Fox My Resurrection Project 84 GT

FoMoCo8485

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I bought this early 1984 GT in 1986 from a librarian that worked at the college I am employed at. I drove it for 10 years, it hasn't been driven since 1994. It has sat outside, blocked up, jack stands and blocks sunk into the driveway over the years. This past weekend I decided to reposition the jacks and blocks and get her up and straight. Other projects, life, and family have kept me busy over the years, it's time the 84 gets my attention. I want to start driving it again, floor pans are decent, body is decent, there are a couple of issues I have to delve into. I found rot in an odd area, to me anyway. See pics.
 

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BlakeusMaximus

Still got to try a little lube on my speedo head
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Yikes, that firewall rust is serious. I dont know if that car is worth saving or can be saved without a ton of money and labor. Even if you got it running, you definitely cant drive it that way, that hood could fly off and who knows what else. Im sure that there is more rust going on that needs to be looked at.
 
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FoMoCo8485

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Yikes, that firewall rust is serious. I dont know if that car is worth saving or can be saved buddy. Even if you got it running, you definitely cant drive it that way. That hood could fly off. Im sure that there is more rust going on that needs to be looked at.
I agree, I have to remove cowl vent, fenders, windshield and hood to see how much further the damage is?
 

BlakeusMaximus

Still got to try a little lube on my speedo head
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Yes sir, I would. Im sure the rot extends down there too. How are your frame rails under the brake reservoir and further back close to the firewall?
 
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FoMoCo8485

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Yes sir, I would. Im sure the rot extends down there too. How are your frame rails under the brake reservoir and further back close to the firewall?
Frame rails look good, have to do more inspecting, floor pan has 1 small hole on passenger front. Have to unbolt battery tray to get a topside look of frame rail.
 

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bird_dog0347

still married haven't seen testicles in years
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Yikes, that's pretty bad on the firewall... I'd bet the door jamb on the A Pillar also has some rust as well, but it will be easier to see with the fender off the car. The frame rails are also another spot that hides rust quite often, usually where the K member is bolted to the frame rails under the brake MC as already mentioned here. Might want to also check the spare tire well while you're at it.
 
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FoMoCo8485

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Yikes, that's pretty bad on the firewall... I'd bet the door jamb on the A Pillar also has some rust as well, but it will be easier to see with the fender off the car. The frame rails are also another spot that hides rust quite often, usually where the K member is bolted to the frame rails under the brake MC as already mentioned here. Might want to also check the spare tire well while you're at it.

Yikes, that's pretty bad on the firewall... I'd bet the door jamb on the A Pillar also has some rust as well, but it will be easier to see with the fender off the car. The frame rails are also another spot that hides rust quite often, usually where the K member is bolted to the frame rails under the brake MC as already mentioned here. Might want to also check the spare tire well while you're at it.
I'm going to be doing that in the next couple of months, unscrewed the cowl vent trim yesterday, checked the frame rails and passenger compartment floor pans.
 

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90sickfox

Wasn't a pretty sight...and I've got big hands
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I expected the inside of the cowl to look worse than that. That repair isn't that bad. The fenders and windshield have to come out. Also, the dash, front seats, and carpet ( unless you are excellent with controlling welding sparks ) A crap ton of spot welds have to be drilled out. A few guys here have replaced them due to hoods flying up and crushing the cowl. The metal at the floor of the cowl is thicker than the top part that is rusted. Still need to poke around and see if any soft spots are in there. Even that wouldn't be all that hard to repair. Especially with the top sheet metal removed.
 
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FoMoCo8485

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I expected the inside of the cowl to look worse than that. That repair isn't that bad. The fenders and windshield have to come out. Also, the dash, front seats, and carpet ( unless you are excellent with controlling welding sparks ) A crap ton of spot welds have to be drilled out. A few guys here have replaced them due to hoods flying up and crushing the cowl. The metal at the floor of the cowl is thicker than the top part that is rusted. Still need to poke around and see if any soft spots are in there. Even that wouldn't be all that hard to repair. Especially with the top sheet metal removed.
I'm not that good at controlling weld sparks, so I'm gonna take the safer route and remove anything I can ignite. As for drilling out a crappy ton of spot welds, I drilled out the cowl on a 63 Falcon I have, it has that popular cowl rust that plagued the early Mustangs, it just took longer to happen on the Falcon.
 

Mustang5L5

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Assuming the rust doesn't extend past the cowl and is just that one area, I would probably opt to find a donor car and prep to drill out the spot welds and replace the cowl panel. I'd have to pull the fenders first and see how those upper inner aprons look under the fenders.

But you'll prob want to seek out a donor in the junkyard and bring a sawzall and get ready to cut. I imagine if you can find a fox it will likely be well stripped anyway, so the windshield will likely be what gives you the most trouble.

1662047026420.png



This video shows some of the tasks needed to replace that cowl peice.


View: https://youtu.be/s78y1z1QCjU




You could also patch it, but I would want to know the extent of the rust first before deciding to go down that path
 
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FoMoCo8485

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Assuming the rust doesn't extend past the cowl and is just that one area, I would probably opt to find a donor car and prep to drill out the spot welds and replace the cowl panel. I'd have to pull the fenders first and see how those upper inner aprons look under the fenders.

But you'll prob want to seek out a donor in the junkyard and bring a sawzall and get ready to cut. I imagine if you can find a fox it will likely be well stripped anyway, so the windshield will likely be what gives you the most trouble.

1662047026420.png



This video shows some of the tasks needed to replace that cowl peice.


View: https://youtu.be/s78y1z1QCjU




You could also patch it, but I would want to know the extent of the rust first before deciding to go down that path

Thank you Mustang 5L5
 

BlakeusMaximus

Still got to try a little lube on my speedo head
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Assuming the rust doesn't extend past the cowl and is just that one area, I would probably opt to find a donor car and prep to drill out the spot welds and replace the cowl panel. I'd have to pull the fenders first and see how those upper inner aprons look under the fenders.

But you'll prob want to seek out a donor in the junkyard and bring a sawzall and get ready to cut. I imagine if you can find a fox it will likely be well stripped anyway, so the windshield will likely be what gives you the most trouble.

1662047026420.png



This video shows some of the tasks needed to replace that cowl peice.


View: https://youtu.be/s78y1z1QCjU




You could also patch it, but I would want to know the extent of the rust first before deciding to go down that path

That would probably be your best option, probably the route I would go.
 

limp

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I don't want to be a debbie downer, but what body and paint people always tell me is that 90% of rust is hidden.. Based on the pictures you have showed I would tear the entire car apart and look it over really well... This car would even be candidate for sand blasting or dipping to see wha tyou have left afterwards... You wouldn't want to find some really bad body problems after you had purchased any parts or " new engines" for this car....... A shame this car was not stored inside..
.. Just my opinion......