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Prodject---My dads Pony

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Old 09-22-2010, 04:41 PM   #1
crashfab
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Vehicle: 1966 pony
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Default Prodject---My dads Pony

In late august my mom had to call an ambulance because my dad was exhibiting symptoms of a heart attack. he was taken to the hospital and they were able to rule out a heart attack but found he was anemic. The doctors were sure his anemic condition was causing his symptoms but needed to look into why. I am not sure if it was was an x-ray or an MRI but they found something in his colon.

On september 1st he had an apointment to have an in depth MRI to find out what it is and of course it would take a day or 2 for the doctor to get back with the results. I was at work on saturday when he called me to tell me the news that they found it was a tumor and it was in his colon but we did not know the extent of it yet. He made another apointment that was a few days later and later that day he sent a text to all of us (me, my older brother and 2 younger sisters) that he wanted us at there house to talk to us.

Thats when he told us that he was at stage 4 and the cancer was spreading and already in his liver. He is going in for chemo next to try and beat this thing and we are all very positive. he's a strong person and we are a close family.

About 10 years ago he bought a 66' stang with the intentions of restoring it. About 6 years ago they sold there big house and bought a place on a lake that they were going to fix up. Well the new place didn't have a garage like the old house so it was driven up to my sisters place where it sat with weeds/brush growing around it.

With the news of something in his colon and the doctors concerns it was what it was--my brother in law called me with a plan. He loaded the car onto a trailer and hauled it over to my shop--we were going to do what we could to get this thing back into shape and at this point we were not going to tell him till it was done.

Here is how it sat right off the trailer around september 1st

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Old 09-22-2010, 04:43 PM   #2
crashfab
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We gutted the interior and pressure washed the whole car. This is our starting point.

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Our origional intention was to suprise him with it but once we found out where he was with his condition we decided to tell him so he could have something to help take his mind off things.
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Old 09-22-2010, 04:45 PM   #3
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So our plan off attack was for my brother in law(more like a brother) who goes by spidertoy here he would take care of the body and I would handle the rest.

So while Don stripped parts off the body my main thing was to start going over the wiring and trying to get it to start.



The stock fuse panel was just sitting and hanging--and its badly rusted out so I am going to replace it with an updated panel.



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I threw a backup battery in it to just see if I could get it to turn over--nothing. I was not getting a crank signal to the relay. I started back tracing and was trying to see if I was getting voltage out of the ignition switch.



Well when I was "barely" touching the back side of the switch this happened.



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I looked it over and thought to myself--I can fix this. So I cleaned it up/greased it and reassembed it and staked it back together--just like new.



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So I threw it back in and it now turns over but won't fire. I pulled the cap off and cleaned the crud off the points and the damn thing fired off and ran pretty decent. While I was doing this my sister called my dad so he could hear it run---he was excited.



One cool thing we learned tonight---as soon as its done they are taking it to california to drive down route 66. So on top of the fact my dad is going to beat this--they have a plan for it...
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Old 09-22-2010, 04:47 PM   #4
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We are just cruising right along. My dad came over on friday(sept 3rd) to see it and he was amazed with what we had so far. He really wanted to hear it run "thats damn nice"--I told him "not good enough" "thumbsup"


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I got it on jack stands to asses the brakes and such.

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I got the interior all wire wheeled. Its not perfect but with the time we are working with--we are just going to have to seal it up the best we can without replacing any panels.

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The drivers floor pan has some small holes but its still pretty solid. We will just have to seal it up for now.

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One thing I am going to fix are the holes for the drivers seat where it mounts to the floor. The drivers seat base had broke and caused this.

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Old 09-22-2010, 04:48 PM   #5
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So we are trucking along.

I got the brakes done. I didn't replace the shoes(sanded them) but I did replace the front wheel cylinders. I also repacked the front wheel bearings and turned the drums.

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I threw some paint on the drums.

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I was kinda scared of this one since it looked pretty rusted and looked like it had never been touched in a long time.

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The bolts actually came out with no issue. But I was right it had not been touched in a very long time--the fluid was the blackest 90w I had ever seen but it was not burnt smelling.

