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dennis111 11-27-2010 03:45 PM

65' Mustang GT
 
Rather than crap all over Gydyup's thread, I thought I should start my own. Due to a mishap at the track I needed to replace the RH front fender which was damaged in 3 places:

http://i113.photobucket.com/albums/n...BadTire002.jpg

http://i113.photobucket.com/albums/n...BadTire001.jpg

Since the paint on the car is over 30 years old with some scratches and the normal fading, I decided to give the body a complete winter makeover. First I removed the tranny and motor, then the interior. Finally I removed the windshield, doors and the front cap. Here is an early November shot:

http://i1132.photobucket.com/albums/...ild2010003.jpg

Since I did not know the condition of the cowl vent area, I decided that I needed to start there. I drilled out 167 spot welds and found that the hats were in great shape.

http://i1132.photobucket.com/albums/...sealant011.jpg

Unfortunately there were other problems that dictated I replace some sheet metal:

http://i1132.photobucket.com/albums/...trepair002.jpg

http://i1132.photobucket.com/albums/...trepair005.jpg

I ordered 2 cowl replacement panels from CJ Pony parts:

http://i1132.photobucket.com/albums/...trepair007.jpg

http://i1132.photobucket.com/albums/...trepair008.jpg

I then proceeded to cut out the offending metal and trimmed my patches to fit:

http://i1132.photobucket.com/albums/...trepair009.jpg

http://i1132.photobucket.com/albums/...trepair011.jpg

You never have enough vice grips for this type of job. :)

I tacked it into place with my mig welder, then kept going over it until all the holes and seams were plugged. Next I brazed over the welded areas to fill any remaining pinholes that were in the pan area:

http://i1132.photobucket.com/albums/...trepair015.jpg

After the grinding was done, I needed to strip the rest of the paint with my DA:

http://i1132.photobucket.com/albums/...trepair001.jpg

http://i1132.photobucket.com/albums/...trepair016.jpg

I then used body filler to blend the new seams:

http://i1132.photobucket.com/albums/...trepair019.jpg

Before I could go on, I needed to repair a couple of rust areas on the upper cowl:

http://i1132.photobucket.com/albums/...trepair017.jpg

http://i1132.photobucket.com/albums/...trepair018.jpg

I cut out the rust and butt welded scrap metal in place:

http://i1132.photobucket.com/albums/...trepair025.jpg

Once done to my satisfaction, I stripped the remaining paint off both the bottom and the top of the cowl:

http://i1132.photobucket.com/albums/...trepair022.jpg

http://i1132.photobucket.com/albums/...trepair024.jpg

dennis111 11-27-2010 03:58 PM

Re: 65' Mustang GT body restoration.
 
This morning I started with this:

http://i1132.photobucket.com/albums/...trepair021.jpg

I masked it off:

http://i1132.photobucket.com/albums/...sealant021.jpg

Then I applied the epoxy primer to both it and the inside of the upper cowl:

http://i1132.photobucket.com/albums/...sealant016.jpg

http://i1132.photobucket.com/albums/...sealant015.jpg

Once it was setup, time for some seam sealer around the cowl hats:

http://i1132.photobucket.com/albums/...sealant012.jpg

http://i1132.photobucket.com/albums/...sealant013.jpg

I allowed the sealant time to setup, then the real fun began when I laid down 3 coats of Rangoon Red acrylic enamel:

http://i1132.photobucket.com/albums/...painted010.jpg

http://i1132.photobucket.com/albums/...painted003.jpg

http://i1132.photobucket.com/albums/...painted006.jpg

Sometimes it is a shame to hide all that good craftsmanship inside where no one will ever see it again:

http://i1132.photobucket.com/albums/...painted015.jpg

FEandGoingBroke 11-27-2010 04:11 PM

Re: 65' Mustang GT body restoration.
 
Going to be a shame to get spot weld splash all over that nice pretty paint :(

Where is the Ground contact coming from during re-installation?

dennis111 11-27-2010 04:26 PM

Re: 65' Mustang GT body restoration.
 
Quote:

Originally Posted by FEandGoingBroke (Post 1609110)

Where is the Ground contact coming from during re-installation?

Just had to remove the tape to reveal some shiny metal that will get a couple of coats of weld through primer before reassembly. :)

http://i1132.photobucket.com/albums/...painted012.jpg

Topside remains bare metal.

FEandGoingBroke 11-27-2010 04:33 PM

Re: 65' Mustang GT body restoration.
 
excellent! I missed that!

dennis111 11-29-2010 03:14 AM

Re: 65' Mustang GT body restoration.
 
Remasked and sprayed weld through primer on the bare metal:

http://i1132.photobucket.com/albums/...uprimer001.jpg
http://i1132.photobucket.com/albums/...uprimer002.jpg http://i1132.photobucket.com/albums/...uprimer003.jpg

Welding up holes in the front apron. Found that a 3/8" thick piece of solid copper works wonders when plugging small holes or as a preventative to blow through:

http://i1132.photobucket.com/albums/...uprimer005.jpg

Yeah, I went too deep with the spot weld tool and need to touch up the divots prior to welding the apron-to-cowling top plate.

n2omike 11-29-2010 04:20 AM

Re: 65' Mustang GT body restoration.
 
Wow, you've got one EXTREMELY winter ahead of you! :)

Looks Great, and good luck!

dennis111 12-05-2010 04:37 PM

Re: 65' Mustang GT body restoration.
 
