New big ford owner in UK - project resto/lowrider

Posted by: andyfanshawe

New big ford owner in UK - project resto/lowrider - 09/30/09 04:48 PM

Hi all.
I want to introduce myself and my newly acquired vehicle to you all. i live in the UK and build somewhat radical american vehicles for a hobby! But this time, I want to do something slightly different with on the forum.

What I am proposing is to fully detail the build/restoration/modifications of it and invite the last 9 owners (phew!) to view the thread and chip in when they want-either in defence or to clear up some history of the vehicle. I'm not nieve enough to think that they all will view it, but one or two might. Imagine the picture that could be built up if only 1 or 2 past owners post their comments. Even if it is to say that I am spoiling it!

I have full details of nearly all of the past owners, so I can write a few letters inviting them to have a look.

So, what is this new project?

It's a 1990 Ford LTD Crown Victoria LX Country Squire station wagon (thats about as long as the car is!) on our roads, this is a BIG car.








More to come.
Andy.

PS may need some help from you guys in the US with this resto!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/30/09 04:54 PM

Spotted on ebay in Abergavenny, South Wales. About a 3 and a half hour drive away from myself in Derbyshire.

Looked good in the photos, sounded good over the phone when spoken to the very nice gentleman who owned it. Obviously this would be bought unseen and uninspected, but a 19 year old car has to have some defects, so lets take a chance!

The owner said the AC belt had shredded and hadn't been replaced. Cruise didn't/had never worked in the last 4 years ish, couple of pieces of trim dented, split in maroon leather drivers seat base (dry leather elsewhere), recent (ish) service and a very full detailed history right back to the first owner in the states, exhaust rerouted to exit under the passenger rear door and lazy central locking.

My 11 year old son and myself caught a train or three to Abergavenny last sunday (20th september) to pick up the car. The owner showed us round the car and pointed out a few more faults. Airbag light flashing, fuel filler cap leaking petrol out on right hand turns (!), parking brake not working correctly, but looked quite splendid!

A very nice and smoooooth journey home. First impressions? This car is BIG, and I mean BIG! Very easy to drive. First fuel stop, noticed that the fuel filler cap didn't have a seal on it! no wonder it leaked. First job then!

Views on the way towards the M50




Stopped off at a little chef roadside cafe for a bite to eat at about 6pm and then found out that the car wouldn't lock! Front right door, back right door and tailgate not locking at all. Back right door showing signs of action, but not quite succeeding.

Here it is in the car park




Set off again and noticed that the red parking brake light was on and wouldn't go off! Temperature gauge had not moved all the way, even when left for an hour or two? Funny? Is it stuck?

Arrived home safely and parked up for the night....unlocked and no parking brake!!!

To be continued.............
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/30/09 05:01 PM

Right, the plans for the car......

1) Put right all the mechanical and electrical issues with the car
2) Sort out the dry leather interior
3) Remove all the "wood" and trim from the car and weld the holes up
4) Remove all door handles and locks-except for the tailgate one that will be redesigned to be more low profile.
5) Get rid of excess chrome trim to clean it all up (final decisions to be made yet)
6) Repaint in a single pastel shade or fade from top to bottom, NOT white!
7) Limo tint all windows.
8) Put on air suspension and 20" suitable wheels (not decided yet).
9) Digital dash.
10) In car entertainment system.

I will photoshop the finished project to give an idea of what it will look like.

Just for a mess about, here it is with black windows!


Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/30/09 05:02 PM

Okay, mechanical side first:

Inspection of the car reveals the following:

1. Front right door, and tailgate won’t central lock and pass rear slow.
2. No parking brake operation and red light lit on dash.
3. Temp gauge stuck on normal.
4. Coolant dark brown and level down to bottom of rad.
5. Themostat housing leaking.
6. Airbag light flashing.
7. Exhaust pipe exiting out the side rather than the back .
8. Cracked and dry leather seats at the front. Drivers split.
9. Wet carpet at front right.
10. Sticker remains on various windows.
11. Chipped paint inside at the rear where the folding seats are.
12. Flaking rust on separate chassis member at the back.
13. Large number plates fitted when smaller ones would fit better.
14. Seized AC compressor and broken clutch.
15. Leaking radiator in both bottom corners.
16. Alt/ps belt in poor condition.
17. Rear tailgate window won't open from dash.
18. Rear tailgate window struggles to open from key.
19. Stress crack around top front passenger door hinge on A post (and consequent rusting).
20. Heavy corrosion in one confined spot under passenger front door.
21. AIR pump noisy.
22. Battery tray rusted.
23. Drivers door mirror casting fractured and repaired by pop rivets.
24. Tailgate check strap corroded and broken in half.

I think I may stop there for the time being and actually repair something!

More photos to come.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/30/09 05:05 PM

Here we go on the long list of jobs:
central locking solenoids stripped out of the front right door, back right door and tailgate. most looked like this





Someones been in before and made a bodged repair. Even the waterproofing shield that should cover them were missing.

Anyway, rebuilt 2 out of three and that now leaves the front right door to get a new solenoid for.

The rear tailgate had its other problems. the rear window wont close with the key from the back as its supposed to. It will open but wont close. So all the lock mechanism came out





Once i figured out how it worked, all it needed was an adjustment of the many rods! Then, good news, the switch on the dashboard that was supposed to operate the rear tailgate window started working! Thats another job crossed off then.

Right, whats next.......
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/30/09 05:12 PM

Rusty coolant time!

The colour of the coolant in the rad had to be seen to be believed! So, removed viscous fan, fan shroud, and pulled bottom water hose off. This was the result:






Then removed the radiator that is in poor shape at the bottom corners



Then removed the thermostat and reinstalled without it so i can flush.

Flushed out the heater matrix



then flushed the block through the top hose and out through the bottom. Took 30 minutes for it to clear.

The flushed out the rad since i want to use it to run the engine up while i wait for the new rad to come.



Lovely stuff coming out!

Then reinstalled the rad, filled it all up and ran the engine up. Then removed the rad again, flushed it all out and put it all back again. Then repeated it again!

Now I should be in a position where the new rad won't instantly block up when it is fitted.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/30/09 05:23 PM

While the engine was running earlier on I had a look at the stuck temp gauge and decided to heartily smack the dash to shock it loose! And it worked!



On a roll now, so i tried the non working switch on the dash that operates the rear tailgate window, and it works! Must have been the adjustment in the tailgate! I like those jobs!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/30/09 05:27 PM

Right, which one do you prefer?







Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/30/09 06:10 PM

Waiting for parts to arrive, so in deeper we go.....

Pulled all the plugs on the drivers side easily, but the last one near the firewall looked suspicious. Corroded contact at the top and corroded HT lead contact inside the rubber boot. Signs of a misfire on the electrode. In fact it dropped apart when removed.
One other plug had a gap a lot tighter than the others. But most looked reasonably recent.





Getting the plugs out from the passenger side was interesting to say the least! The AIR pump diverter valve is seriously in the way, so out it came



Much more space now
BEFORE


AFTER


Plenty of brown staining down there from a past leak-but from where? Time will tell.

Andy.
Posted by: RustyRodder

Re: New big ford owner in UK - project resto/lowrider - 09/30/09 06:11 PM

wow, looks like a heck of a project!

good luck with it all! looks like you know your way around american cars.

And i like the first one- just the windows black.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/30/09 06:53 PM

 Originally Posted By: RustyRodder
wow, looks like a heck of a project!

good luck with it all! looks like you know your way around american cars.



Just a bit!!
Thanks for your input.

