Restoration Log Archive

UP IN THE AIR

Posted March 14, 2012 By jack

With the suspension completely removed, I had only to pull out some key steering components before we could mount the Rotisserie. These included the Pitman arm, the steering arm, the power-steering hydraulic pump, and the idler arm. This last piece must be replaced if there is any play where it mounts to the body; otherwise, its fine to keep yours. Ours showed a minimal amount of movement, but we’ll probably replace it in the interest of optimal handling.

Once all this had been completed, it was time to connect the rotisserie clamps. This required many fine adjustments in the height of the car, the width of the rotisserie arms, the tightness of the bolts, etc. (Many thanks to our friend Christian for helping out). When everything was finally dialed in and secured down, we pumped up the car and rocked it like a cradle. We won’t be able to fully spin the car until we line up the axis of rotation with the car’s center of gravity, but that will come soon: I’ve got plenty of work to keep me busy until then.

That vertical column needs to be raised to a higher setting before we spin the car

Goodbye, rear suspension (and good riddance!)

Posted February 23, 2012 By jack

I returned to TLG last weekend to finish the job I had started: rear-end removal.Once the drum brakes were pulled (a process I detailed in my last post), the only parts between me and the differential were the leaf springs.

A view of the differential, with the left spring already lowered

Before these are removed, jack up the rear axle so that it is barely supported; otherwise, you’ll have quite a load on your hands as you drop the springs. The leaf springs are held in place at the rear with a shackle bolt, which consists of two bolts connected with a metal strip/bracket. I unscrewed the two nuts holding this in, and then used a mallet to free the spring of the shackle bolt. Be careful not to leave anything beneath the spring, because it will fall as soon as the bushing is off the bolt. When both springs were detached in the back, the differential was free the come out. I placed this out of the way, undid the bolts at the front of the leaf springs, and started on the shocks.

The bottoms of the rear shocks were disconnected earlier, but the tops were a little trickier. To access these, I pulled out two rubber plugs in the rear floorpan. However, with the entire body resting on 4 jack stands, I didn’t want to risk getting into the car to unscrew the nuts. In order to do this, I ended up crawling into the trunk from beneath (the gas tank was removed earlier) and leaning into the cabin from the rear. This wasn’t as safe, but lowered the risk of rocking the car off its jack stands. If you have any better method, by all means use it.

Access to rear shock mounts

While working on the springs and rear-end,  I found a spot of rust on the rear frame rail that I had never seen when working on the car or inspecting it when we bought it. It’s the largest spot of corrosion there is, and it’s still smaller than my fist.

Rust

At this point, I had pulled everything off of the frame except for a few steering components left in the engine compartment. I didn’t have much time, so I cut the hoses leading to the power steering pump, drained the fluid and called it a day. This is the weekend my car leaves the ground. This is the weekend we mount the rotisserie.

Time Lapse

Posted February 17, 2012 By jack

It appears two months have passed since my last post, a period during which I’ve been to the garage only twice. I meant to post an update after the first visit, but it slipped my mind and I have absolutely no idea what I meant to write on. Something about disc brakes, wheel spindles, ball joints, and completing front-end suspension removal, but let’s not dwell on the past. After a ski vacation, an SAT, the start of lacrosse season, and Model UN preparation, I finally returned to TLG last Sunday to begin rear suspension work. In an attempt to accomplish as much progress as possible, I completely disregarded the heap of parts that need to be inventoried and neglected to use the camera at all. Please excuse the lack of pictures, I’ll include some in the following post.

I began by removing the rear wheels, and then started on the left drum brake (raise the car onto jacks for this). There are a number of springs and cables that work to connect the wheel cylinder and the brake shoes. These must be removed before the shoes can come off. My sources tell me there is a tool for this, but vice grips will do fine if you can manage not to bend the springs. The shoes can then be pulled right off, and the wheel cylinder is removed by undoing four bolts. The most difficult part of dissembling the brakes is removing the parking brake cable from the backplate. There is a metal casing with three tabs that stick out and keep the cable in place like a wall anchor bolt. These tabs must be pushed in and wiggled through the slot to get it out, but there isn’t much clearance. A pair of pliers and some help from Dad did the job. I’ll take pictures to demonstrate this when I work on the right side this weekend.

