Bare Metal work and heat shrinking on XC Falcon Panel Van #14 Magnum Force

Howard Astill is building an XC falcon panel van to replace the one he had new in 1977.
The Van was a country car from Nyngan NSW and was delivered with air-conditioning, power steering and rear lift gate. Howard Bought the car at auction in Sydney, it has a genuine 52K on the clock and had been parked outside under a tarp for over 20 years.
The Van will be a restomod style build with an old school 351 Cleveland, single rail 4 speed and BW disc bake rear.

The series will follow the restoration and modification over the van in detail as it happens.

Metal Man Tools - Shrinking Discs, Forming Dollies Etc

Howard is no stranger to building street machines with more than 17 major builds for himself and Astill Design customers. These cars have won hundreds of trophies all over Australia including Summernats Top Judged and Grand Champion. Howard helped the Perry’s win Grand Master in 2017 and BOSSXC was a superstars Super Six winner 2023 and 2024 and Summernats people’s Choice winner.

Vehicle Details
351 cleveland 10:1 compression
Ford cast 2V Heads, 63cc open chamber, ported
Yella terra YT 5006 rockers, guide plates
750 double pumper holley
Pacemaker 2V tri y PH4050 headers
3” twin system, Hooker aero chamber mufflers
BW single rail Manual gearbox 11" HD single clutch
Factory Borg Warner Rear end 2.9 ratio
Wheels: Front 18 x 8 245/40 Rear 18 x 9 275/45
Lovells lowered front and rear springs, Bilstein shocks
Lovells front sway bar, Ford sedan rear sway bar
Ford LTD tramp rods (longer than the sedan Coupe)
Standard body, filled side windows, narrowed bumpers
Fairmont square headlight grille
Painted bumpers, taillights, door handles and mouldings
Stock XC rally pack interior, Sports steering wheel
Rear compartment will have basic trim
Rally pack fuel cap and bonnet
Colour: PPG Street Sweets Spearmint
Factory power steering and Air Conditioning
Restomod factory style engine bay
Factory brake booster & master cyl
Ford AU 3 front Calipers, Stock XC disc rear

0:00 Intro
0:19 Front Guard/Fender disassemble
2:12 Paint strip fron guards
4:29 Panel beating
13:45 Dent removal front guard/fender
18:16 PPG advert
19:05 Caustic Soda Paint removal
21:03 Rust removal
23:33 Painting Parts
24:59 Rust removal with deoxidine
27:05 heat shrinking/Panel beating
41:02 Conclusion
42:06 End

Music from Uppbeat (free for Creators!):
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[brianrhodes]

Hi Howard, I really enjoy these videos. some tips,
cover the area that you’re going to use the shrinking disk with a marker pen, the ink acts as a lubricant, it also helps you see where the disc is touching the panel and might also help to show things better on camera.
Try using a heat gun to warm the panel, I’ve found it works really well for situations like you used the oxy for on the front guard. It’s also good during the colder months as it helps to “relax” the metal and with care can be used with air/damp cloth to shrink the metal.

[stevepierce]

Howard your an absolute metal Artist, your patience in doing this sort of work is next level. A true Craftsman.
Well done, keep up the progress on the Panel Van mate, very much enjoying it.

[oldieman]

The van is coming along really well now after a huge amount of work. Great to watch.

[GMCShazamataz]

Awesome work Howard. Thanks for taking the time to share with us.

[darrindouglas]

your heating tip needs cleaning....that's why the flame is spread out and making the hissing sound as well....get some oxy tip cleaners....
Love your work

[scotthunter]

Fantastic content Howard..
Always great information mate thankyou 👍 👌

[johnmarino]

Just a tip on using the shrinking disc (I've got the same one) keep it flat on the panel, if you tilt it the edge goes in the lowes, and you don't want to heat the low spots

[jaybridges]

Thanks for the channel, it's awesome and very inspiring. I really hope you can include some tips on lining up the front of the fenders to the grill and bumper to avoid the droopy eyebrows that some of the x series develop. Love your work.

[tonymontana]

Thanks for another installment Howard. She's coming along slowly but surely.
Regarding the panel pillow, I used to use Armaflex copper pipe insulation. The thickest you can get. Slice it down the middle, slip it over the rails then just tape the ends and one in the middle.
Does the job just fine.

[peterhawkins]

Panel beating and black magic have a lot in common, you have the gift.

[Jim-hvql]

Love the old table idea for the front fenders, differently going to keep an eye out at my recycling center for one. My original fenders will require all the tools you used x 3. They are bad, so bad I ended up buying new ones, but now I might give it another go after watching your video. Cheers Howard.

[BluesShed]

Thanks again Howard for the education I will definitely be using the be using the file and guard rolling technics on my XC Ute build I wish I had rolled the guards on the GXL but that car is complete now so I’ll just accept the occasional scrapping of tyres 😅
Cheers mate

[daviddeakin]

Thanks for showing all the different techniques. Always gain some knowledge when i watch your videos

[Boogz-gdlo]

I used to use brickies bolsters for chasing out dents on swages from the inside . Welded different size round bar or pipe on the tips to conform to the shape. Great vids nice job too👌

[coolstore]

Well done I’m enjoying the series the XA rear bumper turned up in record time to nz fits well.

[mickmeaney]

How the hell did I never think of that timber block trick ... Bunnings fold up table which I'll be happy to drill holes in and that will be a very handy sacrificial tool. Great idea Howard! Also like that panel pillow thing. I imagine it allows panels to sit more securely and take out the wobble. Do they work well? Huge thanks once again. Love your work.

[michaelbyrnes]

I just went to the TWO dollar shop and got kids foam pool noodles for my panel stands and rapped in electrical tape works great 👍

[geoffegan]

just on using a file to check for dent's. when I check I use an oil stone as it doesn't harm the metal. I used to repair Toyota panels straight off the press. it's one of the techniques.

[poydapoyderson]

Absolute magic as usual. Taking a lot out of it. Love the tackling the crap bits like behind that plenum grill, often not dealt with. I have two genuine GTS guards for my ute which have so many old repairs i can't tell what's high and what's low. Any advice for battered stuff like that? Also i use the thick pool noodle for panel stand, just run Stanley knife down the length and push on. cheap enough and much tougher than the thin slip on rubber. I use the same noodle and technique for the hoist ramps to save my head.

[peteredmonds]

Awesome detail as always Howard.
Finally I found something I can do as well as Howard Astill (dropping panels off the stand).
I’m about to redo my two XC guards as I’m not happy with the fit & finish, is there anyone that makes a lower repair section that has the correct reverse curve, as the rare spares one is too flat.
Cheers
Pete Edmonds
PS - had to get my GXL towed for the first time ever, from the Unanderra exit road. Rare spares mechanical fuel pump - 6 months old.