Project "Chihuahua" '65 Formula S Restoration "Estilo Mexicano"

Update: Encountered an unexpected "glitch" when test fitting the rear window chrome accents--on the passenger side there is a body hole missing (must be due to the sheet metal repair that replaced a rusty corner). As carefully as I could, a measured/compared the hole in the corresponding driver's side and drilled a 1/2" hole, which is slightly smaller than the factory hole (used bits in increments of 1/8" steps). The hole is a little rough, but won't be visible when chrome is attached.

Because the interior trim is already fixed in place, at this point in time, it appears near impossible to attach the inside nuts that will secure the rear window chrome. Well, where there is a will, there is a way.

In the fifth photo, if you look carefully about one inch below the new hole, one can see a line that appears to be some kind of fracture/crack in the metal or paint. That defect was already present before I began this work today. In the last photo, one can see the rusty metal that had been cut out previously.

P.S. I later used a Dremel tool sanding disk to smooth out the rough edges (OCD me).

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Your work is of amazing quality!

I discovered that a "stepped bit" is perfect for drilling holes in sheet metal. Although a bit expensive ($29 when I bought mine), I was thrilled at how easily it drilled a hole in the firewall. Each step centers the hole for the next increasing size. The bit does not chatter like a regular fluted drill bit, thus the hole does not need to be smoothed.

I wish I had purchased a stepped bit long ago.