1969 Mach 1 Restoration

[rusty428cj]

This 1969 Mach 1 was bought new by the current owners Aunt who was a school teacher in West Virginia. It has a 351 with a 3 speed manual transmission. The current owner bought it in 1992.

Looks pretty good in the photo.



Around 10 years ago he quit driving it when he noticed this rust around the power steering bracket. He did tell me a few years ago he did take it out for a short drive.



The owner starting taking it apart and had it delivered to us.



I noticed around the quarter scoop hole that something was going on. It looked like they had put a quarter patch on. This is what we found. They had a quarter skin over the original rusted out quarter panel.

 

[horse sence]

I usually see Quarters spliced and over lapped ,but that is the first time i have ever seen that That must have been one of those, What The Hell , moments when you first saw that

 

[rusty428cj]

This is the left rear frame rail



Right wheel well



Front frame rail



The top of all the fender aprons look like this

 

[rusty428cj]

This is inside one of the shock towers



Since the floor and frame rails were so bad we ordered this from Thoroughbred.



Dynacorn parts that have come in



We made a jig with the stock suspension points and correct dimensions to build the car on.

 

[rusty428cj]

I'm not sure what was used for a patch in the wheel well



The quarter panel was cut off



Not much holding the outer wheelhouse



Brian added braces before he cut the floor out

 

[rusty428cj]

Brian has the floor cut out



Needs new torque boxes



I just had to show this again



I was told by the owner that this was done at a Ford dealer in a small town in West Virginia.

 

[horse sence]

You should save that quarter and hang it on the wall

 

[rusty428cj]

Brian wanted the shell sanded and epoxy primed before he starts to install. Almost ready for a couple coats of SPI epoxy

 

[rusty428cj]

Epoxy primed

 

[rusty428cj]

We removed the cart and now Brian is cutting off the front end



There wasn't a lot holding in on

 

[rusty428cj]

The inner rocker was removed and the inside of the outer rocker panel was epoxy primed





The Thoroughbred floor was mounted on our jig and rolled under the body. Jacks were used on both ends. Once everything was level the body was attached with sheetmetal screws to the new floor.





The old inner wheelhouses were left in place to keep the inner structure together and a reference point to line up the floor.



We were surprised to find no rust in the cowl



The cowl was sanded and epoxy primed

 

[rusty428cj]

The firewall, one piece wheelhouses and quarter panels were sanded and epoxy primed.

 

[rusty428cj]

The old inner wheelhouse was removed



New one was screwed in place



Lining up the front end



Test fitting the quarter panels



Brian is attaching the taillight panel with screws





The sheetmetal is lining up great almost ready to start welding.

 

[7991LXnSHO]

WOW! What a lot of work. I hope dipping the newer bodies will avoid a lot of this rust on the back side of panels on newer ones. Speaking of newer ones, how much will this cost compared to a 2013 without the rust, better brakes, more power and AC?

 

[rusty428cj]

It takes a lot of plug welds to weld the cowl back on. The frame is also welded to the floor pan frame extensions.







Left side inner torque box screwed in place



Right side inner torque box welded in place



Outer torque box welded in place

 

[rusty428cj]

Brian finished welding the firewall and torque boxes today

 

[rusty428cj]

Fender apron to cowl extension welded in place



After Brian grinds the welds



Welding wheelhouse in place

 

[Realmongo]

Another great reconstruction story!

 

[rusty428cj]

Both rockers panels had a little rust at the back.

On the left side Brian cut out the damaged area and started welding in a patch from a new outer rocker.



It was easier to do it in two pieces



The rust wasn't as bad on the right side

 

[rusty428cj]

Brian is starting to weld the quarters on.