At what point should you start replacing trunk pans. Mine is mostely surface rust but there are a few spots the size of a quarter that are all the way through. I'll try and get some better pics!

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I would be more worried about that gas tank than I would the trunk pan. If it was mine, I'd take out the tank and then assess the damage to the pan. Most likely, you could patch , use rust encapsulator, and paint. I have seen much worse.

 

Agree totally. You can replace the tank with all new parts, sender, rubber connector, etc...for under $150. While out, hit it with a wire brush, coat with Ospho, then sand/paint.

 

Is it a good idea to replace the tank beings it is 40 years old and not knowing what is in it? Or do you base it on the condition it is in?

 

Drain the tank and remove it. A new tank and related parts like said above are under 150 bucks so its well worth it to just replace it all. Just think how much rust and junk has built up in your tank...

 

And try to buy a cheap 1/3 sander to clean your trunk. Craftman has a 35 dollar one at Sears that works great. Ill post pictures of the work I did on my trunk once Im on a different computer...

 

It's 40 years old, it needs to go! LOL!!

It's cheap enough to replace, so go for it. It's well worth the money spent.

 

Change that tank if for nothing else, ease of mind. It's an easy swap and you can do the trunk at the same time.

The size holes you're describing can be prep'd and filled with JB weld. Or, you can prep it and rivit a patch piece in then JB weld. Do a good Por-15 job on the rest and you're good for another 15 years.

Well worth every dime spent.

 

I went ahead and told the wife we were going to have to buy a new tank. So it will be on its way.

Our local mustang supplier only has tanks w/o drain plug. Is one really neccesary?

Do you recommend replacing anything else (filler hose, filler neck, etc.)

Where can you buy the Por15?

Thanks

 

Go ahead and buy a tank kit, not just the tank. That should include the tank, rubber filler hose, hose clamps, sending unit..and I believe thats it. There is a small metal ring that closes the sending unit down onto the tank, but you can use the one off your old tank. Personally I'd get a tank w/ a drain plug, but it is not necessary.

Por15 can be bought off its website, ebay, and some hardware stores...