As I had already detached the brake lines in the rear, the only parts still attached to the differential were the leaf springs. These are connected with U-bolts and a mounting plate on each side, and are easily detached from the rear-end.

Sometime this weekend I’ll go back to remove the differential, and hopefully start on the steering components.

All the more reason to finish my car…

Posted December 6, 2011 By jack

I am now a licensed driver in the State of California, official as of last Monday. If you value your life, stay off of the roads.

I sometimes resort to self-inflicted verbal abuse when I fall this far behind in my posting. In this case, however, I’ve had excuse enough: PROGRESS!

Yes, I have managed to put in a consistent number of hours per week at TLG. And every Sunday night sees me significantly closer to The Rotisserie than I was before. Let’s recap…

Some time ago (I can no longer recall when), I removed the front wheels for better access to the suspension. Following my trusty bible (the Mustang Restoration Handbook), I started with the shock towers. The previous owner had replaced the originals with newer, more reliable counterparts, which we will most likely reuse.These came out by first undoing the bolts connecting them to the shock tower brackets, and then removing the brackets themselves. After that, two bolts at the bottom of each tower are the only obstacles to removal.

Inside the engine compartment, the only parts left were the brake fluid junction box (pictured right with lines across the firewall) and the power steering booster. The junction box came out by undoing the lines at box (this is easier than pulling it with lines still attached). A flare-nut wrench is useful for this step, as with all other brake/fuel line connections. I would recommend keeping a set handy.

Next, after procuring the correct tools, we started on the tie-rods and the springs. The tie-rods connect the front steering arms to the center steering link with ball joints at both ends. After pulling out a few cotter pins, the nuts will come out. However, the tapered studs on the tie-rods are jammed pretty tightly into their receptacles, and need to be forced out. A mallet and some elbow grease will work just fine, but you risk damaging the ball joint. If you wish to save your old parts, do as we did and get yourself a tie-rod/Pitman-arm puller. It’s a C-shaped contraption that fits over the steering arm, with a bolt that sits up against the stud. Tightening the bolt frees the tie-rod and lets you reuse the ball joints.

Drive with Kendall

For the springs, any heavy-duty spring compressor will get the job done. Our car—originally purchased with a 390 big-block and a GT package to boot—has a nicer front-end suspension kit than did most Mustangs from that year; the beefier springs show their worth during the drive, not the restoration. Without enough clearance to use two outer-compression posts, Dad and I rigged one on the inside. This was difficult to set up, but worked out after some perseverance on both our parts. With the compressed spring out of the car, we locked it into a bench vise to decompress… Dad was clearly getting uncomfortably with me tossing around a loaded bomb. Then he removed the outer spring cover, a step that will definitely serve us better before we attempt removing the other spring next weekend.

Since I’ll be driving the London taxi to school, I checked the oil and filled up the tires with air while Dad spruced up the garage a bit with some new signs.

Wrenchin’ and chillaxin’ with Pops

Posted November 26, 2011 By dad

Ponyboy hard at work - last stages of disassembly

In Leaps and Bounds

Posted November 12, 2011 By jack

Long time, no post. Quick update:

We actually salvaged this one!

At this point, our goal is to get everything off that we need to before we place the body on the rotisserie. Last time at TLG (was it a week ago, or two?) I started with the backlite (rear windshield). Thankfully, it wasn’t glued in place with a non-drying adhesive, as was the windshield, and didn’t require the piano-wire tool we used last time. With the combined use of a gasket-scraper and box-opener, I sliced the weatherstripping away from the top side of the backlite. Using suction cups, Dad and I were able to lift it right out.

Front disc brakes were a definite deal-sealer when we bought the car

Looking for a better way to access the brake lines, I then removed the front wheels. Dad’s new floor jack came in handy for this one, as did our large breaker-bar (our impact wrench is broken). Only five lugs on the Mustang wheels, which we plan on replacing with Minilites later on.

