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Discussion Starter #41
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.
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Discussion Starter #42
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!
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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.
 

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Discussion Starter #44
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
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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.
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Discussion Starter #45
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.
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Discussion Starter #46
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.
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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
 

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Discussion Starter #48
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
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.
 

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Discussion Starter #49
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.
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Discussion Starter #50
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.
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Discussion Starter #51
Well, I'm not getting much done on the car because the engine in my mower started blowing by and I'm switching engines. Not to mention the grass mowing and putting siding on the garage. However, here's a couple shots of the donor piece and the new frame rails from KP Automotive. Jerry's a top notch guy there.
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Discussion Starter #52
So, I decided that it would be easier to fix the small holes on the donor front end while it was on the rotisserie. Here's
a couple shots of the start of that.
 

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It's Friday!!!
If it's Friday it must be rust bucket update!!!

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Discussion Starter #55
It's been awhile since I've been able to do much. I've been on 13 hour-6 day shifts since the Early September. However, we are about done for this year. Maybe two more weeks. The latest update is I've bought a 3 stall garage on it's own little lot not far from my house. I still can't believe I got it. My plans are to get the remaining cars and parts into it and out of the weather. The Rustbucket has been put on hold as I have an immense amount of stuff to take care of right now. I'm getting things ready for winter and once everything is tucked away, I will resume my endeavor on the Falcon. As I recall I left off at needing to paint the areas that will be closed off after they are assembled. (inner rockers, inside the frame rails, inside under the seat pans, etc, I'm still looking for some brakes for the nine inch rear end. (Old style big bearing) I have also procured an engine hoist and another engine stand. It's about to get interesting.
 

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Thanks for the update, can't wait to see more progress 👍, keep checking to see if any updates, I know how it is about work and getting other stuff done, just finished a bathroom remodel this past week! Gotta get the Honey do list done first before playing with our toy's 😁
 

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Discussion Starter #58

Here's a couple shots of the start of the repairs to the donor front end. This is the footboard on the passenger side. These were taken late last spring. I move the Cougar, the Ranchero and my old F250 highboy into the new garage next week, Be safe.
 

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It seems like awhile since you have posted. I have missed the rust repairs!!!!!


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