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Cleaned the heck out of the diff and cleaned the cover and no prodject of mine is never complete without the use of hammerite hammered paint.

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Old 09-22-2010, 04:50 PM   #6
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I finally got the correct vacuum advance. I totaly dissassembled the distributor, polished all needed parts and reassembled it with the new vacuum advance/points and now it works like it should.

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Got it reinstalled and set the timing to spec. I didn't set the dwell yet as I will do that after I get the carb off and rebuilt. This vacuum advance used hardline (3/16 brakeline) to go the carb. Long ago it was cut off so I am going to remake a new one and make it look factory again.

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Old 09-22-2010, 04:50 PM   #7
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There are small freeze plugs just below the headgasket level on the block. Now I would not mind this but its behind the exhaust manifold and looking at the bolts for it--ya I didn't have a good feeling about pulling it.



So I did everything I could to be gentle with the bolts. I did get it off.



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I did end up having 3 bolts brake. One near the center and both upper outer ones(one front/one rear).



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Old 09-22-2010, 04:51 PM   #8
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Now you can see them very nicely. I am going to just go ahead and replace all the freeze plugs since I will have full access to them.

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Now onto the fun part--removing the broken bolts. Luckily I have alot of experiance doing this since I have been in the biz for 20 years. The center one was easy. I just grabbed my torch with a rosebud tip and got the bolt cherry red. After that I grabbed vice grips and you justshock the bolt back/forth and it cracked loose and came out. The others were a bit more fun. Since they were on the outer edges you could see the top of the bolt but I had to remove the valve cover (which I was going to anyways to repaint it), the rocker assy and the outer valve springs. With this I was able to drill into the top of the bolt.

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I first tried using my slick extractor. These things were in there and it busted it off. With this style you need to drill all the way thru the bolt which I did so removing the broken piece was easy.

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I ended up having to just drill the bolts out completely and run a tap down the hole to remove the rest and yes they were virtually rusted in place.

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I had mentioned earlier that there was an exhaust leak at the pipe to manifold area and I was going to drop the exhaust anyways. Well I found out why it was getting worse. The pipe/lip that the donut sits in is 1/3 gone.

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I will have to see if I can locate a replacement.
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Old 09-22-2010, 04:53 PM   #9
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After Don's buddy who is going to do the body/paint work looked it over don went and pulled the doors off because they are no good. At that point don started stripping more areas that we could not get on the body with the doors on.



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The door shell itself is toast--just too much rust in them to try and repair them. So now we are on the hunt for a good replacement set and they also reproduce them but are kinda spendy so we are trying to figure out what to do there.



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Old 09-22-2010, 04:54 PM   #10
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I got the freeze plugs popped out. The lower 5 were not in too bad of shape and didn't pop thru when I knocked them out. The top 4 smaller ones were just toast as every one I popped a hole in it removing.



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Unfortunately I had one small one turn installing(they were very difficult to do) so I will have to grab another one tommorow. But the rest are in/done.



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I got his new tires mounted and ballanced at work today. I just gotta clean them up so you can see the white walls (what he wanted).



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Old 09-22-2010, 04:55 PM   #11
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The headliner is in GREAT shape and from what I can tell unlike the rest of the interior(that has either been painted or dyed black) it was origionally black. The only issue was some mold/mildew on it(just surface from what I can tell).



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So I cleaned it with a toothbrush and got it about 80% clean on the first round and the odor is now gone. I will do it again one more time and pay close attention to the few spots left behind.



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Old 09-22-2010, 04:56 PM   #12
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I got the exhaust manifold all cleaned up and it was a task--thank god for files lol. The metal portion of the gasket had rusted to the manifold side and I had to file it off every post but it turned out better than I thought it would. Hopefully it don't leak.



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All bolted down with new bolts(and anti-sieze on all the bolts just in case,lol)



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I still have to get the exhaust pipe fixed/portion replaced where it mates to the manifold. My dad said he thinks he bought some exhaust parts for the car a number of years ago. He is going to look thru his stuff to see before I look at fixing it.



I went and pulled the carb off to clean it out. Doesn't look too awfully bad but it still needs cleaned out along with the fuel drained from the fuel tank.