I’ve been noticing a trend: I make really good progress on my car, when I go to the garage! EARTH TO JACK: GET MOVING!

Brake Cylinder

Posted October 21, 2011 By jack

This past weekend, Dad, Charlie and I managed to put in a good number of hours at TLG (I know, its Friday already, but school and cross-country get in the way of writing these things). I wasn’t too productive; the only things left to remove from the car before I start suspension work will require Dad’s help. That’s why I left them for last.

I started by inventorying and storing the massive amount of parts that have been sitting out.

Bagged-up lines best collect brake fluid

Dad cleaned off a storage shelf we had so I could make room for the driveshaft, heater assembly, and steering column. After that, I looked at a couple of my books, and the 1969 shop manual, to determine the best way to approach bleeding the brake system. Having found the bleeding vacuum pump I needed, I first drained the master cylinder reservoir (most of the literature I had told me never to let this empty, but this is only the case if you’re looking to replace the brake fluid). Then, I disconnected the brake lines at the brakes, fastened plastic bags around the ends, and pumped the brake pedal a few times to expel any remaining fluid. Finally, I unfastened the two bolts holding the master cylinder to the brake booster, and removed the unit altogether.

Dual master brake cylinder

This weekend I’ll be hiking Mt. Whitney with Mom, so don’t expect any progress within the next few days. On my next visit, off come the brake lines, brake booster, and power steering (hopefully).

Inch by Inch

Posted September 20, 2011 By jack

Charlie is almost, if not, taller than I am. With brothers, height is all-out warfare. And every inch counts. The tape measure is the battlefield, and hair gel is strategic weaponry. And as my brother and I inch along, so too does progress at TLG.

Another milestone day this past Sunday. The interior is finished (well, except for the rear lap belts and brake pedal, but that’s pretty much it). Thankfully, I remembered to take pictures this time. Dad brought the camera with him to the Goodwood Revival, so I was forced to used my phone, but we nevertheless have photographic coverage.

Your assignment: match the following pictures with their description (answers below, but don’t cheat). 

a) windshield wiper motor (requires much wiggling and many blows with a mallet to separate from the wiper arms beneath the cowl vent)

b) steering column (held in with a bracket attached to the underside of the dash and bolted to the firewall—don’t forget to disconnect from steering box)

c) transmission (I only steam-cleaned this, it was pulled months ago)

d) fuse box (finally removed the last part of the wiring harness—this pops out after you loosen a single screw on the cabin side of the firewall)

e) heater core (be careful not to damage the core fins when removing–also, the fluid hoses must be completely pulled off to remove this; don’t cut them like I did)

f) heater assembly (some five bolts on the engine side of the firewall hold this one in place)

g) front windshield defroster duct (remove two nuts under the dash and the whole duct pops right out)

1

2

3

4

5

6

7


ANSWERS: a) 4; b) 6; c) 2; d) 7; e) 1; f) 5; g)3

Don’t expect too much progress next weekend: I have plenty of part inventorying to catch up on…

Back from camp, back to school, and back to work! Right before I left for Kona I managed to pull the entire rear wiring harness (the only thing holding in the front wiring is the firewall). Packing, however, managed to rob me of a chance to blog about it. The fact that I didn’t take any pictures of the process will make for an interesting post later on…

Last Sunday, I finished some parts inventorying and cleaned up some old parts to list and sell on eBay. The automatic shifter, oil pump, water pump, timing set, rocker arm nuts, and transmission are all being peddled for some funds in the coffers. Most of these were fairly clean already, with the exception of the tranny, which was covered in gunk. Some engine degreaser, a steam cleaner, and many shop towels helped polish it up a bit. Pictures and info on the parts will follow, along with links to the eBay listings if you’re interested in buying any (please help pay for my paint job!)

Meanwhile, Dad added a touch of flair to the normally drab garage doors:

A little more legit than your average nametag