If you think this is a project, have a look at my recently finished airride camaro.

http://www.lowcamaro.com

Andy.
Posted by: ElBlue89

Re: New big ford owner in UK - project resto/lowrider - 10/01/09 03:31 AM

Cool project, welcome aboard! It's neat that you're jumping into it right away, look forward to see the progress you make. Keep up with the photos \:\)

Out of curiosity, was the coolant you drained out of the radiator really that rusty, or was it Dex-Cool red coolant to being with? I'm just wondering because if that was green or yellow coolant I'm amazed at how bad it looks.

As for the window tint options, of the 3 choices you gave I'd go with the first one also. But depending on the body color you choose, I might prefer a combination of the 1st and 3rd options like this:

Posted by: PseudoBoat

Re: New big ford owner in UK - project resto/lowrider - 10/01/09 09:27 AM

I like the second, looks modern.

I'm curious about the door lock motors when you say you rebuilt them... most of us around here buy new ones, but they are expensive. I wonder if you could detail how you get them apart/back together again, etc.
Posted by: 88grandmarq

Re: New big ford owner in UK - project resto/lowrider - 10/02/09 10:25 AM

you mentioned a wet spot on the passenger floor board... judging from the looks of the cooling system, I would bet the heater core is corroded and leaking. same with the radiator, if its leaking, replace it.

some other tune up/maintainence items I would suggest; replace the PCV valve, screen and grommett. these are located in the center of the lower intake manifold at the rear of the engine.

also replace the fuel filter... located on the passenger frame rail, just in front of the rear tire.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/02/09 04:58 PM

Todays job list was to find out why the parking brake pedal won't stay down. The pawl is not engaging with the ratchet teeth because the pedal doesn't come up far enough, unless it is pulled up the last cm or so with your foot! The last owner kindly emailed me to say a new handbrake cable had been fitted but had not been set up properly. He is quite right, the tension in the handbrake cable is not enough to set the pawl in position.



I am doing the brakes next, so I will do that job at the same time.


An unexpected job next. I removed the front seat (armchair!?) so I could get my head under the dash and had a look under there-just to make sure. Now, when I was driving back from picking the car up there was a bit of free play in the steering wheel. The wheel rotated about an inch and a half before anything happened, and there was a slight knocking feel through the column. imagine my surprise when i grabbed hold of the UJ at the base of the steering column and it wobbled around!

I took a video of it, so i hope it works!

http://s167.photobucket.com/albums/u141/andyfanshawe/big%20ford/?action=view¤t=SDC10798.flv

To see why it was wobbling i removed the steering column



I took the UJ off the end of the shaft and moticed it had worked loose and slightly worn away. I also noticed the UJ was symmetrical, so turned it round and put everything back. worked like a charm! Until i was bolting the shifetr linkage back and pulled it out of park accidentally (parking brake off) and the car set off down the hill with me buried under the dash Luckily I had left a piece of wood across the bottom of the drive just in case!

The prices of the parts at RockAuto were roughly the same as the ones from USAutomotive, once the dreaded VAT etc was added on. So USAutomotive it is.
Parts ordered were: 8 platinum spark plugs, rotor arm, dizzy cap, thermostat, rad cap, oil, air and fuel filters, Alt/PS serpentine belt, intake manifold gaskets and 2 valve cover gaskets (last 2 for top end engine stripdown this winter!)

Came to a grand total of £153. Which I don't think is too bad. Oh, then ordered a radiator from RockAuto ($233) with VAT included.

Brakes next.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/02/09 05:11 PM

 Originally Posted By: ElBlue89
Cool project, welcome aboard! It's neat that you're jumping into it right away, look forward to see the progress you make. Keep up with the photos \:\)

Out of curiosity, was the coolant you drained out of the radiator really that rusty, or was it Dex-Cool red coolant to being with? I'm just wondering because if that was green or yellow coolant I'm amazed at how bad it looks.

As for the window tint options, of the 3 choices you gave I'd go with the first one also. But depending on the body color you choose, I might prefer a combination of the 1st and 3rd options like this:



Hi Elblue89.
Not sure whether the coolant used to be red or not, but it looked pretty rusty to me! Better out than in though! Even if it is dexcool.

Plenty of photos coming I can tell ya!
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/02/09 05:23 PM

 Originally Posted By: 88grandmarq
you mentioned a wet spot on the passenger floor board... judging from the looks of the cooling system, I would bet the heater core is corroded and leaking. same with the radiator, if its leaking, replace it.

some other tune up/maintainence items I would suggest; replace the PCV valve, screen and grommett. these are located in the center of the lower intake manifold at the rear of the engine.

also replace the fuel filter... located on the passenger frame rail, just in front of the rear tire.


Hi 88grandmarq.
Thanks for your comments. I didn't know about the breather at the back, but it explains why it is pretty oily back there! I have just ordered a new plenum gasket, so will do that while it is off. Fuel filter is also on its way.
Regarding the heater core, I ran the engine up filled with clean water and went for a drive but there was no sign of leakage. Once the antifreeze is in I will give it a good check out. Considering the coolant was very brown when it came out of the heater core, I would have thought there would be brown stains around the heter box and on the carpet. But nothing. Fingers crossed.

Thanks again.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/02/09 05:43 PM

 Originally Posted By: PseudoBoat
I like the second, looks modern.

I'm curious about the door lock motors when you say you rebuilt them... most of us around here buy new ones, but they are expensive. I wonder if you could detail how you get them apart/back together again, etc.

Hi PseudoBoat.
I uncrimp the end of the metal casing and pull out the innards. Do the same for the others and swap parts. Then glue the end back on! I'll try and get a photo or two for you.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/03/09 04:40 PM

Right, the next exciting installment. Rear brakes.
I know the last owner said the front calipers had been changed, and a handbrake cable, but nothing about the rear brakes. So lets have a look

Centre cap off on passenger side. Doesn't look too bad.


First view of the drum. Rusty, but not too bad.


Drum off, doesn't look too bad.


Shoes okay, lets have a closer look at the slave cylinder.


Shoes off to have an even closer look at the cylinder. Doesn't look damp.


Lets get the dust cover off and really see what it's like.


Oh dear, lets have a look at the other side


Well I'm not a pro mechanic but that I don't like and the LH piston is stuck solid. So, onto the bench we go, Extract the pistons with compressed air and a hammer, and this is what we have


Serious clean up and the cylinder and seals are not too bad, so its rebuild time. Now I have rebuilt loads of slaves over the years by cleaning up the seals and cylinders and having no problems, so lets try it again. New ones ordered just in case (£18 each + VAT - US Automotive).

All put back and brake bleeding time. Time to call in my lady Wife to monitor the and top up the level in the master cylinder.
Now I have seen some funny colour brake fluid, but this looks like stagnant pond water or is it LHM fluid. In fact I had to check the M/C cap to make sure it is brake fluid and not LHM fluid!




Heres where its starting to look a bit cleaner


Heres my trusty mityvac in operation and a comparison between the old and new fluid.


Other side tomorrow, but a last look at the wagon before I have a well deserved rest!


Oh, forgot to mention. Nobody told me it has self levelling rear suspension!

I wondered what that compressor on the front LH inner fender was!!

Front brakes check next. Last owner said these had been changed, and there is a spare new one in the back.

Andy.
Posted by: PseudoBoat

Re: New big ford owner in UK - project resto/lowrider - 10/03/09 05:54 PM

Right, definitely that's the basic procedure. I guess my question relates to how to uncrimp it. I've been tempted to use a rotary tool with a cutting wheel to basically cut the crimp off... so far I've just bought new ones off ebay for cheap, but they don't last very long.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/04/09 02:40 PM

Repeated all he above on the other side, and moved to the front drivers side.

Wheel off



to reveal.......



new caliper, disc, pads and flexy line. Good news.

