1965 Mustang rust repair

Discussion in 'Classic Mustang Specific Tech' started by rusty428cj, Dec 16, 2010.


  1. rusty428cj

    rusty428cj Member

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    Brian finished welding the subframe connectors

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    #81
  2. rusty428cj

    rusty428cj Member

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    Brian wanted to keep the original fender aprons so he would have something to line up the new firewall and cowl. Most of the rust was on the bottom and the very top edge. He replaced the bottom and made a few small patches on the right side but still has one small area outlined in black to repair.

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    #82
    Rebelgd likes this.
  3. rusty428cj

    rusty428cj Member

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    Brian test fit the firewall. Marked where the holes where than removed it to grind down that area to bare metal. He also used sheetmetal screws to get a good tight fit before welding.

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    #83
  4. mustangmutt

    mustangmutt Member

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    I noticed in other pics the trans/driveshaft tunnel was removed. Are you just using it now for fitment?
    Also, using sheet metal screws is a real good idea. Not only do they pull things together tightly, when you pull them out and rosette weld the panel to the frame it ensures good penetration.
    #84
  5. rusty428cj

    rusty428cj Member

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    We have been working on another project but Brian had a little time this afternoon and started patching the rear floor.

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    #85
  6. Realmongo

    Realmongo I prefer to be called "Evil Genius" Founding Member

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    It's all comining together really nice!

    What will it have for a powertrain?
    #86
  7. rusty428cj

    rusty428cj Member

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    She had the stock 6 cyl rebuilt with Clifford headers before we started on it.
    #87
  8. Realmongo

    Realmongo I prefer to be called "Evil Genius" Founding Member

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    Be a good candidate for a 5 bolt V8 axle and suspension then.

    Did the engine get one of the clifford exhaust port divider plates?
    #88
  9. rusty428cj

    rusty428cj Member

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    Brian has the floor pan installed in the passenger side

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    #89
  10. rusty428cj

    rusty428cj Member

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    Brian starting rebuilding the drivers side

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    #90
  11. stangman16

    stangman16 Active Member

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    After this point, can you share what you do to the metal to prevent rust before painting? I see slight surface rust on the new patch - do you sand it down completely, wipe off with wax & degreaser, and then epoxy prime?



    #91
  12. rusty428cj

    rusty428cj Member

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    Yes it is so humid here in Florida right now there is surface rust the next day
    #92
  13. rusty428cj

    rusty428cj Member

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    Brian has the floor pan in. He still has to remove the screws and finish welding

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    #93
  14. Fibersport

    Fibersport New Member

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    I'm a new member here who just brought his high school sweetheart home after rusting for 25 years. Reading this post made me realize that I can resurrect my car. Great job and thank you for giving me the realization that anything can be done!
    #94
  15. Realmongo

    Realmongo I prefer to be called "Evil Genius" Founding Member

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    This is about the worst rust-damaged restoration I can ever remember seeing. How many hours of metal work does it take to repair?
    #95
  16. robbz28

    robbz28 Member

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    Anything is possible with enough time and money! I got lots of time, but its that whole money part i dont have figured out yet :shrug:
    #96
  17. Fstbk

    Fstbk Member

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    I have found that the sheet metal parts for these cars are downright cheap, its the install that can cost you if you cant DIY.
    #97
  18. rusty428cj

    rusty428cj Member

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    The floor and the area on the drivers side that Brian repaired is now black epoxy.

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    #98
  19. Federico Garza

    Federico Garza Member

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    Talk about a new lease on life... Ive said it before, you guys do outstanding work thanks for sharing:nice:
    #99
  20. rusty428cj

    rusty428cj Member

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    We have a couple of other projects we need to work on but Brian wanted to finish the trunk area before we stopped.

    Brian started by marking the outline of the frame rail on the back side than drilled his holes for the plug welds

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    Started plug welding but still has the sheet metal screws that will come out and holes welded.

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    Finished welding, grinding and sanding

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    Sprayed SPI epoxy to keep it from rusting

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