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Old 09-22-2010, 04:56 PM   #13
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Here are the seats that came out of the car. One thing that was odd that I never noticed was the material is different on the front seats to the rear bench. The new covers we ordered will make them all the same.



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So I decided to dig into the rear seats first last night. I started with the upper part of the bench.



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Started by removing the cover/padding and inspecting everything. The spring assembly was is decent shape with some rust from moisture.



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I found 2 places where the main frame had broken the welds. So I cleaned them and welded it back together and had to do some work to make it all straight but turned out pretty good.



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Once done I scraped what rust I could off the frame and then painted it to not only protect it but hold what rust was there to the frame/keep it from flaking off. I also figured it could help with killing any odors (old smells).



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The padding was in great shape still and I spayed it down to kill any odors as well. This old stuff is certainly allot different than what we use in the industry these days.



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The next part made me VERY nervouse. I am by no means an upolstery guy and I had second thoughts about doing the seats. But I know my dad would be happier if I did them vs. somebody else. So I dug in and I think I did a faily good job on my first seat.



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So I got the cover off the bottom bench seat and thats where I made it last night.



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Old 09-22-2010, 04:57 PM   #14
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Well the bottom was certainly harder and I was even more nervous doing it,lol. The lower frame was is perfect shape/nothing broken like the top frame. But I was able to get a great fitment on the cover.



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So now time to dig into the drivers front seat. These will need more work to get them right but I hopefully should be able to pull it off.



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Old 09-22-2010, 04:58 PM   #15
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Ok so I was informed we have hit just about the 2 week mark for the car to head to the bodyman for the body work/paint. So we have in our stash a new hood, both rear quarters, replacement decklid, filler panel between the rear window/deck lid and my dad got a pair of doors (thanks for the link tony).



So I am shifting up a gear or 2 to get it ready.



So I was wrong I started with the passenger front seat--doh..



So I got the seat back all stripped and frame cleaned and painted. Besides the rust it was in great shape.



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The cushion was also in really good shape. To pull the seat face around inward around the material seam they use wire thats looped around a seam on the inside of the cover. I had to sand the wire smooth and it was still tough to work it into the new cover.



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And here is how the seat back turned out. I was pretty happy with the outcome and I think I got it pulled just right.



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Old 09-22-2010, 04:58 PM   #16
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I got the seat base stripped down. The shop looks like a war zone with pieces of hop ring clips everywhere,lol...



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Can you tell which one the new one is,lol. The drivers side was broken so we ordered a new one.



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Old 09-22-2010, 04:59 PM   #17
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So I changed gears and decided to get back to the floor since I need to get that done and sealed up.



Here was one of the damaged areas for the drivers seat mount(LH rear).



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All fixed up.



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The Rh front



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All fixed up



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The only access on the back side was like 1 1/2" thru hole under the car since the seat basicly sit on a riser off the floor. I ended up bringing my air hammer home from work and working the sheetmetal back up into place/working it flat and welding it up.
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Old 09-22-2010, 05:00 PM   #18
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And now some fun REALLY begins. This was as of last friday(getting the project up to date)



Here is the start of the mess---flinstone mobile...



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And here is where I got tonight with it. With the understructure of the car and the fact the spot welds are kinda hidden by the deep rust its been slow and I have been removing the floor pan in sections.



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So its up bright and early and back at it..
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Old 09-22-2010, 05:01 PM   #19
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So it was another good productive day on sunday. And a big thanks to my best friend kyle for coming out and lending a hand taking care of a bunch of small odds/ends--thanks bud..



So I continued to cut away at the floor to where I got rid of the natsy nasty.. But here is the floor with 99% of the material removed that is going to be.



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Old 09-22-2010, 05:02 PM   #20
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Here is the new floor pan. Its a bit different than whats on the car in 2 places. There is a panel for the firewall that overlaps the floor pan and on the far left front corner the pan reverses how its spot welded on the rocker. This was not a big deal but made it a bit trickier.



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I had kyle pull the rear driveshaft so I could replace the rear u-joint. I am amazed at how tiny they are (seen bigger joints on steering shafts,lol).



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New u-joint in and kyle threw the driveshaft back in.



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Old 09-22-2010, 05:02 PM
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