Well, not all good, because the plastic dust shield behind the disc has melted and deformed





So, the caliper and disc had to come off to extract it.



Order one of those later.

have a look at this photo of the drop link, and more specifically the bushes that have perished.
Something else for the order book!



Have a close look where the link goes through the lower control arm. The hole has worn oval. i will remove that and weld it up in my next holidays (3 weeks time).



Some of my parts should be arriving tomorrow, so I may be able to get the engine together in time for a test run and then the plenum coming off and the PCV valve. grommet and screen to be replaced.

Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 10/05/09 09:37 AM

I like this project. Keep us updated.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/05/09 04:56 PM

 Originally Posted By: Jeff2
I like this project. Keep us updated.


No problems Jeff2.

Some parts arrived today, and I'm still dismantling!!



Top box contains the official thick workshop manual ($20 for the book and $45 shipping!!).
Bottom box is from US Automotive and contains plugs, dizzy cap, rotor arm, oil, air and fuel filter, thermostat, rad cap, AC/PS serpentine belt and intake gaskets (plenum and 2 inlet to head). Well, I hope they are in there! Not checked yet.

Back to the car:
Removed battery and noticed that the battery tray is an extension of the plastic inner wing and reinforced by steel bracing underneath. This is the remains of that support



Need to make one of those then, Should be straightforward, then I will stand the battery on one of those battery mats.

Over to the plenum. Major oil leak back there and I bet its the PCV valve.
Here are better views with the plenum removed.





Got some serious cleaning up to do there!

And guess what? The PCV valve was off its seat. Excessive crankcase pressure? Tell me it aint so!!!

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 10/05/09 05:46 PM

Your doing great so far!

Alex.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 10/05/09 07:45 PM

This story is fantastic! Maybe the Admin will make it a sticky under maintenance! Hint, hint...
Posted by: interceptor1985

Re: New big ford owner in UK - project resto/lowrider - 10/05/09 08:02 PM

You can upgrade to bigger brakes and rear disks ya know:) BUT you'll need larger wheels 16" or bigger (no more then 20's please!)
Posted by: 88grandmarq

Re: New big ford owner in UK - project resto/lowrider - 10/05/09 09:30 PM

 Originally Posted By: andyfanshawe

Well, not all good, because the plastic dust shield behind the disc has melted and deformed






Order one of those later.

Andy.



It's common for the caliper to hang or stick and cause the front brakes to catch on fire.... judging by the picture of the backing plate, I would say thats what happened to your car.
backing plate is not super important, removing it will allow more heat to escape.
Posted by: 88grandmarq

Re: New big ford owner in UK - project resto/lowrider - 10/05/09 09:39 PM

 Originally Posted By: andyfanshawe




Got some serious cleaning up to do there!

And guess what? The PCV valve was off its seat. Excessive crankcase pressure? Tell me it aint so!!!

Andy.


Fairly common problem there... the rubber grommett gets hard and brittle, then the breather screen under the valve clogs and it popps the PCV out.

take a long (4"-6") dry wall or decking screw and screw into the hole where the PCV goes, then yank the screen out with some pliers... you will be amazed at the junk in there.
Posted by: 89LTDBoy

Re: New big ford owner in UK - project resto/lowrider - 10/06/09 12:27 AM

Good work! All this makes me miss my box even more. \:\( My interior was the same color, but with the older dash of course.
Posted by: 89LTDBoy

Re: New big ford owner in UK - project resto/lowrider - 10/06/09 12:28 AM

Where do you get auto parts in the UK?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/06/09 12:04 PM

 Originally Posted By: GM_Guy
Your doing great so far!

Alex.


Thanks GM_Guy. Much appreciated.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/06/09 12:09 PM

 Originally Posted By: interceptor999
You can upgrade to bigger brakes and rear disks ya know:) BUT you'll need larger wheels 16" or bigger (no more then 20's please!)


Thanks interceptor999.
The upgrades will come when the mechanicals and electricals are in good order (few weeks only).
Wheels will most likely be 20's. Definitely not bigger that that. Rear discs would be nice, but a constraining factor is that I am in the UK! No junkyards round here with crown vics in!

Luckily I have a very understanding friend in SoCal who will ship me bits over.

Thanks for the advice. Greatly needed. I bow down to your superior knowledge of these cars.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/06/09 12:14 PM

 Originally Posted By: 88grandmarq
 Originally Posted By: andyfanshawe




Got some serious cleaning up to do there!

And guess what? The PCV valve was off its seat. Excessive crankcase pressure? Tell me it aint so!!!

Andy.


Fairly common problem there... the rubber grommett gets hard and brittle, then the breather screen under the valve clogs and it popps the PCV out.

take a long (4"-6") dry wall or decking screw and screw into the hole where the PCV goes, then yank the screen out with some pliers... you will be amazed at the junk in there.


Fantastic advice 88grandmarq. Just the input I am needing. Thank you very much.

I will do exactly what you say with the PCV valve, grommet and screen.

I got a mental picture of the under fender fire centred around the caliper! Scarey.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/06/09 12:17 PM

 Originally Posted By: 89LTDBoy
Good work! All this makes me miss my box even more. \:\( My interior was the same color, but with the older dash of course.


Hi 89LTDBoy.
We have quite a few parts warehouses that stock many parts here in the UK. Crown vics are well catered for luckily.

What happened to your box? My apologies if it makes you feel sad.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/06/09 02:55 PM

Heres a photo of the PCV valve and its grommet and the screen thats underneath.



As you can tell from this picture of the grommet, someone has tried to glue it in. You can see the glue on the top section.



I'll get one of them ordered tomorrow. PCV valve is clear now and screen has been degreased and blown through with 150 psi air line.

I have sprayed the heavily oiled area (even down to the transmission and beyond) with degreaser and I will leave it overnight to soak in. Careful application of water and air, and it should be a lot cleaner. Then its valve covers off and on with new gaskets. Trouble is my Wife says I absolutely stink now due to the degreaser, so I got thrown out of the house to get changed!!

Have a close look at the passenger side rear light. It should be secured down with 4 screws. There is actually only 1 left!!



Easy fix though!

Heres a couple of photos of the front leather seats. The drivers has a split in it where the leather has dried out, and the passenger is just about to go as well. Got a leather expert out yesterday who confirmed the leather was irrepairable and neede replacing. Matching the colour won't be a problem. Cost? Well, I asked if i could help do it to cut down the cost and he agreed. Should be somewhere near £300 to replace the bases of the front seats and dye and condition the rest.





Andy.
Posted by: 88grandmarq

Re: New big ford owner in UK - project resto/lowrider - 10/07/09 07:15 AM

 Originally Posted By: andyfanshawe
My Wife says I absolutely stink now due to the degreaser, so I got thrown out of the house to get changed!!


Andy.


LOL... that's a daily occurance here !

I really need my own wash room to get cleaned up and changed before I come into the house.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/08/09 04:34 PM

Spent an interesting 2 nights with a can of degreaser, a hose, a rag and an airline! Can't believe how much oil is on this engine and behind it!

Heres a quick shot of the various vacuum pipes behind the plenum as a result of the pcv valve losing its grip!



And guess what, I can't locate a PCV valve grommet in the UK. So Rockauto it is, at $1.71 for the part and $23 shipping! Phew! I'm so jealous of you guys in the US!

Right, how about a before and after photo

Before

After


A bit cleaner eh? And far smellier! Can't wait for the headers to burn that lot off!

Next job while I'm waiting for the grommet to arrive? Valve cover gaskets.

Valve cover removed and it's looking pretty black in there



On to the bench, and all cleaned up for the new gasket.



Other one tomorrow.

