1965 Mustang rust repair

[rusty428cj]

Rusty, with the drip rail that you removed early in the project, do you replace this or will it stay off for good? I'm curious as I have rust issues along mine and was hoping to keep the rail.

Well done too and thank you so much, can't tell you how much tuition your threads give me!

The drip rails will not be replaced.

 

[Ash]

Thanks for the reply, Rusty!

 

[Rustbuster77]

So Brian us sanding down all rust to bare metal and epoxy only after that? Meaning no ospho or other treatment?

 

[rusty428cj]

So Brian us sanding down all rust to bare metal and epoxy only after that? Meaning no ospho or other treatment?

NEVER use Ospho

 

[rusty428cj]

I sanded the roof than sprayed 2 coats of SPI black epoxy primer

 

['68 Coronet R/T]

I assume Brian will cut those rusted sections on the sail panel areas out later once he gets it positioned properly?

 

[rusty428cj]

Brian is starting the rust repair on the front frame rails.

 

[rusty428cj]

Buddy doesn't like all the rust he sees in the front frame rails.

 

[rusty428cj]

To replace the front of the frame rail the shock tower had to be removed. Brian drilled out all the spot welds.

He cut off the bad section than epoxy primed inside the frame rail and the new section

Brian plug welded a small piece of 2 x 2 box tubing on the top side of the frame rail leaving enough room to weld a nut on the new frame rail section for the lower crossmember.

 

[Rustbuster77]

Man, you guys are so thorough when doing restorations. I bet you sleep great at night knowing you're doing the best possible work around.

 

[rusty428cj]

Brian replaced the left frame rail section

Lining up the shock tower using the original drilled out spot welds for an alignment guide.

 

[rusty428cj]

Left side shock tower and frame rail back together

 

[rusty428cj]

The right front frame rail had a lot of rust

Brian cut it off and repaired it the same way as the left side

 

[rusty428cj]

I epoxy primed while I was waiting for the front crossmember and left fender apron.

 

[Raymond_B]

Rusty, what kind of hours total do you think you'll have in that car? That is just a fantastic amount of work!

 

[rusty428cj]

Brian lining up the sheetmetal before welding.

Welded in place

 

[Desertdave]

This one has come a long way already.

 

[rusty428cj]

We have not made a lot of progress on this project. Brian fit and welded the strut rod and sway bar brackets

I epoxy primed the engine compartment

 

[rusty428cj]

I sanded the front valance, headlight buckets, and end caps down to bare metal than epoxy primed.

I block sanded than did a little bodywork.

Next another coat of SPI epoxy to seal everything

I sprayed a couple of coats of Slick Sand

 

[rusty428cj]

Now the fun begins! This has to be made piece by piece and Brian is not happy.