1966 Mustang Convertible Restoration

Discussion in 'Classic Mustang Specific Tech' started by rusty428cj, Sep 18, 2013.

  1. rusty428cj

    rusty428cj Member

    Joined:
    Sep 29, 2007
    Messages:
    718
    Likes Received:
    18
    Trophy Points:
    19
    Location:
    Port Richey Fl
    We started this project last year but I have not had the time to share the build. At first this looks like an easy project until you start looking a little closer. It has been sitting a long time and at one time outside.

    DSCN2785_zps96059f1d.jpg

    02_zpsbab6993a.jpg

    05_zps6b27209f.jpg

    The rear of both frame rails need to be replaced

    DSCN2794_zps74dff3f4.jpg

    A little rust in the quarter panels

    DSCN2797_zpsa90d4a28.jpg

    The convertible has an inner torque box and it was rusted under that

    DSCN2798_zps8a7861b0.jpg

    DSCN2799_zpsee72907c.jpg

    DSCN2800_zpsc399e2f5.jpg

    The fender had been patched a long time ago and needed to be fixed

    DSCN3226_zps062441ed.jpg

    DSCN3231_zps15e4c08f.jpg

    DSCN3232_zpsf427a3ee.jpg

    DSCN3234_zpsb37795fc.jpg

    Brian removed the inner brace on both fenders

    DSCN3237_zps3c1097a4.jpg

    DSCN3238_zps52164dba.jpg

    DSCN3239_zps1ab8d5f1.jpg

    DSCN3240_zpsaf05b336.jpg

    DSCN3254_zps0b7d2ddf.jpg

    Sanded to bare metal and I sprayed a couple coats of SPI epoxy primer

    DSCN3250_zps3dd9b068.jpg

    DSCN3288_zps4a16c422.jpg
     
    #1
  2. horse sence

    horse sence Please don't call me Mom
    SN Certified Technician

    Joined:
    Nov 29, 1999
    Messages:
    4,905
    Likes Received:
    322
    Trophy Points:
    163
    Location:
    Wile Coyote's stunt double
    i know how hard it is to do patch work that comes out like that on the front fenders. nice work, i prefer butt welding over lapped panels any time.
     
    #2
  3. rusty428cj

    rusty428cj Member

    Joined:
    Sep 29, 2007
    Messages:
    718
    Likes Received:
    18
    Trophy Points:
    19
    Location:
    Port Richey Fl
    Everything stripped off of the body and mounted on a cart.

    DSCN4427_zps91460c34.jpg

    Quarter panels and trunk floor removed

    DSCN4522_zpsbbf76300.jpg

    Normal problem with the cowl

    DSCN4593_zps412f69a3.jpg

    New cowl sanded and epoxy primed

    DSCN4596_zps58d9c9ab.jpg

    DSCN4600_zpsec0d2f00.jpg

    Engine compartment stripped to bare metal

    DSCN4632_zps939181ff.jpg

    I ordered a new battery apron from CJ's and it did not fit. We had installed one from NPD on Modified Mustangs & Fords project car that fit so I ordered one from them and got the same thing as CJ's. I sent an email with photos to Rick at NPD and he got right back to me and said he would look into it. Rick got with the manufacturer and it is being redesigned so it will fit and we are waiting for the new design.

    We are using this convertible so we can make a jig for another wrecked 1966 convertible we are fixing in the future.

    DSCN5849_zps5c4f09c9.jpg

    The floor had been repaired with fiberglass mat so it was cut out.

    DSCN5852_zps753bacee.jpg

    The torque boxes needed to be replaced

    DSCN5862_zpsec0e6802.jpg

    The rear section of both frame rails were replaced

    DSCN5872_zps62f3e8c6.jpg

    DSCN5878_zps99b1ed72.jpg
     
    #3
  4. 65FBE2

    65FBE2 Member

    Joined:
    Mar 8, 2007
    Messages:
    283
    Likes Received:
    0
    Trophy Points:
    17
    Location:
    Minnasnowta
    Roughly what does it cost to get a restoration on a car like this? Just the body work and paint.
     