Xmas came early today!


and my youngest popping his head in to see


Future cutom car builder?

Radiator arrived in the UK from Rockauto in 4 days! $83 for the rad and $120 shipping. Bit better ratio than the grommet.
Very difficult to get one from the UK. Most don't stock it and require a couple of weeks delivery!


Andy.
Posted by: 89LTDBoy

Re: New big ford owner in UK - project resto/lowrider - 10/08/09 05:43 PM

 Originally Posted By: andyfanshawe
 Originally Posted By: 89LTDBoy
Good work! All this makes me miss my box even more. \:\( My interior was the same color, but with the older dash of course.


Hi 89LTDBoy.
We have quite a few parts warehouses that stock many parts here in the UK. Crown vics are well catered for luckily.

What happened to your box? My apologies if it makes you feel sad.

Andy.


Very cool! Always like to see an old box get new life. \:\)

My box was actually my parents, it began to have issues and they decided they didn't want me to have it at the last minute.

It is 4 years ago today since I last saw it. \:\(

But anyway, looks like yours is really coming along! Mine had those same color leather seats. It ended up ripping too one day; when I heard the sound at first I thought I split my pants. \:\)
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/10/09 03:31 PM

Interesting day today! My dad broke down in his Yaris (left his lights on), our caravan started to show signs of water droplets inside and our big Ford (renamed project Marmite by my good lady Wife-for obvious reasons!!) made a few more tentative steps to a fire up and reliability.

So, inbetween rescuing my dad and stripping the caravan down, I managed to do a few jobs on the car.

First was the replacing of the valve covers with the new gaskets. But, not quite as simple as it seemed because there is a bracket at the back of the drivers side valve cover that secures some wiring multiplug connectors. And its rusty.




Needs a good clean up and repaint. So, out with the media blaster


Here it is after blasting

Etch primer next


Then painted black and reinstalled.

Next? Engine bay clean up of unecessary bits. ie thermactor components and brackets (not needed for our emission tests and badly mangled up. Pipes are rusty and full of holes, air pump is noisy in operation, pipes have rotted off the catalytic converters, 1 has been plugged but the other hasn't!

These are the remains after a bit of cutting and pulling!




This is the pipe that connects to the back of the heads to exhaust passages


...........................
Posted by: andyfanshawe

Project Marmite! - 10/10/09 03:44 PM

This was the pipe as it was in place


Now I just can't leave the holes in the back of the heads, so it's out with the hacksaw and a bit of gas welding

Heres one already welded and one about to be



My Wife caught me in action!


That leaves the bracket for the diverter valve to be shifted and the bracket that use to hold one of the pipes. All located on the passenger side exhaust manifold studs.


All not been moved for 19 years and seriously rusted.
Theres only 1 wrench that will move them, and here it is (a hot wrench!)-nuts already removed



Sorry its not in action, but i would probably set the car on fire while taking the photo!

Heres the new space minus brackets



Battery tray reinforcement next.

Andy,
Posted by: Colt45

Re: Project Marmite! - 10/11/09 01:09 AM

Coming along nice. I like the little details like painting that bracket.
What do other people think of your BIG Ford over there?
Posted by: andyfanshawe

Re: Project Marmite! - 10/11/09 02:09 AM

Hi Colt45.
My neighbours can't believe the size of the car! Its like nothing we see over here. There is supposedly 1 more country squire in the UK, and I have already spoke to the owner. he thought his was the only one!
The roads are just about wide enough for the car (just!), but the parking spaces at local shopping malls, multi storey car parks, supermarkets etc, certainly aren't big enough though. But i don't care!

My Wife has nicknamed it project marmite (do you get marmite over there?) because the adverts say you either love it or hate it. At the mo I think it is ugly, but that will change, but opinions are extreme. Ranging from looking really bad to a lovely old boat!
The wood effect sides and all the chrome trim are a real eyesore (too much for the eyes). Its clear up time soon though.

Thanks for the question though. Your car would look lovely here and turn a few heads.

Andy.
Posted by: GM_Guy

Re: Project Marmite! - 10/11/09 09:47 AM

 Quote:
The wood effect sides and all the chrome trim are a real eyesore (too much for the eyes). Its clear up time soon though.


Surely the woodgrain makes it even more unique in the UK. =-)

Alex.
Posted by: 88grandmarq

Re: Project Marmite! - 10/11/09 10:00 AM

 Originally Posted By: andyfanshawe


Heres one already welded and one about to be



Andy,


Fantastic work..... However, all you had to do was cut the ends off the air pipe and flip them around (with the flat side against the head) I usually dab a little silicone on there and bolt them down. Never had one leak.
Posted by: 88grandmarq

Re: Project Marmite! - 10/11/09 10:15 AM

I see you cut the air pipe off at the cat converters too.
make sure you seal those holes off or you will have a big exhaust leak.

Usually, I cut the pipe and leave a 2" nipple, squeeze it flat with a big set of pliers then weld it shut.

also, seeing how you have removed all the air injection piping, you may want to run a shorter belt and by-pass the air pump, or simply remove the air pump all together.
Posted by: andyfanshawe

Re: Project Marmite! - 10/11/09 11:09 AM

 Quote:

Fantastic work..... However, all you had to do was cut the ends off the air pipe and flip them around (with the flat side against the head) I usually dab a little silicone on there and bolt them down. Never had one leak.


Oops! you're quite right! Didn't spot that one. Oh dear, must be losing it. My excuse is that i had the welding equipment out anyway

Thanks for pointing that out though.
Andy.
Posted by: andyfanshawe

Re: Project Marmite! - 10/11/09 11:16 AM

 Originally Posted By: GM_Guy
 Quote:
The wood effect sides and all the chrome trim are a real eyesore (too much for the eyes). Its clear up time soon though.


Surely the woodgrain makes it even more unique in the UK. =-)

Alex.


It sure does. But I want a different style of unique \:\)
To give you an idea, have a look at my custom camaro that I built



Stick on graphics are okay, but not for me. This country squire will be a lowrider like the camaro, but have a modern paint job also. Looking around the car there are numerous repair patches consisting of stuck on wood grain patches that are very close to the original. Darn effective repairs though. Certainly a lot easier to repair then painting!

Andy,
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/11/09 03:34 PM

 Originally Posted By: "v8mad0"
 Originally Posted By: "andyfanshawe"

This is the pipe that connects to the back of the heads to exhaust passages


...........................



Another good day, I had to have that pipe on my wagon welded twice as it kept rotting and made a noise inside the car when the engine was running


Glad that parts gone then!
Today is battery tray day. Simple procedure-make a cardboard template, transfer to steel (thickish ally plate in this case), cut out, bend, drill holes and paint. Install and heavy duty rustproofing (Dinitrl 3125) + battery mat.




Then cut out with my favourite tool-air saw




Andy.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 10/11/09 07:55 PM

Hi Andy,

I had to do a Google search on "Marmite", but then I had a good laugh!

I'll have to check on the local grocer's "International" section and try that stuff. Maybe its next to the PG Tips tea I like so much!

Thanks for posting so much detail on your buildup. I have a similar Mercury wagon, and I have learned much from you in this short time.

That pic with your son made me imagine you saying "Stay outta me box, boy!" haha
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/12/09 01:31 AM

 Originally Posted By: Al Von
Hi Andy,

I had to do a Google search on "Marmite", but then I had a good laugh!

I'll have to check on the local grocer's "International" section and try that stuff. Maybe its next to the PG Tips tea I like so much!

Thanks for posting so much detail on your buildup. I have a similar Mercury wagon, and I have learned much from you in this short time.

