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Ford Taunus DIY: Reconstructing the Front Pillar with Handmade Sheet Metal

Model: Ford Taunus TC - Years: 1970, 1971, 1972, 1973, 1974, 1975
Part: Body

Video tutorial

On the 1974 Ford Taunus Coupé, the video shows the handcrafted reconstruction of the corroded front pillar. The operator starts with a strip of smooth sheet metal secured in a vice and, using a shaping machine and targeted hammer blows, recreates the original curved profile of the A-pillar.

When the section has the desired shape, clean the damaged area on the Taunus body down to healthy metal with a grinder and brush, removing old welds and oxide at the base of the pillar. The new piece is then shown already welded in position, with a series of spots along the edge and the surface finished with a grinding disc to smooth the joint.

Next, prepare a wider sheet metal that will form the outer cover: place the panel against the side, secure it with clamps, and trace it, then create a narrow reinforcement that is spot welded along its entire height. In the final shots, the reinforcement and new sheet metal are fixed to the body with a dense series of welds, restoring the Ford Taunus A-pillar to its correct structural geometry, ready for the subsequent stages of filling and painting.


Posted on 16 May 2026 by ScegliAuto


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by ScegliAuto

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