I picked up the car last Friday and hauled it home on my trailer.
So it is now rust free. Although it has numerous holes from the rust.
damage estimated: firewall rusted out quite a bit. cowl - driver side hat channel rusted out. Floor pans - almost gone. Floor pan over transmission has rust. Both rear quarters have rust on over wheel wells and lower rear areas, tail light panel around tail light bezels rusted out, lower parts of the shock towers rusted out and the inner fender panel tops where the panel overlap are rusted out.
I spent a couple days setting up the jig frame using measurements from the Ford manual and cross referencing them to the car. Some measurements from the book were little different, but the measrements were consistent from driver to passenger, front to back so I don't know if that was differences between the 3 production plants.
I talked to Nate at Thoroughbred GT and he said that when installing the floor pans in early mustangs, the measurements were a little different depending on the assembly plant.
So I leveled up the jig moutning locations and checked them with a spirit level and a laser lavel, then mounted the car on the jig.
although the jig is on wheels, I lock the wheels and do not move it until the major frame work is complete and my panels are lining up.
Here are a few photos.
Last edited by rkmiller73 on Mon Mar 25, 2013 1:54 am; edited 1 time in total
I had to work most of the weekend, but I spent some time in the shop Saturday night.
This took about 4.5 hours with a spot weld drill bit, drill, a 3 lb hammer and a very thin hardened steel masonary chisel.
Now the floor is out and I cleaned up the passenger side front frame extension. I need to get the torque box off the driver side and take off what is left of the driver side frame extension.
Due to limited shop space down here in Texas, I moved the jig for now. I have everything marked on the jig and on the floor to put it back exactly where it was and then I will recheck it before I put the car back on it.
I am debating on if I should take out the inner rocker panel piece - an new inner piece is on the new floor pan assembly. I cut a small hole in the fender well at the back of the rocker to look inside and it doesn't look too bad, but there is a lot of debris still in there.
Last edited by rkmiller73 on Mon Mar 25, 2013 1:57 am; edited 1 time in total
Do not throw anything away until the job is finished. There are lots of little brackets on that floor section you just cut out that you will need. I also keep the seat belt plates that are welded to the floor. That can fit in the roof rails if you want to fit inertia reel seat belts later on.
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