That pic with your son made me imagine you saying "Stay outta me box, boy!" haha


Hi Al Von.
Glad to hear you are enjoying the write up! Makes it all worthwhile for me. Yes I am restoring/rebuilding a car, but I have done this many times before and passing knowledge on is a major bonus.

PG tips eh? Lovely. Ironically we don't like marmite \:\)

My son, in that photograph, thought it was a box of fireworks!
Good luck with your adventures with your wagon.
Stay tuned though. The interesting bits start soon (bodywork and mods)

Andy.
Posted by: mikei1983

Re: New big ford owner in UK - project resto/lowrider - 10/12/09 02:57 PM

Nice work so far.

Makes me want to empty my garage out except for my Merq. and tools. To start pulling everything apart, and start the build. I have almost everything needed for the engine.

But I still have to get my truck going first...lol...
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/12/09 03:44 PM

 Originally Posted By: mikei1983
Nice work so far.

Makes me want to empty my garage out except for my Merq. and tools. To start pulling everything apart, and start the build. I have almost everything needed for the engine.

But I still have to get my truck going first...lol...



Hi mikei1983.
Go on, you know you want to
I know what you mean though. This is a drug for me. The more I fix, the more I want to! When its finished I am really disappointed! The more things that go wrong the better I like it. My Wife doesn't get too impressed though-but I am redeemed when I fix her car when it goes wrong

What does your truck need? Want any help?



Anyway, next exciting installment!

Parcel arrived today from rockauto. Only ordered last thursday! But.......I only ordered a PCV grommet. Thats a big box for a grommet



Lets open up and see whats inside


Can't believe it! One grommet box and a big bag of air!



Now need to finish off so I can get the plenum back. But heres a clip that's not been put back (against the firewall)



This is supposedly secured under the wiper motor, but obviously isn't! And I can tell why, because it was a pain attaching it back!

Here is a view of the vacuum block connector at the firewall. I have blocked off the one that came from the AIR pump and plugged it (yellow plug).



The degreaser I used has softened some of the connectors at this block so I have secured 2 of them with tie wraps just in case.

Then spark plugs installed



It says "Nascar performance" on the box! A nascar country squire! I bet Tom Cruise would drive it!i

Dinitrol 3125 ordered and should arrive tomorrow. Battery reinforcement panel rust proofed and installed then.

HT lead clean up and new dizzy cap and rotor arm install next. Then plenum on, other little jobs (not forgetting new rad and thermostat) and we will go for a fire up!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/12/09 03:52 PM

This is what I don't like.
Wires that have been cut free of their clips and not put back. Just under the air filter box is the clip, but the wires have been stuffed behind the PS pump and are too close to the exhaust manifold.



4 tie wraps and they are back.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/13/09 04:09 PM

Simple jobs today.

Clean all the ht leads and make sure all ends are tight and grip the plugs properly.
Then replace the distributor cap and rotor arm.





Plenum replaced and all bolts tightened to spec.

May be able to fire this beast up tomorrow evening!

But...........................I've been thinking again...........

I know this is a major job and doesn't get much more major, but what about......, no, I daren't think about it,,,,,,,,,,,,oh go on then.........what about removing the whole frame from under the car and getting it media blasted, and rebuilding it and putting it all back!!!? Now that is something i would seriously enjoy. make for some interesting photos I can tell ya!
Hmmm. wonder if i can borrow a big workshop for a few weeks? After all overhaulin' did it in 7 days!

Andy.
Posted by: ElBlue89

Re: New big ford owner in UK - project resto/lowrider - 10/13/09 07:39 PM

OMG dude, DO IT!

Well, ok, don't do it if it's too much cost or time you can't afford. I just wanna see the pics that'd go along. I bet most people dream of doing such big jobs but never get around to it. I'd love to have all the surface rust blasted off my frame but it'll never happen.

Enjoying this thread.
Posted by: PseudoBoat

Re: New big ford owner in UK - project resto/lowrider - 10/14/09 08:50 AM

DO IT!

I drive a nice 90 MGM. It's pretty good all over except for the frame. The frame is rotted. I'm going to have to let it go next year unless I undertake to replace the frame...

So if your frame is good, do what you gotta do to keep it that way.... frame off resto will be fun!
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 10/14/09 09:54 AM

Taking the body off the frame would certainly allow you to attack any and all rust underneath the car. You might want to price the parts to do this though. If you take the body off the frame, I'd guess you'd want to replace the hardware that goes between the two.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/14/09 03:09 PM

Interesting evening tonight.
Cleaned out throttle body and the water passages



Made a gasket for it and installed all throttle body and air filter trunking/

Heres the old and new air filters-bet you can't tell the new one :dontknow:



Fuel filter next, and it doesn't look quite like the old one. The inlet and outlets on the new one have a shoulder where the fuel pipe connections lock onto-the old one didn't. So how did they hold on?



Thats it-the favourite tie wraps.

Here it is removed


Notice just straight pipes-bit dodgy.

Battery on it's new reinforcing base, and the battery clamp doesn't fit properly! Didn't notice that when I took it off. Looks like battery is not wide enough.



Turned the key, and it fired straight up! Well, coughed a bit but then ran smooth. Rad flush chucked in the cooling system and ran for 20 mins to circulate it. Drop it all out tomorrow, another hosepipe flush and the new radiator and thermostat and rad cap goes on. Antifreeze following.

Noticed an exhaust blow on the CAT on the drivers side where the old thermactor pipe used to connect to. Rotten remains. I will weld that up tomorrow.

Andy.
Posted by: 88grandmarq

Re: Project Marmite! - 10/15/09 09:26 AM

 Originally Posted By: 88grandmarq
I see you cut the air pipe off at the cat converters too.
make sure you seal those holes off or you will have a big exhaust leak.

Usually, I cut the pipe and leave a 2" nipple, squeeze it flat with a big set of pliers then weld it shut.

also, seeing how you have removed all the air injection piping, you may want to run a shorter belt and by-pass the air pump, or simply remove the air pump all together.


I mentioned about the exhaust leak and how to fix it several posts up... .guess you missed it.
Posted by: 88grandmarq

Re: Project Marmite! - 10/15/09 09:37 AM

on the battery bracket.... these cars came from the factory with 2 different size batteries.

Standard battery is the small battery (group size 58)
optional, HD battery is the larger (group size 65)

obviously each one had a specific battery bracket for the application. judging by the picture, your car came with the larger battery, those hold down brackets are getting difficult to find, btw.
Posted by: andyfanshawe

Re: Project Marmite! - 10/15/09 11:19 AM

 Originally Posted By: 88grandmarq
on the battery bracket.... these cars came from the factory with 2 different size batteries.

Standard battery is the small battery (group size 58)
optional, HD battery is the larger (group size 65)

obviously each one had a specific battery bracket for the application. judging by the picture, your car came with the larger battery, those hold down brackets are getting difficult to find, btw.


Hi 88grandmarq.
Difficult to find but easy to make

Andy.
Posted by: andyfanshawe

Re: Project Marmite! - 10/15/09 11:25 AM

 Originally Posted By: 88grandmarq
 Originally Posted By: 88grandmarq
I see you cut the air pipe off at the cat converters too.
make sure you seal those holes off or you will have a big exhaust leak.

Usually, I cut the pipe and leave a 2" nipple, squeeze it flat with a big set of pliers then weld it shut.

also, seeing how you have removed all the air injection piping, you may want to run a shorter belt and by-pass the air pump, or simply remove the air pump all together.


I mentioned about the exhaust leak and how to fix it several posts up... .guess you missed it.


Hi again!
No i didn't miss it! Any advice greatfully received.
I had enough space to get under the car to get the air pipe off (just broke off!), but not enough space to get the car up in the air and weld or plug the hole up. Sloping driveway you see!

