1966 Mustang Coupe Restomod

rusty428cj · Apr 15, 2015

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.

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

The quarter panels were removed

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

rusty428cj · Apr 16, 2015

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.

rusty428cj · Apr 17, 2015

New firewall and cowl was sanded and epoxy primed

The cowl side panels and A pillars needed to be replaced

Test fitting

rusty428cj · May 3, 2015

Ready for epoxy primer

Two coats of SPI black epoxy primer

rusty428cj · May 3, 2015

Lower cowl welded in place

The welds were ground down and epoxy was brushed on

Upper cowl fit and welded

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

edgars23 · May 15, 2015

This is gonna be better than new when done.

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rusty428cj · May 29, 2015

Brian has done a lot of work since I last posted

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

Test fitting the trunk floor and gas tank

Plug welding the trunk drop offs

Fitting the rear package tray and sail panels

The quarter panels were shaped wrong and had to be modified

Fitting the taillight panel and end caps

Left outer wheelhouse welded in place

The right side was to long and had to be modified

Starting to weld the sail panels

Rear panel welded in place along with the sail panels

rusty428cj · Jun 7, 2015

The quarter panels, roof, rear deck panel and taillight panel lined up and welded in place

rusty428cj · Jun 26, 2015

The drip rails were removed and welded

Welds ground

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

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

rusty428cj · Jul 19, 2015

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

Rear bulkhead panel welded in place

Welds ground and interior sanded and ready for SPI epoxy

SpareParts · Jul 23, 2015

Looks great! Nice work.

rusty428cj · Aug 22, 2015

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.

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

rusty428cj · Aug 25, 2015

The repair is finished and a little epoxy was brushed on to stop the surface rust on the weld

Fitting the shock tower panels

Welding finished just need to start grinding

rusty428cj · Sep 2, 2015

After Brian finished the front end repair we sent if out to get the engine compartment and undercarriage sand blasted

rusty428cj · Sep 23, 2015

Epoxy primed the engine compartment and undercarriage

Started the bodywork on the fender aprons

The extra holes in the firewall were patched and the engine compartment epoxy primed

I still wasn't happy with the fender aprons and we did a little bodywork on the firewall

One coat of SPI epoxy primer

Two coats of SPI Turbo urethane primer

rusty428cj · Sep 25, 2015

I never have liked the way Ford just stuck the taillights on the outside of the taillight panel and the owner agreed. He wanted to install 67 taillights but the taillight panel is to small so we are recessing the taillights. He ordered a set of billet bezels from Eddie Motorsports.

The first step was to get the taillights to fit the new taillight panel and trace around it.

Brian decided to make a new inner bracket out of thicker metal.

This was his first attempt but it was a little to small so he had to make another one out of an old seat riser.

Test fitting the taillight

His new bracket tack welded in place

The top piece is just to hold it in place and will be trimmed.

The next step will be to make the filler pieces

rusty428cj · Sep 25, 2015

Brian cut out the other side and test fit the taillights

other_shoe · Sep 25, 2015

The recessed taillights are a really fine touch.

Hack · Sep 26, 2015

Cool custom touch with the tail lights. Thanks for posting the photos!

rusty428cj · Sep 30, 2015

Back side welded

This is how Brian filled in the gaps

Next he trimmed it and welded it solid

Brian isn't finished yet but after grinding it will look like something like this.

1966 Mustang Coupe Restomod

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