The Ford Barn - 30-31 Roadster Dash Rail Repair

Bob, I guess what you need to decide is how you want to go about making the repair. Also, what tools do you have to work with? Maybe Antique Auto Sheetmetal (Brookville Roadster) has a defective rail that you could purchase and saw out a replacement patch and TIG weld in.

For the sake of food for thought, --or a little stimulation, how I would probably approach it in my shop would be to make a large 'X' scribe mark to reference the correct center of the hole. Make sure this X is larger than the area you will be cutting out. Next, just install a piece of sheetmetal into the entire area and metalfinish smooth. Using your X as a reference, find your center and then drill a .250" hole. Now spray the backside of another hole with Pam cooking oil or Pledge to act as a release agent and then mix some Kevlar-stranded Bondo and apply a huge 'glob' over the backside of a good hole so you can determine the correct taper, After this has dried, this can act as a temporary hammer form. Now, using a hardwood dowel, shape the end of the dowel to fit the front side of the taper in the bolt hole. Next with the help of a buddy or two, heat the sheetmetal in the area of the newly drilled hole until red and then quickly place the dash rail over the Bondo buck. Then use a hammer to smack the wood dowel on the front side to create the taper shape you are seeking.

Yes, it is gonna smell, and yes it will likely ruin the Bondo hammer form and/or the dowel, but this is just a temporary tool to serve as a quick way to get the job done. Another way can be to use a deep-well socket on the backside to support the perimeter of the taper and a dowel to press the front side. The benefit you will get from using heat is it will control the stretch required for making the taper. Good luck in whatever you choose to do and let us know how it came out.