Progress Thread 69 Sheet Metal Repair

Discussion in 'Classic Mustang Specific Tech' started by candphall, Jul 10, 2013.

  1. horse sence

    horse sence Please don't call me Mom
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    yeah if you are talking about the part behind the tire area ,above the toe board ,that is part of the fire wall. i am not sure if that patch is made. it is a real job to replace a fire wall. what you may have to do is buy a fire wall just for patches. toe board patches do not go high enough.
     
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  2. candphall

    candphall Member

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    This is what I need to repair
     

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  3. candphall

    candphall Member

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  4. horse sence

    horse sence Please don't call me Mom
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    yeah, that looks like the fire wall it runs full width of the front of the body, in the wheel well area? you will probably have to buy a full fire wall to make patches from
     
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  5. horse sence

    horse sence Please don't call me Mom
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    the full fire wall has the toe boards in them so one patch can do the fire wall and the toe board in one piece,a lot less cutting and welding
     
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  6. horse sence

    horse sence Please don't call me Mom
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    this is the fire wall ,they look pretty much the same for 64-70 they are slightly different for each year. it is the full front of the car with the toe boards images.jpg
     
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  7. candphall

    candphall Member

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    I got all of the big pieces of the torque box cut out today. All that's left are the welded edges. I started to use an air chisel but punctured the frame on the first pass. So it's grind, grind, grind from this point on.
     
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  8. candphall

    candphall Member

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    So in about ten hours I have removed the passenger side floor a toe board and most of the torque box . I was also successful puncturing the frame with an air chisel.

    In those same ten hours Horse Sense was able to complete about 10 fastback conversions. In addition to that at the end of my project , if I live that long, I will probably discover he lives right around the corner.
     
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  9. horse sence

    horse sence Please don't call me Mom
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    after all those cut fingers,bruises ,burns and cussing,when it is all done.you can look back and say (damn ,i am not going to do that again):lol:
     
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  10. 66Coupe289POWER

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    I'm not going to say how long I have been working on my car...:zzz:
     
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  11. candphall

    candphall Member

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    Does this owner induced gouge require a patch, or just a weld up and grind down? This one portion of the torque box is the most difficult yet. It needs to be ground off completely, there is no better other way I can figure out.
     

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  12. horse sence

    horse sence Please don't call me Mom
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    it looks like it will be inside the torque box and covered up.its small nothing to worry about
     
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  13. candphall

    candphall Member

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    The torque box is officially out all,thatnremainsmis to trim out the remaining floor and clean and prep for replacement. I created son tears in the side bent panel that will need to be patched. The panel that covers the inner rocker that the floor pan attaches to will need a patch where the torque box was attached. But all in all not to bad.

    I have attached photo of some rust thru I discovered on the outside frame rail forward of the door post. I believe it can be patched, it seem local to that area.

    In addition I have included a photo from NPD of an outer firewall extension I believe that this is the piece I need to replace the panel between the outer cowel and the rear engine compartment sheet metal.
    Take a look and let me know your thoughts .
     

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  14. candphall

    candphall Member

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    Frame rail rust. Patch?
     

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  15. 66Coupe289POWER

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    The NPD piece you linked to is not what you need to patch. That part goes at the top of the fender apron and connects it to the cowl behind the hood hinge. Here is a link to the outer rocker patch, it says 65-68 but you should be able to make it work on your car http://www.cjponyparts.com/rocker-panel-extension-front-passenger-side-1965-1968/p/M141R/
    Here is a firewall patch for the right side, it will prob take this and a toe board to patch your firewall http://www.cjponyparts.com/firewall-rt-partial-outer-1964-1968/p/M134R/
     
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  16. candphall

    candphall Member

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    Thanks 66. I also need thisart I believe it is the inner rocker cover
     

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  17. horse sence

    horse sence Please don't call me Mom
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    any flat pieces i would just make from sheet metal
     
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  18. candphall

    candphall Member

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    Those were my initial thoughts. Thanks
     
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  19. 66Coupe289POWER

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    +1 on making it from sheet metal. Just make sure you use the same thickness for the patch. The rockers are pretty thick.
     
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  20. candphall

    candphall Member

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    Discovered today that the blades for the Harbor Freight panel saw will fit the Rigid saw sold at Home Depot. Much cheaper and work just as well. Saw on!
     
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