Tonights job is to repair the hole that you quite correctly predicted would happen!

Unfortunately my airride custom camaro is in my garage/workshop so I am limited to doing this car completely outside \:\(

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/15/09 04:38 PM

One of the interesting things about buying a used car is you dont quite know what you'll find in it!

Under the drivers seat was this tape (tape? whats that then? :dontknow: ). the very best of Foster and Allen.



I have emailed the last owner to ask if he wants it back, and he did. So it went off in the post today. Now how many owners of cars take the trouble to do that?

Anyway, back to the car. The next task is to get the radiator in.
Coolant dropped out again that I put in last night and the hosepipe brought back into play for one last flush through.

Then its out with the new rad and transfer all clips and connectors/adaptors

New and old together


Moving trans cooler connection adaptors over



This is the lower radiator panel that is showing signs of light rust. So, a clean up first



followed by a coat of dinitrol 3125 with this



to get this



Then its in with the radiator



New thermostat fitted and new rad cap.

then the system filled with 50/50 ethyl glycol antifreeze/inhibitor



Heres the coolant colour after an engine run up until the thermostat opens and it all starts to circulate. The heater got warm so it must be circulating well round there. No wet carpets yet either. :yay:



Andy.
Posted by: ElBlue89

Re: Project Marmite! - 10/16/09 12:41 AM

 Originally Posted By: andyfanshawe
Unfortunately my airride custom camaro is in my garage/workshop so I am limited to doing this car completely outside \:\(
Andy.
You can't put the current project in the shop and the camaro outside?
Posted by: andyfanshawe

Re: Project Marmite! - 10/16/09 01:22 AM

 Originally Posted By: ElBlue89
 Originally Posted By: andyfanshawe
Unfortunately my airride custom camaro is in my garage/workshop so I am limited to doing this car completely outside \:\(
Andy.
You can't put the current project in the shop and the camaro outside?


Hi Elblue89.
Put my camaro outside?!! And get it wet? In the wind? And dust? Never!!! ;\)

Nah, don't think it would fit in the garage anyway! If it did I wouldn't be able to get the doors undone!

Andy.

PS Tell me more about the car in your sig pic please.
Posted by: ElBlue89

Re: Project Marmite! - 10/17/09 02:37 AM

 Quote:
Hi Elblue89.
Put my camaro outside?!! And get it wet? In the wind? And dust? Never!!! ;\)

Nah, don't think it would fit in the garage anyway! If it did I wouldn't be able to get the doors undone!

Andy.

PS Tell me more about the car in your sig pic please.

Haha I thought maybe you could put a car cover or tarp over the camaro, but I guess if the wagon won't fit in the shop anyway there's no point!

The car in my sig pic is the stock car my boyfriend raced this past season at our local dirt track. (I am female in case you didn't know.) The board of directors there decided to drop that class of car after this year. That's why it says "RIP" on it. It's unfortunate, and I believe they made a poor choice, but I won't start in about that lol. Information on the Street Stock class can be found if you Google "WISSOTA rule book" and then jump to the section on that class... WISSOTA is the name of the race sanctioning body.

So that's what the sig picture is about. Did you want to know something about the car itself?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/18/09 04:34 PM

Well, this weekend and a few days leading up to it have been mind blowing to say the least!

To put you all in the picture, the last owner of the car, but one, had found out all the previous owners and wrote a letter to every one. Some had responded and some hadn't. I found out that the car has had 10 owners in 19 years. most of the time being spent in the south of our country and in Wales. But 1 past owner was located in Clay Cross which is only a few miles from me now. They sold it in 1999, A good 10 years ago. According to a letter, this particular gentleman sold the car due to possible redundancy (which turned out to be true) but was sorry to see it go.
Anyway, I took the car for a longish test drive on saaturday morning . On the way back I could smell a slight odour of hot coolant. Probably due to a heater matrix (heater core) after 19 years and especially after the colour of the coolant that came out. So, I ordered one (£56). If it turns out that it isn't that after all, I' m going to change it anyway.
I pulled down the under dash panel on the passenger side and this fell down



It was an envelope that had been there a long time. Probably gone through the back of the glovebox.

Imagine my surprise when the name and address on it matched the owner in Clay Cross from 10 years ago! Not any of the others that were miles and miles away, but the most local one!

But there was someting else up there. A brown leather pouch that was wedged tight. I pulled it down and this was it



Inside was these



Loads of american cents and a dime! Now the car left the states in about 1997, so this has been there for over 12 years!

Wonder who it belonged to?

My Wife wanted to open the envelope but I said no, let me see if I can return it to its rightful owner. She asked if I was going to have a drive out to see if I could find them. i said of course i was, and I would also take the car with me to reintroduce it 10 years after they had sold it!

30 mins later and I arrive at the house that was on the envelope. A knock on the door and a lady answered who confirmed they used to own it! So they were still in the same house that they were in when they owned the car!

I took them both out to see the car they hadn't seen for those 10 long years. I had an amzing chat to them about the car and tried to fill them in about its whereabouts since they owned it.
I gave the envelope to the Lady who's name was on it and she was very surprised. She said she thought it was a birthday card, but definitely from her Mum who had unfortunately died a few years earlier. I was concerned that it would be upsetting for her, but she said it had made her day. To receive 1 more thing from her Mum.

The gentleman told me he had to have the rearmost seat belts changed because they had seized up due to lack of use! Also the interior light lenses were changed because they had cracked. Said they were very expensive,

He noticed the slight dent in the bonnet (hood) and told me it had been caused by a stone thrown up by a passing car in a caravan site that had bounced across it. A simple bit of info but invaluable in the sense that it is filling in a small piece of the big history jigsaw of the car.

I left them feeling extremely pleased thay I had reunited them with a piece of their past (and a happy one at that), and I had delivered an envelope that had waited probably 11 years to be delivered. I have pointed them in the directon of this forum so that they may keep up to date with the cars restoration, and hopefully chip in some comments every so often. just as I quoted I wanted the past owners to do in the very first paragraph of this thread..... Magic!

Andy.
Posted by: 04clone

Re: New big ford owner in UK - project resto/lowrider - 10/18/09 04:42 PM

Were you able to determine where the coolant smell was coming from? I've been watching this thread for a while now, nice work. Keep posting pictures for us to enjoy.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 10/18/09 04:59 PM

Hi Andy,

I dont understand what you meant when you wrote that a previous owner sold the car "due to possible redundancy"?

And that was very kind of you to return that item to its rightful owner!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/18/09 05:22 PM

Okay, weld up CAT time. Up in the air we go to weld up the hole in the side of the CAT where the AIR/thermactor pipe used to be.





Here you can see where the pipe used to be. The clamp is still there and the remains of the pipe also.



Here it is again with the old rotten pipe removed and a small plate welded on the end.



Successful, but hang on, something doesn't look right.
The frame at the side of the cat has been welded and painted





The other side hasn't been welded but is corroding in the corner.

The box section is full of rust debris and plates have been welded over the top. Not at all good.

So. out with the hammer and around the frame we go. Luckily no where else is rotted. Probably due to the fact that water/salt gets thrown up there and sits inside the frame.

This will have to be done properly. Car put up in the air and secured in one place. Exhausts removed, fuel pipes removed and ALL the corroded sections removed and properly welded up back to factory specs. If the frame has to come off the car to do it-so be it. Shouldn't take too long once I get started.

In the meantime, back under the dash we go. Preparing to replace the heater core.
Bit of corrosion here on the flap control vacuum solenoid arm. Must be some type of water/coolant down there to cause this.



It is now clean and greased and free to move. The solenoid couldn't move it at all, but it can now!

