1966 Mustang Coupe Restomod

rusty428cj

Rusty Gillis
This is what we are starting with. There is not a lot of rust but since Ford did not prime a lot of the inner structure we will be removing all the sheetmetal do any needed rust repair and epoxy priming. The plans are to install Rod & Custom front and rear suspension, Wilwood brakes, Currie 9", AOD and a 347. The body mods will be fender flares, drip rails removed, cowl vents filled in and maybe a few other things as we go.

DSCN0651_zpsyrrctx59.jpg


One of the first things we did after bracing the body was to remove the cowl

DSCN0668_zps5qfpl1ed.jpg


The quarter panels were removed

DSCN0678_zpsfmirr3go.jpg


The roof was also removed and there was only surface rust but in a few years it will get worse if it is not cleaned up now

DSCN0692_zpsb3jcn1vv.jpg
 
I'm sure a lot of you are wondering why do we remove all the sheetmetal. The quarters were replaced at one time and we did not trust the workmanship and once they were removed we found rust in the outer wheelhouse. The roof was removed because Mustangs are known to rust in the inner structure in the front by the top of the A pillar. In this case we were lucky and only had surface rust but over time would became holes. The other area on coupes is the sail panel inner structure and we did find rust. A little rust on the left side but the right side had a few small rust holes starting.

DSCN0714_zps8flekmil.jpg
 
New firewall and cowl was sanded and epoxy primed

DSCN0601_zpsnvtkufya.jpg


DSCN0602_zps4nhse7zj.jpg


The cowl side panels and A pillars needed to be replaced

DSCN0727_zpsulmzjctf.jpg


Test fitting

DSCN0744_zpsppnm5etu.jpg
 
Do you have any dimension charts to go by? I see you guys do this all the time and without all the dimensions for the car you are working on that would be, IMO, almost impossible without knowing what the measurements are suppose to be. Especially how far you dismantle the vehicles. Your work and attention to detail are surely impressive.
 
DATEC;n72886 said:
Do you have any dimension charts to go by? I see you guys do this all the time and without all the dimensions for the car you are working on that would be, IMO, almost impossible without knowing what the measurements are suppose to be. Especially how far you dismantle the vehicles. Your work and attention to detail are surely impressive.

We made two jigs one for the 65 and another for a 69 that has the correct factory suspension mounting locations. We mounted a good body on this and attached several upright supports to the front and rear frame rails. We also have several Mustangs in the shop to compare the measurements to.
 
Lower cowl welded in place

DSCN0849_zpsadjpr1bd.jpg


The welds were ground down and epoxy was brushed on

DSCN0851_zps1sv5d3dp.jpg


Upper cowl fit and welded

DSCN0854_zpsof24gag8.jpg


Fender apron to cowl extensions welded in place and started to test fit the roof after it was sanded and the back side epoxy primed

DSCN0860_zpsyl9p7kox.jpg
 
Dam nice and clean job, I can't hardly imagine a rust problem now. Seems to be moving along nicely.
 
Very nice work Rusty. It's interesting to me that customers are willing to invest into these cars. And.. you never seem to run out of them.

I'm not knocking the Mustang itself, just wrapping my head around the money it takes to finish one right vs. the average selling price.
 
"And... you never seem to run out of them"

I don't think I worded that right. I understand why you keep getting them because your procedures and quality is spot on. It just seems like they would dry up after awhile.
 
Brian has done a lot of work since I last posted

The rear frame rails had a little rust and needed to be replaced

DSCN0859_zps14tmldnz.jpg


DSCN0867_zpsfoh60jbn.jpg


Test fitting the trunk floor and gas tank

DSCN0870_zpshgzls9dn.jpg


Plug welding the trunk drop offs

DSCN0873_zpsr6h8lznj.jpg


DSCN0888_zpsbs2beg0p.jpg


Fitting the rear package tray and sail panels

DSCN0885_zpsl3suurp6.jpg


The quarter panels were shaped wrong and had to be modified

DSCN0934_zpsjeqehrgd.jpg


DSCN0938_zpsgodqym4k.jpg


Fitting the taillight panel and end caps

DSCN0939_zpsr3vxrqbb.jpg


Left outer wheelhouse welded in place

DSCN0954_zps49ny4ubk.jpg


The right side was to long and had to be modified

DSCN0955_zpst3w89xgp.jpg


Starting to weld the sail panels

DSCN0969_zps61qgehht.jpg


Rear panel welded in place along with the sail panels

DSCN0978_zps2hlh596m.jpg


DSCN0980_zps69dwomyx.jpg
 
Wow! thats amazing - its a whole new car. So my 66 mustang project will not receive the awesome Rusty "royal treatment" that you provide but I'm wondering about recommendations of replacement panel companies you use ?

I either need new replacement stuff like compete trunk lid, fender lip or quarter panel patches or make them for the small stuff or find original used metal. I've never done a mustang so not sure of best products to pursue - any advise is much appreciated !

Thanks,
Evan
 
Very nice work indeed. The only way to do it and know it will last another 50 years or more. Rusty you guys have built enough of these cars that you know where the rust is hiding. I've learned a lot just by looking at the photos. Thanks for sharing.
 
edp;n73956 said:
Wow! thats amazing - its a whole new car. So my 66 mustang project will not receive the awesome Rusty "royal treatment" that you provide but I'm wondering about recommendations of replacement panel companies you use ?

I either need new replacement stuff like compete trunk lid, fender lip or quarter panel patches or make them for the small stuff or find original used metal. I've never done a mustang so not sure of best products to pursue - any advise is much appreciated !

Thanks,
Evan

I'm a Dynacorn dealer so I order direct from them for panel replacement or NPD for smaller patch panels.
 
The drip rails were removed and welded

DSCN0982_zpskta0qkag.jpg


Welds ground

DSCN1099_zpsffzm0ere.jpg


We still have more work to do inside the car but to stop the surface Brian sanded it down to bare metal

DSCN1110_zpsqyj4yyzn.jpg


I sprayed two coats of SPI black epoxy and it is back in the fab shop

DSCN1120_zps9kcn3gzz.jpg
 
Brian is welding the rear floor and modifying the inner wheelhouse for more tire clearance.

DSCN1000_zpsutcdojfy.jpg


DSCN1044_zpslmpgkm7h.jpg


Rear bulkhead panel welded in place

DSCN1124_zpswbq7nlfp.jpg


Welds ground and interior sanded and ready for SPI epoxy

DSCN1285_zpsh93ntx8e.jpg
 
We had a major set back. Brian lined up the doors but when he went to line up the fenders and hood he found a major problem. A former employee welded the front end on wrong even though he measured and remeasured before welding. There was very little gap on the left door and a large gap on the right side so the front end had to be cut off. After working on this about two weeks at my expense Brian is satisfied with how it lines up and we should be able to start charging the customer again early next week.

DSCN1505_zpsw7etyowk.jpg


DSCN1506_zpsqw3y43yp.jpg


The replacement outer torque box had to be modified to get it to fit.

DSCN1509_zpshwrfkidu.jpg
 
Back
Top