Opened up the right quarter panel and found this – no surprises… I knew the outer wheelhouse would be munched. Time to cut out the bad stuff and get ready to repair the wheelhouse.

You can see right through the car now! Pulled the quarter window and removed the rest of the quarter panel.

I got the new outer wheelhouse section welded on. Still gotta clean it up some more, grind down the welds, apply seam sealer and Rust Bullet, and it’ll look like the other side.

Just about ready for the new quarter panel section after some more cleaning and ‘stepping’ the Rustang’s sheet metal to fit it on.

Here’s the corner patch after ‘blasting, and all welded in. Fits like a glove.

After getting the corner patch installed, I worked on the tail light panel. Here it is all welded in with the welds ground down. Came out just like it was supposed to… which had me scratching my head for a little while – until I realized that I actually did do everything right and it’s all good.

Used the trunk lid to help line up the tail light panel. Also cleaned off the yellow writing from the junk yard, and decided to make it a ‘Mach 1’ again – Sharpies Rule. LOL!

Popped the quarter extensions on and lined everything up. I’m not saying it’s perfect, but I think I can be really happy with how it came out (with proper alignment of the extensions and everything once the new quarters are on, that is).

After my favorite thing in the world (drilling out spot-welds – yay…) here we are with no more yucky rusted-out metal.

Then, after having a hard time keeping the ‘patch’ piece from the junkyard steady to drill out more spot-welds on it, I decided to use the plasma cutter to just burn through the spot-welds. Things went a lot faster from that point. Here’s the ‘patch’ being test-fitted before media blasting – almost perfect!

While I was having fun test-fitting (and burned out the spot-welds from the old panel on the driver side), I decided to see what it would look like with the new tail light panel in there as well. I’m thinking this is going to work out, after all!

Here’s a shot of the sub-frame connectors welded in – I wish this weld would’ve come out better, but it’s not the worst one, and only one of a few that don’t actually look good. I AM getting better… really.

Got the frame rails cleaned out and painted on some Rust Bullet Black Shell I STILL have left over. That stuff’s awesome! Just did the frame rails and inside of the rear cross member for now since I’ll never be able to get to them again.

After getting the ‘gap’ patch installed, I zapped down the trunk pan after getting it all lined up. Still gotta weld it to the frame rails from underneath, but it’s in there solid now.

Toward the top is the ‘gap’ patch I made for $10. Worked like a champ and got creative using the vise and bent it all into shape. There’s going to be a big ol’ box with a couple of subs riding on top of it someday, so ‘perfect’ doesn’t matter so much to me.

I’m committed now. Tacked in the ‘gas tank hammock’ to keep the frame rails straight, and fired up the plasma cutter, and took out the tail light panel, rear cross-member, and lower rear portions of the quarter panels.

Rear cross member all welded in. Nice and tight fit, thanks to the Redneck Gas Tank Hammock’s last gasp of holding the frame rails together.

Here’s the new trunk pan dropped in for test-fitting. Fits like a glove, except that the sheet metal comes up about 6″ short in the front. Turns out the pan from CJ Pony Parts is about 6″ ‘shorter’ than the one from Ohio Mustang Supply – WTF?! My Bad. Now I gotta fit a new piece of sheet metal in there, bash it into shape, and weld it in before zapping this one down.

Instead of the ‘new Redneck shock mounts’ I came up with a few weeks back, I picked up a reproduction shock mount cross-member for a ’69-’70. It’s too narrow, so I going to graft-in the shock mount ‘pockets’ only. Here we are with the old stuff cut out.

Here are the new shock mount ‘pockets’ tacked in. Still gotta tweak the original cross member a little for final welding (gonna go in through the access holes with a big hammer and MAKE ’em fit – LOL!).

Got the patches welded in, ground down the welds, seam-sealed the air hats and patches before welding, the applied the Rust Bullet Black Shell. Just gotta fold down the cowl and weld it back in place now.

So happy this is finally going back together and those patches fit so well!

Got the cowl folded back down and welded in-place. Then ‘blasted the ‘ends’, treated the insides with Rust Bullet, and welded them down as well. Just gotta grind the welds, zap down the cowl/apron tie-ins and more Rust Bullet and call it done (next Saturday).

The cowl is Done! Got everything patched, cleaned up, and Rust Bullet’d. Now that it’s done, I can move onto the trunk (tomorrow).

Here’s the passenger side – had to patch a couple small places today as well as weld on the apron extensions. Slowly but surely, the ‘new’ look of the car is making its way to the back.

Driver side all cleaned up and made new with Rust Bullet Black Shell. It’s sad that a new coat of Rust Bullet makes the old stuff look… well… old. Gonna clean it all up and spray on another coat later anyway, but it’s protected for now, and that’s the important part.

Got the cowl opened up, and the metal looks pretty good (aside from the ‘normal’ damage around the air hats). Also pulled the windshield – which came out all cracked (which is typical as well).

