1965 Mustang rust repair

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

  1. i counted the spot welds ,just in removing the cowl it was somthing like 180
    spot welds that i had to drill .i think thats why my shoulder pops and cracks the way it does,an ice pack helps a little, its not to good on the hands either .i know the pain
     
  2. 167 on mine-and it only took one $5 harbor freight spot weld tool to get the job done.

    Cowlventrepair022.jpg
     
    brightbill likes this.
  3. looks like you got off lucky , the last couple i did the spot welds were stacked 2 -3 times overlaped making one long weld,they must have been bored or just playing around with the welder
     
  4. rusty the work you guys are doing just blows a us away, speaking of blowing away
    you guys be safe in that storm over there
     
  5. any progress on this one?
     
  6. We have not made a lot of progress on this project. Brian fit and welded the strut rod and sway bar brackets

    275.jpg

    276.jpg

    I epoxy primed the engine compartment

    282.jpg
     

    Attached Files:

    • 275.jpg
      275.jpg
      File size:
      128.4 KB
      Views:
      38
    • 276.jpg
      276.jpg
      File size:
      121.6 KB
      Views:
      40
    • 282.jpg
      282.jpg
      File size:
      106.3 KB
      Views:
      39
  7. All right, an update. Looking really good Rusty!:nice:
     
  8. I sanded the front valance, headlight buckets, and end caps down to bare metal than epoxy primed.

    285.jpg

    288.jpg

    I block sanded than did a little bodywork.

    289.jpg

    290.jpg

    Next another coat of SPI epoxy to seal everything

    291.jpg

    293.jpg

    I sprayed a couple of coats of Slick Sand

    296.jpg
     

    Attached Files:

    • 285.jpg
      285.jpg
      File size:
      90.1 KB
      Views:
      42
    • 288.jpg
      288.jpg
      File size:
      92.6 KB
      Views:
      43
    • 289.jpg
      289.jpg
      File size:
      94.6 KB
      Views:
      41
    • 290.jpg
      290.jpg
      File size:
      88.6 KB
      Views:
      42
    • 291.jpg
      291.jpg
      File size:
      97.6 KB
      Views:
      37
    • 293.jpg
      293.jpg
      File size:
      88.8 KB
      Views:
      43
    • 296.jpg
      296.jpg
      File size:
      85 KB
      Views:
      41
  9. Now the fun begins! This has to be made piece by piece and Brian is not happy.

    298.jpg

    299.jpg

    300.jpg

    301.jpg
     

    Attached Files:

    • 298.jpg
      298.jpg
      File size:
      120.6 KB
      Views:
      43
    • 299.jpg
      299.jpg
      File size:
      123 KB
      Views:
      38
    • 300.jpg
      300.jpg
      File size:
      121.6 KB
      Views:
      37
    • 301.jpg
      301.jpg
      File size:
      122.1 KB
      Views:
      40
  10. Brian may not be happy, but I'm always impressed with his skills.
     
  11. Now Brian has to fabricate the windshield post

    302.jpg

    303.jpg

    305.jpg

    306.jpg

    307.jpg

    311.jpg

    312.jpg

    313.jpg

    314.jpg

    316.jpg

    317.jpg

    318.jpg

    319.jpg

    320.jpg

    321.jpg

    322.jpg

    323.jpg

    324.jpg
     

    Attached Files:

    • 302.jpg
      302.jpg
      File size:
      117.2 KB
      Views:
      44
    • 303.jpg
      303.jpg
      File size:
      114.6 KB
      Views:
      39
    • 305.jpg
      305.jpg
      File size:
      116.6 KB
      Views:
      51
    • 306.jpg
      306.jpg
      File size:
      104.6 KB
      Views:
      40
    • 307.jpg
      307.jpg
      File size:
      103.1 KB
      Views:
      35
    • 311.jpg
      311.jpg
      File size:
      123.3 KB
      Views:
      38
    • 312.jpg
      312.jpg
      File size:
      129 KB
      Views:
      36
    • 313.jpg
      313.jpg
      File size:
      118.1 KB
      Views:
      38
    • 314.jpg
      314.jpg
      File size:
      123.1 KB
      Views:
      42
    • 316.jpg
      316.jpg
      File size:
      106.6 KB
      Views:
      43
    • 317.jpg
      317.jpg
      File size:
      104.1 KB
      Views:
      39
    • 318.jpg
      318.jpg
      File size:
      106.9 KB
      Views:
      42
    • 319.jpg
      319.jpg
      File size:
      107.9 KB
      Views:
      42
    • 320.jpg
      320.jpg
      File size:
      114.4 KB
      Views:
      41
    • 321.jpg
      321.jpg
      File size:
      127.6 KB
      Views:
      42
    • 322.jpg
      322.jpg
      File size:
      124.9 KB
      Views:
      40
    • 323.jpg
      323.jpg
      File size:
      100.5 KB
      Views:
      40
    • 324.jpg
      324.jpg
      File size:
      94.8 KB
      Views:
      36
  12. wish i knew you needed that post, had it left over from the coupe to fast back
    conversion .it was 67 but its pretymuch the same thing .
     
  13. Brian replaced the inner and outer cowl

    325.jpg

    326.jpg

    327.jpg

    329.jpg
     

    Attached Files:

    • 325.jpg
      325.jpg
      File size:
      112.3 KB
      Views:
      41
    • 326.jpg
      326.jpg
      File size:
      108.1 KB
      Views:
      38
    • 327.jpg
      327.jpg
      File size:
      116.1 KB
      Views:
      41
    • 329.jpg
      329.jpg
      File size:
      121.1 KB
      Views:
      38
  14. At one time somebody had drilled extra holes in the dash for a radio. We had an old dash that was replaced on another car so Brian cut it out and installed in this car.

    331.jpg

    332.jpg

    333.jpg
     

    Attached Files:

    • 331.jpg
      331.jpg
      File size:
      125.5 KB
      Views:
      38
    • 332.jpg
      332.jpg
      File size:
      105.5 KB
      Views:
      43
    • 333.jpg
      333.jpg
      File size:
      110.9 KB
      Views:
      36
  15. The world needs more Brians!
     
  16. Brian welded the roof back on.

    334.jpg

    335.jpg

    Now the rust repair begins on the roof.

    336.jpg

    339.jpg
     

    Attached Files:

    • 334.jpg
      334.jpg
      File size:
      132 KB
      Views:
      43
    • 335.jpg
      335.jpg
      File size:
      112.6 KB
      Views:
      43
    • 336.jpg
      336.jpg
      File size:
      111.4 KB
      Views:
      39
    • 339.jpg
      339.jpg
      File size:
      104.1 KB
      Views:
      45
  17. More rust repair on the roof

    341.jpg

    342.jpg

    344.jpg
     

    Attached Files:

    • 341.jpg
      341.jpg
      File size:
      106.8 KB
      Views:
      46
    • 342.jpg
      342.jpg
      File size:
      116.5 KB
      Views:
      45
    • 344.jpg
      344.jpg
      File size:
      117.1 KB
      Views:
      42
  18. Wow, obviously Brian being happy or not has no effect on the quality of his work, that is just amazing work.
     
  19. Brian finished the last rust repair now he has a lot of grinding to do.

    345.jpg

    346.jpg
     

    Attached Files:

    • 345.jpg
      345.jpg
      File size:
      111 KB
      Views:
      40
    • 346.jpg
      346.jpg
      File size:
      116.3 KB
      Views:
      44
  20. Brian ground the welds than I went over the area with Duraglas than epoxy primed

    348.jpg

    350.jpg

    351.jpg

    353.jpg
     

    Attached Files:

    • 348.jpg
      348.jpg
      File size:
      113.6 KB
      Views:
      37
    • 350.jpg
      350.jpg
      File size:
      95.9 KB
      Views:
      37
    • 351.jpg
      351.jpg
      File size:
      104.6 KB
      Views:
      43
    • 353.jpg
      353.jpg
      File size:
      100.2 KB
      Views:
      43