top edge inward more.

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Flattening the tucks. You can see how much shrinking is happening, the lower part is flat while the upper part is still holding the shape of the tuck.

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Bowl shape starting to form after one pass of full depth tucks.

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