77xcfalcon 177 Posted January 8, 2018 Hi all. I am about to tackle the drip rails on my xc. It’s the last of the rust repairs( saved the best till last). I can’t find any repair sections available and the sheet metal guys i have talked to aren’t interested or don’t have the right gear. Does any body know were to get repair sections from or had any luck making them themselves Sent from my iPad using Tapatalk Share this post Link to post Share on other sites
bear351c 10,260 Posted January 8, 2018 Dont know of any aftermarket companies making them. Any XA, XB, XC coupe, ute, van or wagon should have similar gutters, you take patches out of. Never could understand why XC gutters rusted out, before XA or XB. Seen so many bad XC roof rails. Share this post Link to post Share on other sites
gerg 10,871 Posted January 8, 2018 A lot of manufacturers in the 70s had to cut corners to keep costs down, one of those areas was body protection. That's why many 70s cars, Ford, Holden, Chrysler, Datsun, gained the reputation of being rust-buckets. Also, paint processes were changing rapidly around that time, with the introduction of 2 pack paint and phasing out Duco/enamel style paints.My XB coupe had rotted out gutters, so I cut the fuckers right off and welded them shut. I was young and stupid and have devalued the car beyond repair but on the plus side, i won't feel too bad about all the other shit i want to do to it.To answer your question (I'll get there eventually), the gutters are very hard to do right. They're actually part of the roof skin which is rolled into the window frame. All you'd be doing is welding on an extension of the frame and body-sealing it to the skin. The frame is also pinch-welded to the roof frame so cutting that out will be a barrel of fun as well. So short of getting a new roof skin and starting over, it's all cosmetic.If possible, I'd try and work with what's left there.Sent from my CPH1607 using Tapatalk 1 scottly reacted to this Share this post Link to post Share on other sites
scottly 475 Posted January 8, 2018 Were the gutters on these models welded from the inside which requires the roof skin to be removed to repair correctly? Share this post Link to post Share on other sites
gerg 10,871 Posted January 8, 2018 Were the gutters on these models welded from the inside which requires the roof skin to be removed to repair correctly?Sorry I wasn't quite right in my description. The roof skin folds right under and welds to the inner frame, and the gutter rail has a flange that spot-welds along underneath. Drill out these spot welds and the gutter and outer door frame come out leaving the roof skin and inner frame behind. Instead of trying to describe it in (probably) bad terminology, here's a youtube clip of a Mustang gutter rail repair:NOTE: he dicks around for a while so fast forward about 7 minutes into it for the actual job.Sent from my CPH1607 using Tapatalk 1 77xcfalcon reacted to this Share this post Link to post Share on other sites
77xcfalcon 177 Posted January 8, 2018 Thanks guys, I think if I keep taking it back until it’s clean steal and treating it I should be able to make a sound repair, the only thing I think I might have trouble with is the little lip on the bottom that the mouldings clips to. Sent from my iPad using Tapatalk Share this post Link to post Share on other sites
deankxf 20,231 Posted January 8, 2018 if you can go see an XD XE XF etc one, it wouldn't surprise me if they are similar(may be the trim width edge thickness like in the clip above also) 1 77xcfalcon reacted to this Share this post Link to post Share on other sites
77xcfalcon 177 Posted January 10, 2018 So this is my plan, going to get some angle bent up with the top lip bent over. Then make up a jig so I can stamp the lower lip in, then cut some key ways into the roof Flange and match new new pieces into that, I don’t think I explained it very well, I will probably start a build thread and put some pictures up soonSent from my iPad using Tapatalk 2 gerg and deankxf reacted to this Share this post Link to post Share on other sites
deankxf 20,231 Posted January 10, 2018 sounds great! pics will be very helpful, but i think i get what you plan to do 1 77xcfalcon reacted to this Share this post Link to post Share on other sites
Jacked 8 Posted September 13, 2020 Soooooo..... im up to this step now so would love some hints Share this post Link to post Share on other sites
bear351c 10,260 Posted September 13, 2020 Expensive, but, Howard Astill. Share this post Link to post Share on other sites
dvfalcon 352 Posted September 14, 2020 Another repair job Share this post Link to post Share on other sites
scottly 475 Posted September 14, 2020 10 hours ago, bear351c said: Expensive, but, Howard Astill. I think bear is correct Howard astill makes and sells gutter replacement sections now. Share this post Link to post Share on other sites
Big Blue 17 Posted September 23, 2020 Your ears must have been burning DV Falcon, I was thinking of exactly this process today as I’m ready to fit the XD roof skin, that is drilling drip rail and mig it from underneath. Whilst glueing has been suggested, as has spot welding (I have a good spot welder) and maybe I just don’t have enough faith in technology, but given its old metal, I see this method in the video the long term solution. Nicely done!, Share this post Link to post Share on other sites