It looks as if the all the dash is coming out to change the core. I don't have to, but I can check all types of things while I am there.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/18/09 05:27 PM

 Originally Posted By: NPRKRS
Were you able to determine where the coolant smell was coming from? I've been watching this thread for a while now, nice work. Keep posting pictures for us to enjoy.


Hi NPRKRS.
No, I haven't found where the coolant smell is coming from yet. But the heater core is old and needs changing anyway. A good place to start. I know it may be an awkward job, but I love it!!

Glad you are enjoying the thread. Many many more pics to come. Passing my enjoyment on to you guys.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/18/09 05:40 PM

 Originally Posted By: Al Von
Hi Andy,

I dont understand what you meant when you wrote that a previous owner sold the car "due to possible redundancy"?

And that was very kind of you to return that item to its rightful owner!



Hi Al Von.
No problem returning the envelope to its new owner. It was the right thing to do.

He sold the car because he thought he was just about to lose his job. Which in fact he did. 10 years on and all is better! in fact he is browsing the american car for sale sections in our media as we speak for a possible next one!

Thank you for your comments.
Andy.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 10/19/09 03:16 PM

Nice looking neighbourhood, Andy. Looks like some houses are separate, some duplexes?

Now I can see how small your garage is, and the slope of your drive.

Makes for some challenges while working under the car!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/19/09 04:32 PM

Hi Al Von.
Believe it or not my garage is a lot bigger than the average one! My camaro fits in their nice though, and plenty of space left at the front for my bench and various tools/welders.

No duplexes, all semi detached houses. Do you use the words "semi detached" in the US of A?

Andy.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 10/19/09 08:06 PM

No, what does it mean?

We have "condominiums" here, where each home is owned separately, but the property is held in common. The homes are usually attached to each other. Each owner has rights to use the grounds, and pays a maintenance fee monthly.

In my region, we also have "cluster homes", where property is held in common, but houses are detached. This gives one a little more freedom in landscaping, but still must meet the rules of the common property. Owners also pay monthly maintenance fee.

How old are the homes in the background of your pics?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/20/09 12:03 PM


Right, next exciting installment:

Time to start removing rust off the frame and rustproofing before its too late

Heres a starter photo of the frame in the back left corner



Scaly rust but nothing major. But hang on, whats that hanging off the rear bumper? Remnants of rusty brackets? Ah, now this is something that americans won't understand...the remains of a rear fog light. This light is a bright red light that is a legal requirement and is there to make the car highly visible in poor conditions



Those have been there for a long time. It'll be good fun trying to shift them.

More photos later of the cleaned up first bit of the frame.

Moved onto the front lights that are hit and miss. Sometimes bulbs are out, sometimes they are not. When a vehicle comes into the UK, the lights have to been changed to our standards. Which usually means hacked up wiring and bodge jobs.



The middle bulb should be on, but isn't due to those horrible blue scothlock connectors.

So, its all wiring out and start again. The bottom yellow corner light unit is not used for some reason, so an amber LED light has been fitted to the fender for pedestrians to see the yellow flashing light from the side. I am going to remove them and wire in LED bulbs in the afore mentioned lower corner light unit.

Oh, also have a look at the trunk floor in the photo above-where the rubber grommets are. Look rusty? You'd be quite right. Put my hammer through them. More welding then. Lovely.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/20/09 12:08 PM

 Originally Posted By: Al Von
No, what does it mean?

We have "condominiums" here, where each home is owned separately, but the property is held in common. The homes are usually attached to each other. Each owner has rights to use the grounds, and pays a maintenance fee monthly.

In my region, we also have "cluster homes", where property is held in common, but houses are detached. This gives one a little more freedom in landscaping, but still must meet the rules of the common property. Owners also pay monthly maintenance fee.

How old are the homes in the background of your pics?


Hi Al.
Semi detached means the houses are joined on one side. 2 together, then another 2, and so on. Some are fully detached, like your cluster homes. But all houses are owned by one family/occupant and each have their own gardens and outside space. Usually well fenced off and guarded! I'll get you some more photos to explain better.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/20/09 12:22 PM

Oops, forgot to say. The houses were built around 1964, so are about 45 years old.

Andy.
Posted by: 88grandmarq

Re: New big ford owner in UK - project resto/lowrider - 10/20/09 01:55 PM

 Originally Posted By: andyfanshawe








Rust in the area is quite common.
water from the A/C evaporator drains onto and into the frame there. Several other CV/MGM/TownCar owners have had to repair that spot. Re-route the drain with a longer hose.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/20/09 02:13 PM

 Quote:


Rust in the area is quite common.
water from the A/C evaporator drains onto and into the frame there. Several other CV/MGM/TownCar owners have had to repair that spot. Re-route the drain with a longer hose.


Thanks 88grandmarq.
Our weather and salt roads don't help either! This photo was taken on the opposite side to the AC. Next time I am under there I will have a look for the pipe.

Thanks for the brill info.
Andy.
Posted by: 88grandmarq

Re: New big ford owner in UK - project resto/lowrider - 10/20/09 02:23 PM

wait... thats the Left side(drivers side)frame rail?

hmmm... might check all the drains for the cowl then. make sure there is no debris in there and the drain holes are clean.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 10/20/09 07:29 PM

Hi Andy
Thanks for answering my questions. I see your low beam headlights are H4. I wish those were more common here. I used them on my first Box, an '81 LTD police car. It had the 2, larger headlamps and I replaced them with Hella H4's with 80/100W bulbs. I loved'em! Looks like you have the plastic high beams, like my Mercury.

Funny you should mention a rear fog lamp. Great idea! I have only seen them on European cars, such as a Porsche 928 and my friend's Alpha Romeo Graduate. Following that Porsche in heavy rain, the rear fog lamp was the only thing visible on the car! The side-mounted turn signals [another good idea for lane changing] are finally showing up on American cars. Up until the last few years, we would only see them on German cars, such as Audi and Volkswagen.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/23/09 04:34 PM

Okay, next simple job. Sort these lights out that keep going on and off!

This is the amber LED unit that has been put on the side of the fender and a hole drilled through for the wiring.





I'm going to remove the light, weld the hole up and get the lower corner of the front light unit working.



This is the rear view



There isn't a bulb holder for this one, so I need one. No american scrapyards round here, so I made up an aluminium disc and bonded it to the unit, and used a renault megane light unit.









leave it overnight to set and its repairing the wiring time.

After that, on the job list is

1) Front drivers seat electric mechanism isn't working properly.
2) Tailgate central locking has stopped working again!
3) Find reason why airbag light is flashing.

....and many more.....!
Andy.
Posted by: mikei1983

Re: New big ford owner in UK - project resto/lowrider - 10/23/09 10:51 PM

For #3

My brothers truck had a problem like that. When he started the truck, the air bag light would flash 2 times, then another 7 times, then it would stay on. Meaning code 27.

The bulb was burned out and they did not sell replacement bulbs and the computer was registering it as (airbag) as not working. He had to buy the key mechanism to fix it.

This is the also on a 2003 F-250, so It may be completely different for you.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/25/09 03:14 AM


More lights today. The plan is to wire each group of lights as a unit and terminate the wiring in a multiplug. So when the light unit needs to come out just unplug and remove. No leaving any bulbs and bulb holders dangling on the front bumper.

Lets sort out the corner white light first. The bulb holder is heat damaged and so is the hole it goes into. So, put the holder in a tight fitting grommet and grind the hole out so the damage disappears and the grommet fits! Easy!









Then make up a harness to fit them all







Other side



Now tell me if this is bad workmanship or not! Always good to see someone take pride in their work! Sort this lot out next.



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/25/09 09:47 AM

Managed to install the front lights on their new harnesses and multiplug quick release connectors. All well corrosion proofed.

