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The Rustbucket Report

Discussion in 'Ford Falcon' started by Rodbender, Apr 25, 2020.

  1. Rodbender

    Rodbender Member

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    So, the new plan is to attach the donor front end onto the rear half of the car. I had to remove the inner frame rails to get the donor piece ready. Also, I wanted to repair as much of the rusted areas as possible before I attached it. Apparently, someone thought it was a race car in it's past as the roll bar mounts were still there. ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_s960x960_87100192_1021651c813bafaf59c7dbbc2385ae169675e.jpg ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_87754369_10216643171971a69df6fdbf627ed776050d18bff22d32.jpg ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_87084354_102165817351551069c3ebfd4fdfcd35130f823439f248.jpg
  2. Rodbender

    Rodbender Member

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    The inner frame rail sections had to go on the donor piece. The next few shots show a progression of that work and the "saving" of what would be needed in the future when it comes time to reassemble the two halves. I love making replacement pieces for these old bombs. Here's a couple. The donor also came with the windshield washer option. Score! ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_s960x960_89039244_10216722861401eedf1fe37434d0affd44353.jpg ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_87448926_10216616314260057445a7b3bf2008c295801f09846eec.jpg ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_s960x960_87480039_102161c63552ced420acaf4b7d8e1e87e4b18.jpg
    Dominick 1 likes this.
  3. Iowan

    Iowan Well-Known Member Respected Member

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    I did bodywork for forty years and the last twenty building gems from turds. At the time I enjoyed the challenge but looking back it was one hell of a lot of work. The last car I did was 1900 hours of work.
    Rodbender likes this.
  4. Rodbender

    Rodbender Member

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    Thanks everyone for your comments. It's always nice to share experiences with people who share the same interests. It's been busy. I've been a mowing fool lately and the old Mustang needed some attention in the form of a 5 speed. Here's a couple more on ascontent.fpia1_1.fna.fbcdn.net_v_t1.0_9_87450504_102166163351eda73e81b7cb5e88ed7afe1d2db4afa1.jpg the progress. One is the lost screw for the visor clip. Second pic was the washer pump. (Sorry. redundant).Last is the removal of the windshield and the start of the dash disassembly. ascontent.fpia1_1.fna.fbcdn.net_v_t1.0_9_s960x960_89039244_102537af9c809db326e073f91952dea9a6e.jpg ascontent.fpia1_1.fna.fbcdn.net_v_t1.0_9_87754369_10216643171911c8722a785c86d70be73585018869d0.jpg
  5. Rodbender

    Rodbender Member

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    In order to swap front sections, everything had to go from the dash. On rainy days, I work in the garage, no precipitation and I worked on the donor section in the yard. The first pic shows the dissection of the rocker and inner frame rail on the donor. The section pictured in the second pic, had a slight bow to it and needed straightening. ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_87460571_102166692845843fd75c8c693cf4f1658784538817ad9c.jpg ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_s960x960_88132413_10216d3ec7f0a843e5800840d0b2894c7fcc3.jpg ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_88988852_10216652211557c5fb9ab8fcf1d4d202ea2c8cf486a1e6.jpg
    Iowan and Action like this.
  6. Rodbender

    Rodbender Member

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    There was a substantial amount of metal to cut out of the rockers and inner frame rails. The trick was how to drill the spot welds out of the pieces to be able to weld them together later. ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_87464236_102166854478281b52e9f67d8218736b909856d77b9ca3.jpg ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_86874644_1021668544902805c2062f94163e738860f33032551e10.jpg ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_87636343_10216707493459723b48808c249e22a9b688cd4964adc9.jpg
  7. Action

    Action Moderator Staff Member Respected Member

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    Thanks so much for the pics.

    Every time you post I am so thankful for the rust I don't have!

    Keep up the good work. You deserve a medal!

    >>>>>>Action
  8. Rodbender

    Rodbender Member

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    You're welcome! I haven't been working on the car much lately, but I'm still behind on posting the pics and my commentary. I hope that some people will realize what can be done to save a car.
  9. Rodbender

    Rodbender Member

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    As previously posted I had the door pillar that was pushed in a little. I made a simple puller with some 3/8 all thread a few washers, a 1/4 thick plate and a length of 2x4 steel tubing. ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_s960x960_88977296_102161d9b9ce38f43acf8079e1afba021fe11.jpg ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_s960x960_89035606_1021634f415847d6a0561964e2705ff45c1a3.jpg
  10. Rodbender

    Rodbender Member

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    In order to stitch the body halves together, all the rockers and inner frame rails had to go. This meant drilling the spot welds on the toque boxes and carefully removing them to put back in later. Shown is the Vivco spot weld cutters and the Blair. Notice the Vivco that's broken. Used maybe 20 times and shattered. Both are good in different applications. ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_s960x960_89823218_10216ef970a186d30d886da2456239cc2f30b.jpg ascontent_ort2_2.xx.fbcdn.net_v_t1.0_9_s960x960_89112612_102163d37f0fbb469f49deb376581a56966b9.jpg

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