Test fitting the passenger side cowl patch. Just gotta ‘blast it, clean the edges a bit more, finish cutting out the bad stuff, then zap it down.

Test fitting the driver side cowl patch. I cut this one a little too long – oh well, better than too short. The ‘yard dawgs chunked it out a bit with their Sawz-All taking the front clip off. Gotta repair that before I get it in there for good.

After ‘blasting, repairing the bad spots from where the ‘yard dawgs cut through, and adjusting everything to fit, here we are just about ready to weld in. Just gotta grind smooth the assembly welds and glob on the seam sealer and we’re all set.

Finally got back to the battery tray apron. I had intended on just replacing the whole panel, but one of my friends at 7173 Mustangs.com convinced me to just patch the bad stuff… so here we are. I’ve since ground down the crappy welds on the bottom

Lots going on here over Christmas Break, so here we go:

Tore open the cowl and found this. It’s typical for the cowls on these cars to rust out… but this one’s a little worse than I was expecting. Oh well – got plans to repair it soon, and easier than I originally thought.

Passenger side cowl damage – the air horn was mostly gone, and the latex coating in the shape of an air horn was pretty much what was left. Also got a way to fix this as well.

Here’s my Christmas Present all bolted down and ready for a carb. Edelbrock 2750 Dual-Plane Performer intake manifold. SWEET! The stickers that came with it alone are worth 5 horsepower each – LOL!

Valve covers on after re-checking the adjustment on the roller rockers. Also picked up a Mr. Gasket ported breather, and an Edelbrock breather for the driver side (which will double as the ‘710’ cap. (LOL!)

My pal Jim noticed I didn’t have a fan for it yet, and generously gave me the cut-out from the box for the flex fan he bought for his 1963 1/2 Galaxie 500 XL. I don’t know – doesn’t look like the ‘blade pitch’ is aggressive enough.

Noticed that I had one more heater hose outlet on the water pump than I needed. Gonna hafta figure out what to do about that.

It ain’t cool if the chrome don’t shine. It’s all about the details. I took a page from Jim’s book and polished the emblems for a little extra bling on the cool new intake manifold I got for Christmas.

My Master Mechanic pal Jim hooked me up with the old fan and fan clutch from his 1963 1/2 Galaxie 500 XL after getting a flex fan, and the Holley Black electric fuel pump he had stashed in his garage. Thanks Jim!

After I finished the battery apron, I prepped the floor pans to receive the seat platforms. This is after cleaning the black paint away and spraying down some weld-thru primer.

Got the seat platforms in. I had to modify them to sit lower, since they weren’t the correct platforms, but they work after test fitting the seats. Also, moved ’em back a few inches for more legroom. This picture is skewed a little – because they really are in line.

In another picture, I showed the Redneck Engineered air shocks (because the previous owner bashed through the stock shock mounts). Here’s my solution – took a piece of angle stock, trimmed one side off to make it flat stock, and bent it to mostly fit the contour of the cross-member. Gonna weld it in-place tomorrow

Since the outer edge is just hanging out there with no support, I chopped off a small piece of the left over battery apron and made a support bracket to weld on. Sorry for my crappy old 3.2Megapixel camera’s crappy auto focus.

Here’s the passenger side shock mocked up in-place with the new mount I made. Looks like it should work.

This is the driver side shock mocked up in the bashed-in stock shock mount location. So far, so good.

Moved to the trunk area and this is what we have after removing all the trim and tail lights. Not so bad, but still needs to be removed to fit the trunk pan in there.

Passenger side is a little more damaged, but repairable. I have the junkyard guys cutting the trunk surround out of the same car I stole the front clip from, so it shouldn’t be too bad.

Here’s the damage to the passenger side tail light area. Looks pretty bad, but I have a new piece to replace the bad stuff with.

Here’s yet another piece from the poor ’72 ‘donor’ car at the junkyard. The yard dawg cut it off a little short on the trunk surround (toward the left), so I’ll have to use the other side to graft in more of the weatherstripping channel. It’s all good.

Got the suspension apart and after a little bit of picking, discovered that these old school Lakewood traction bars came in Yellow! (and right now, they’re actually a blah shade of rust)

OK – after ‘blasting for almost two hours (as my back has been so good about reminding me), here we are with a fresh coat of black Duplicolor High Temp Engine Enamel. Painted both so the surface rust doesn’t start coming back before I get them installed next weekend. Gonna run some Rust Bullet through the insides when I get the chance. The picture of the other one didn’t come out so well… but they both look like this.

Here’s the trunk with a better view of the ‘Redneck Gas Tank Hammock’ I’ve been talking about. Yee-hah, Y’all!

Here we are at the end of the day after cutting out the rest of the nasty trunk pan. I decided not to waste my time with the spot-weld removal drill bit and just took the air chisel to the whole thing and separated all the spot welds the hard way. Quite therapeutic, actually.