    #4
  5. rusty428cj

    rusty428cj Member

    Joined:
    Sep 29, 2007
    Messages:
    718
    Likes Received:
    18
    Trophy Points:
    19
    Location:
    Port Richey Fl
    $50.00 per hour plus parts and materials
     
    #5
  6. rusty428cj

    rusty428cj Member

    Joined:
    Sep 29, 2007
    Messages:
    718
    Likes Received:
    18
    Trophy Points:
    19
    Location:
    Port Richey Fl
    The inner rocker has rust

    DSCN5882_zps6164000c.jpg

    Brian wanted to finish the trunk floor before he fixed the rockers

    DSCN5892_zps7dc326d4.jpg

    DSCN5952_zps179851b1.jpg

    This is what it looked like after Brian took the top of the torque box off

    DSCN5894_zps923ad8f8.jpg

    This is how it looked once the inner rocker was cut off

    DSCN5913_zps8dbf65ef.jpg

    I epoxy primed the back side

    DSCN5950_zps8bf7245e.jpg

    Sanded and ready for epoxy

    DSCN5953_zps0346bc39.jpg

    DSCN5956_zpse639d746.jpg

    Brian had to make this it did not come with the Dynacorn convertible inner rocker

    DSCN6048_zps6176b73b.jpg

    More epoxy and holes drilled on the inner rocker

    DSCN6050_zps0b0eadae.jpg

    Inner rocker installed

    DSCN6052_zps086c83f8.jpg
     
    #6
  7. rusty428cj

    rusty428cj Member

    Joined:
    Sep 29, 2007
    Messages:
    718
    Likes Received:
    18
    Trophy Points:
    19
    Location:
    Port Richey Fl
    Brian had the floor in then marked where he wanted to drill all the holes for the plug welds

    DSCN6258_zps0f6380e8.jpg

    Test fitting one more time and getting it to fit around the trans tunnel in the front than he marked where the subframe was.

    DSCN6272_zps2c057c86.jpg

    DSCN6275_zpse6dfca8a.jpg

    Welded in place

    DSCN6283_zps8d27e546.jpg

    DSCN6284_zpsbba15d14.jpg
     
    #7
  8. rusty428cj

    rusty428cj Member

    Joined:
    Sep 29, 2007
    Messages:
    718
    Likes Received:
    18
    Trophy Points:
    19
    Location:
    Port Richey Fl
    Seat riser installed

    DSCN6300_zpsdee99518.jpg

    Brackets for the rear seat welded in place

    DSCN6329_zps42087a4b.jpg

    Test fitting the rear seat

    DSCN6328_zpsa5f0b421.jpg

    Time to come off the jig

    DSCN6309_zps66de8dd4.jpg

    DSCN6322_zps95d18094.jpg
     
    #8
  9. rusty428cj

    rusty428cj Member

    Joined:
    Sep 29, 2007
    Messages:
    718
    Likes Received:
    18
    Trophy Points:
    19
    Location:
    Port Richey Fl
    Sanded the floor pan

    DSCN7019_zps92678a8d.jpg

    Epoxy primed

    DSCN7024_zps1dd44148.jpg

    Brian wasn't finished welding the undercarriage but we wanted epoxy under the convertible brace before it was welded in place

    DSCN7224_zps62c6fc5f.jpg

    Fitting the quarter and taillight panel

    DSCN7236_zps40a58ded.jpg

    DSCN7251_zpsa872a849.jpg

    I have not been able to find a convertible trunk corner brace only fastbacks and the shape is wrong

    DSCN7253_zps5f6c2122.jpg

    After Brian modified it

    DSCN7283_zpse7f0d518.jpg

    DSCN7298_zpse5fe7816.jpg .
     
    #9
  10. rusty428cj

    rusty428cj Member

    Joined:
    Sep 29, 2007
    Messages:
    718
    Likes Received:
    18
    Trophy Points:
    19
    Location:
    Port Richey Fl
    Ready for epoxy

    DSCN7357_zps117c56e2.jpg

    Two coats of SPI red oxide

    DSCN7361_zps576d4825.jpg
     
    #10
  11. palerider94

    palerider94 Member

    Joined:
    Feb 21, 2006
    Messages:
    572
    Likes Received:
    1
    Trophy Points:
    19
    Just curious why did you replace rear frame rail section looked solid in pictures. Also is there any easier way to remove inner rockers other than drilling out all spot welds?
     
