Progress Thread Front Frame Rail Fixture ...and More

horse sence · Jun 25, 2016

I got the passenger side front door post and side panel welded together and welded in place .I set the cowl on to make sure everything lines up ,and it does .I need to X brace the front door posts ,but i don't think they will move ,they are very solid like they are . I will have to do the window posts next ,after i trim out the roof on the car ,and then the cowl because the cowl sets on top of the door post and window post .

horse sence · Jun 25, 2016

I finished trimming the roof patch and cut it down to 3 1/2 inches wide .I blasted and primered the front roof support and visor brackets .

I marked the front of the roof at 2 1/2 inches and cut the rusted window channel away . Then i cut the roof support and and trimmed out the last of the old door post pieces.

I started with the out side door posts and clamped them in place .Them i set the cowl in place and clamped it down .I set an old ford windshield in place and it fit perfect .

horse sence · Jun 25, 2016

I took it all back apart and drilled the posts and the cowl for plug welds .I welded in the outer posts and then the cowl . I clamped in the inner door post and welded them with my spot welder .

And look at what goes in tomorrow .

dennis112 · Jun 26, 2016

Amazing work that usually reserved for the ultra rare or for irreplaceable vehicles. Very impressive.

Thanks for sharing!

horse sence · Jun 26, 2016

I set the front clip on my Harbor Freight lift table and rolled into place .It slipped right in place and i did it all by my self

I jacked up the lift table and used the holes in the cowl and fire wall for the engine compartment braces to bolt it together and it pulled up tight .

I leveled it and clamped it together .Then i bolted on a set of ford fenders .the fenders fit right up to the rocker and the top point on the fender over to the top of the door jamb was perfect for the door to fit so i removed the fenders and screwed it all together and clamped it also and started welding it up.

I set the fender apron to cowl brackets in place and they were a perfect fit ,i drilled them for plug welds and welded them in

All welded up and the welds ground . I still need to weld the floor down ,this one fit really well ,it is nice and tight .
Soon as i do this it will go up on the rotisserie and get a couple of weld i couldn't easily get to done ,and finish the roof patch .

horse sence · Jun 26, 2016

horse sence · Jul 2, 2016

I got the floor all welded in ,and the seat boxes also. Still need to grind the weld s but i will do that on the rotisserie

horse sence · Jul 2, 2016

While the dash was out i sand blasted it on both sides ,and primered it ,and welded it in .It is ready to go on the rotisserie ,as soon as i get the 64 1/2 off of it . I still have some small patches ,but i will do that on the rotisserie .

mross · Nov 27, 2016

horse sence said:
The transmission mount floor bracket and the floor supports were next .I drilled them for plug welds and clamped them in place and welded them

Hi horse sence,

that's some beautiful work you doing on the mustang. Can you tell me your process for finding the correct locations for your plug welds on the strut rod brackets and the radiator cross member. Do you just approximate where the plug welds should be from the old panel or do you make a template or is it something else. They sure look great. regards mross

horse sence · Nov 27, 2016

I actually added a few ,but mostly just placed them where i thought it needed them ,and where it looked like factory placement .I took measurements from another 67 that i have here to locate the correct positions of the actual brackets .

mross · Nov 27, 2016

horse sence said:
I actually added a few ,but mostly just placed them where i thought it needed them ,and where it looked like factory placement .I took measurements from another 67 that i have here to locate the correct positions of the actual brackets .

horse,

horse sence said:
I actually added a few ,but mostly just placed them where i thought it needed them ,and where it looked like factory placement .I took measurements from another 67 that i have here to locate the correct positions of the actual brackets .

mross said:
Hi horse sence,

that's some beautiful work you doing on the mustang. Can you tell me your process for finding the correct locations for your plug welds on the strut rod brackets and the radiator cross member. Do you just approximate where the plug welds should be from the old panel or do you make a template or is it something else. They sure look great. regards mross

horse sence said:
I actually added a few ,but mostly just placed them where i thought it needed them ,and where it looked like factory placement .I took measurements from another 67 that i have here to locate the correct positions of the actual brackets .

horsse,
Thanks for your quick reply. So, it was a combination of where you thought the plug weld would do the most good and where the factory placed the welds, is that correct? Well they look excellent and I'm hoping to duplicate them on my 67, that I'm working on. I noticed you replaced the front cross member separately, as opposed to replacing the radiator support with the cross member attached, as a unit, was there a reason for doing it that way? You replaced quite a bit of metal with new panels, did you have to straighten any of the original frame structures? Can you tell me the plug weld hole sizes you uses.

thank you

mross

horse sence · Nov 27, 2016

I did the cross member seperate because the owner bought it that way,i prefure the bracket made on because it saves me time and welding .Spot weld hole size depends on the thickness of the metal ,i like 3/16 for the lighter gauge metal and 1/4 - 5/16 for the heavier gauge .. The front rails were rotted out so no wreck damage ,i just had to square it all up .

Ryan Miller · Jan 8, 2017

Awesome as usual!

Horseeraser · Aug 20, 2025

Your post is pretty awesome! What part of the states are you in?

horse sence · Aug 20, 2025

California .

Cdunning83 · Dec 17, 2025

Love this thread. I’m in the process of doing my own 67 rebuild. I was told that the front rails are parallel (level) to the rockers but then I was told the front rails slope down slightly compared to level rockers. What did you do for this build?

Thanks!

horse sence · Dec 17, 2025

Not exactly level with the rockers ,I have a laser i use to get the line using the datum measurements off the laser its self ,the body must be level first

Cdunning83 · Dec 17, 2025

Thanks! Do you use the ford shop manual dimensions?

Cdunning83 · Dec 17, 2025

horse sence said:
Not exactly level with the rockers ,I have a laser i use to get the line using the datum measurements off the laser its self ,the body must be level first

Or would you mind sharing your measurements? Unfortunately, I put my car together with the front frame rails parallel to the rockers. All the sheet metal seems to fit fine, but I’m afraid the nose of the car might be sitting up too high, which would make sense.

horse sence · Dec 17, 2025

There is a diagram you can down load ,I don't have it anymore

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