Throughout the week I've been tack welding the cowl in place and finally finished it up yesterday:

http://i1132.photobucket.com/albums/...dedbare001.jpg http://i1132.photobucket.com/albums/...dedbare006.jpg http://i1132.photobucket.com/albums/...dedbare007.jpg

Note that the tape is over the vent to help cut down on the amount of grinding and sanding crap that might fall in there.

Today I broke out the DA sander and went to town on the roof. 3 hours later It was bare (except for around the rear window.) There is some repair work to be done on the driver's side roof where apparently someone sat on it in the past. Although the dent covers a somewhat large area, it is minor and an easy repair.

http://i1132.photobucket.com/albums/...dedbare002.jpg http://i1132.photobucket.com/albums/...dedbare004.jpg http://i1132.photobucket.com/albums/...dedbare005.jpg

The rear glass removal is being saved as an evening, after work project.

The car looks kind of cool in its current 2 tone appearance:

http://i1132.photobucket.com/albums/...dedbare010.jpg

Hope to get the roof repaired and all the current bare metal primered this coming weekend.

Oh, here is a shot of the cheap $5 spot weld tool that I used when removing the cowl:

http://i1132.photobucket.com/albums/...rimered001.jpg

It worked terrific. This one tool cut 167 spot welds plus it was used to make holes in the patch panels before plug welding.

dennis111 12-12-2010 03:59 PM

Re: 65' Mustang GT body restoration.
 
Removed the rear window and found scaly rust in the channel:

http://i1132.photobucket.com/albums/...rimered005.jpg

Attempted to wirebrush it but all it did was burnish the rust so that it was shiny. I ran to our nearest farming supply and purchased this $10 spot sand blaster and some media:

http://i1132.photobucket.com/albums/...rimered006.jpg

http://i1132.photobucket.com/albums/...rimered013.jpg

I did a decent job, but I had to fill the bag at least 40-50 times to do the bottom channel. Unfortunately I found some rust holes that need repair:

http://i1132.photobucket.com/albums/...rimered015.jpg

Not wanting to let the roof and cowl remain bare another couple of weeks (Christmas is coming, you know) I went ahead and repaired the dings in the roof by first doing some hammer and dolly work. Once it was fairly level, I covered the offending areas with lightweight body filler:

http://i1132.photobucket.com/albums/...rimered008.jpg

Once it was sanded to my satisfaction, I masked off much of the car in preparation for the epoxy primer coat:

http://i1132.photobucket.com/albums/...rimered017.jpg

http://i1132.photobucket.com/albums/...rimered018.jpg

I wiped it down with wax and paint remover and then shot on 2 wet coats:

http://i1132.photobucket.com/albums/...rimered021.jpg

http://i1132.photobucket.com/albums/...rimered019.jpg

I waited a couple of hours for the epoxy primer to dry and then I covered it up with 3 coats of primer surfacer. Once it set up, I removed the masking:

http://i1132.photobucket.com/albums/...rimered025.jpg

http://i1132.photobucket.com/albums/...rimered026.jpg

As seen below, I did not primer the complete roof sail panels as I need to do some work in in the rear window channel and I need to re-mig the area where the roof joins the quarter panel, at the quarter window:

http://i1132.photobucket.com/albums/...rimered027.jpg

http://i1132.photobucket.com/albums/...rimered012.jpg

Next up will be stripping the quarter panels and then making the wheel flair opening a little wider at the front for taller slicks.

frdnut 12-12-2010 07:37 PM

Re: 65' Mustang GT body restoration.
 
Damn Dennis is there anything you can't do?..Now it's bodywork and paint..:D

gbic1 12-12-2010 10:48 PM

Re: 65' Mustang GT body restoration.
 
Nice work:tup:

FEandGoingBroke 12-13-2010 10:07 AM

Re: 65' Mustang GT body restoration.
 
Looking good!

dennis111 12-13-2010 01:23 PM

Re: 65' Mustang GT body restoration.
 
Quote:

Originally Posted by frdnut (Post 1611528)
Damn Dennis is there anything you can't do?..Now it's bodywork and paint..:D

Didn't you know that I am a Renaissance man? http://i113.photobucket.com/albums/n.../lmaoonflr.gif

Nah,

I'm just a jack(off) of many trades but master of none.

Thanks guys for the good words.


http://i1132.photobucket.com/albums/...-burnout-o.gif

cornhauler 12-13-2010 05:28 PM

Re: 65' Mustang GT body restoration.
 
Dennis,
Car's looking good. Looks like fun. What epoxy product are you using? In the past I've used the Omni product (PPG) availible from O'Rielly's. Sometimes it takes a day to get it but at $77.99/gal, hardener $15.99/qt. seems to work pretty good and i like the confidence of that layer of epoxy. Again thanks for sharing!!
don

dennis111 12-13-2010 05:56 PM

Re: 65' Mustang GT body restoration.
 
I too am using Omni products-for the first time. I was a Dupont guy, but my supplier retired. So far I am happy with Omni which is easy for me to get here in the sticks.

Epoxy primer/hardener:

http://i1132.photobucket.com/albums/...rimered016.jpg

Primer Surfacer/hardener:

http://i1132.photobucket.com/albums/...rimered023.jpg

The filler I use is Evercoat Rage Gold. Great stuff, applies well, sands good but is on the expensive side.

Topcoat will probably be plain old hardened Omni Acrylic Enamel. I prefer BC/CC, but Figure that Acrylic Enamel will be the easiest to repair should I have another racing incident, such as dropping a wrench on the fender.


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