    #11
  12. rusty428cj

    rusty428cj Member

    Joined:
    Sep 29, 2007
    Messages:
    718
    Likes Received:
    18
    Trophy Points:
    19
    Location:
    Port Richey Fl
    There was a lot of rust.

    Not that I know of without making a big mess and creating more work.
     
    #12
  13. horse sence

    horse sence Please don't call me Mom
    SN Certified Technician

    Joined:
    Nov 29, 1999
    Messages:
    4,905
    Likes Received:
    322
    Trophy Points:
    163
    Location:
    Wile Coyote's stunt double
    The best way of removing pieces is to drill the spot welds .An air chisel or a cutting torch can distort the metal,not to mention cutting through pieces you don't want to cut. It's hard work drilling them but it can be even harder to clean up from a torch or a chisel ,just look how clean Brians work is.
     
    #13
  14. palerider94

    palerider94 Member

    Joined:
    Feb 21, 2006
    Messages:
    572
    Likes Received:
    1
    Trophy Points:
    19
    Thinking about getting a rotisseries for next project. Did it help with any of the floor welds or do you need to have full floor welded in before putting it on. Getting to old to be laying on my back doing plug welds.
     
    #14
  15. rusty428cj

    rusty428cj Member

    Joined:
    Sep 29, 2007
    Messages:
    718
    Likes Received:
    18
    Trophy Points:
    19
    Location:
    Port Richey Fl
    The floor was welded in on a cart then it was mounted on the rotisserie to finish welding the bottom side and prime.
     
    #15
  16. palerider94

    palerider94 Member

    Joined:
    Feb 21, 2006
    Messages:
    572
    Likes Received:
    1
    Trophy Points:
    19
    So you welded the topside first and then flipped to do spot welds on the inner rockers?

    Great build BTW - Amazed how you can remove whole back end and get everything to line back up.
     
    #16
  17. candphall

    candphall Member

    Joined:
    Jun 8, 2009
    Messages:
    365
    Likes Received:
    23
    Trophy Points:
    19
    Location:
    Orlando Florida
    image.jpg image.jpg A word about spot welds. I am a novice mustang, and I hesitate to use the word restorer, but I am plodding along. Thanks to solid contributors such as Rusty and Horse. I very rarely give advice but in this case I will. If you are removing a panel for replacement and want to save whats beneth it drill the spot welds. Yes it is time consuming but not nearly as much as replacing the panel you damage with an air chisel. My first attempts a drilling were unsuccessful primarily because of the cutter I was using. It was nothing more than a small hole saw. It was good for about three welds if that. All it took was a google search for spot weld cutters. And It returned a set by Blair that I purchased. It is a true cutter and comes as a complete set . Check it out.
     
    #17
  18. robert912005

    robert912005 Member

    Joined:
    Sep 7, 2009
    Messages:
    147
    Likes Received:
    3
    Trophy Points:
    19
    Location:
    Evansville, Indiana
    thoes are very good... I have used spot weld cutters from harbor freight and they work pretty good as well.
     
    #18
  19. horse sence

    horse sence Please don't call me Mom
    SN Certified Technician

    Joined:
    Nov 29, 1999
    Messages:
    4,905
    Likes Received:
    322
    Trophy Points:
    163
    Location:
    Wile Coyote's stunt double
    My cutter is also a Blair. Cadillac of cutters . I have the spring loaded center pin ,it is a little harder to use until you get used to it ,you have to center punch the spot weld . It cuts from one side . My kit goes to 3/4 inch .I bought 3 extra mandrels so i don't have to change the cutters ,unless i break one. but you can buy the cutters separately so no problem .I couldn't do without it.
     
    #19
  20. palerider94

    palerider94 Member

    Joined:
    Feb 21, 2006
    Messages:
    572
    Likes Received:
    1
    Trophy Points:
    19
    yup same one. Blair nice cutters
     
    #20

Share This Page