1960 Falcon Belly Pan Replacement

[Bob rigney]

I'm renovating a 1960 22' Falcon and am at the belly pan replacement stage. I researched and then unsuccessfully attempted to cut and install the back panel, having problems with the radius. BTW - I was unable to salvage the original belly pan, so I had no template to use. Any assistance in helping either to better understand how to fabricate and install the belly pan or even suggest someone who can perform the service within a short drive distance from Louisville, KY would be greatly appreciated.

[Bubba L]

Bob, for me, that was one of the most difficult parts of our renovation. I’ve read some theads where the guy breezes thru the belly pan corners . Not me. Anyway, I had some chilled water jacketing that I made a test template. This jacketing is thin corrugated aluminum with thin cardboard on one side. It is thin and holds its shape. I used 2’-6” strips of 5052 .032 for the perimeter edge of the belly pan. I will finish off with a wide piece down the middle. I did this mainly to get to the tanks in the future if needed. The radius corners have to be slit so the aluminum will bend in two different directions. On our 55 Flying Cloud reno thread I show this starting on post #67. But like I indicated, I’m a rookie compared to some of the guys here. But it did come out looking like it’s supposed to. Good luck, Bubba

[Bob rigney]

Thank you for the feedback, Bubba.