So lets move the side LED lights off the fenders. Heat gun to the rescue.



Looks a lot better without them



While i was under the car sorting the wiring, I noticed a puddle of antifreeze under the xmember. Is this where the coolant has been leaking from? Where is it actually coming from then? Core/freeze plug? That brown staining on the passenger side of the block is directly above there. So lets have a look at that area again.

This is the view from the passenger side of the car looking at cylinders 2 and 3. looks a bit damp.



A closer look then



Coolant seems to be coming out from round that circle in the head. What used to be there then? Oh oh. We all know what that was dont we...............? Someone has sheared the head off one of the head bolts
Andy
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 10/25/09 07:30 PM

ooohhhh my, that looks like a snapped head bolt...

Well, here's your chance to have the heads redone, or swap in a set of E7s...
Posted by: Colt45

Re: New big ford owner in UK - project resto/lowrider - 10/25/09 11:37 PM

Oh, no.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/26/09 03:53 PM

Okay, nothing else for it but to get the head off, remove the stud and reassemble. Sounds simple eh?

Heres a few shots of the engine in its various states



This is my special tool (clothes prop tube with a hacksaw cut!) for disconnecting the fuel line connectors.



Careful levering to get the inlet off



First view with the inlet removed-mucky



Considering this engine has done nearly 200K miles, the backs of those inlet valves are spotless



This is a view behind the passenger side head with a big earth lead attached





And another on the back of the inlet on the drivers side



Heres a view of the famous PCV valve in the back of the inlet



Final shot for today. Exhaust manifold bolts came loose very easily (surprising since 2 of them have been sprayed with coolant for who knows how long).



Manifold to downpipe bolts tomorrow (need burning off) and we'll see if the head will come off that sheared bolt. Thats assuming all the others come off!

Andy.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 10/26/09 07:16 PM

Man, you didnt miss a beat! You'll have that thing running again in NO time!

Do you believe all that junk in the coolant passages? My 200K wagon probably looks the same...
Posted by: 88grandmarq

Re: New big ford owner in UK - project resto/lowrider - 10/27/09 11:02 AM

broken head bolts are fairly common. usually the front head head bolt under #1 or #5 cylinders break off.

Not sure what your plans are for the engine, but a set of E7 (HO) cylinder heads would be a huge improvement !

at the very least, install new valve seals and grind/lapp the valves to the seats on the stock E6 heads.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/27/09 02:44 PM

 Originally Posted By: 88grandmarq
broken head bolts are fairly common. usually the front head head bolt under #1 or #5 cylinders break off.

Not sure what your plans are for the engine, but a set of E7 (HO) cylinder heads would be a huge improvement !

at the very least, install new valve seals and grind/lapp the valves to the seats on the stock E6 heads.


Hi.
Thanks. Why do the bolts shear in those positions? I have changed many pontiac/chevy/cadillac cylinder heads and never sheared one or come across one sheared.

How easy do these come out once sheared? Not tried to move it yet.

Andy.

Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/27/09 03:34 PM

Would be nice to put more efficient heads on, but being in the UK, availabilty is very limited and shipping is really expensive. So, a stock rebuild it is I'm afraid. Wish list though

Managed to get deeper down to the broken bolt today.

The exhaust manifold to downpipe nuts on the studs had to be warmed up with an acetylene torch to persuade them loose, but other than that all came off easily.
This is the first view of the starter when the headers were removed. This leak has been happening for some time.



Head came off easily even with the broken stud. View of the starter was even more disturbing and brown now!



Heres the offending bolt





Need to get a stud remover and have a try at shifting it.

The amount of solidified carbon/oil deposits in the valley was amazing. Heres a few bits.



Perhaps this engine needs a new lease of life? I'm thinking about pulling the motor completely and rebuilding it. Need to have a look at how much money I can chuck at it! I still need a full paint job, air suspension and 20" wheels!! My Wife may need to be REALLY understanding

Andy.
Posted by: 89LTDBoy

Re: New big ford owner in UK - project resto/lowrider - 10/28/09 12:35 AM

Did you flush the engine when you changed the radiator? The coolant passages look pretty nasty...

Good luck with the broken stud. At least it's sticking out a ways so removal might be easier.

The cornering lamps were one of my favorite features of my old Vic. The area I live in is poorly planned, and many places have no streetlights. Furthermore, the subdivision I live in has no streetlights at all and people often wander the streets at night, in the pitch dark. It's very hard to see around corners and those lights made it easier.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/28/09 04:17 AM

 Originally Posted By: 89LTDBoy
Did you flush the engine when you changed the radiator? The coolant passages look pretty nasty...



Hi 89LTDBoy.
The engine coolant was flushed for days and days, with hosepipes and coolant flush chemicals. It was filled with fresh coolant 4 times and run up till warm and then dropped out again. Couldn't really do much more!

Andy.
Posted by: 88grandmarq

Re: New big ford owner in UK - project resto/lowrider - 10/28/09 01:48 PM

 Originally Posted By: andyfanshawe

Hi.
Thanks. Why do the bolts shear in those positions? I have changed many pontiac/chevy/cadillac cylinder heads and never sheared one or come across one sheared.

How easy do these come out once sheared? Not tried to move it yet.

Andy.



No clue why they break... just do.
Personally have NOT worked on one with a broken head bolt, so no clue how difficult they are to remove.
I would recommend replacing all the head bolts with new ones.

FYI... the short head bolts that go in the lower part of the head (under exhaust manifold) go into coolant passages in the block. they REQUIRE you apply some sort of sealer to the threads when you re-assemble.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/28/09 02:01 PM

 Originally Posted By: 88grandmarq
 Originally Posted By: andyfanshawe

Hi.
Thanks. Why do the bolts shear in those positions? I have changed many pontiac/chevy/cadillac cylinder heads and never sheared one or come across one sheared.

How easy do these come out once sheared? Not tried to move it yet.

Andy.



No clue why they break... just do.
Personally have NOT worked on one with a broken head bolt, so no clue how difficult they are to remove.
I would recommend replacing all the head bolts with new ones.

FYI... the short head bolts that go in the lower part of the head (under exhaust manifold) go into coolant passages in the block. they REQUIRE you apply some sort of sealer to the threads when you re-assemble.


Thank you for that. I always replace bolts anyway. Trying to find them in this country may be interesting though!

I have RTV ready and waiting for the install!

Okay, its stud removal time. Heres the tools to do it - hopefully.



Here we go:



Did it move? Yes it did. It was not tight at all. A pair of pliers would have moved it! So did it shear when it was being tightened then?

Heres the offending bolt remains. Now, where to get another one in the UK?



Drivers side head off next, but the middle nut holding the air filter cradle to the exhaust headers had rusted away to almost nothing, so cut through the centre section with my air saw and then weld it back together when it is due to go back





Head off at last.



Now then, its rethink time. Theres not much left in the engine bay now so this may be a very good time to pull the motor and clean and inspect it properly. Then that may be a good time to drop the frame off and media blast. Then that may be a good time to repair and repaint any body damage that I cant get to if the frame was there. That my be a good time to get alll bushes replaced and all pipes/lines and design, build and fit the air suspension. The that me be a good time to...........................oh dear, its all happening again. How many times have we all started a simple rebuild and gone mad?!!!!!!!

Engine crane next.
Andy.



Posted by: 88grandmarq

Re: New big ford owner in UK - project resto/lowrider - 10/28/09 02:19 PM

Thread sealer would be better than RTV.

check on E-bay for the head bolts. Most parts stores sell replacement head bolts in sets.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 10/28/09 03:38 PM

I've never done a rebuild like you're doing, so keep updating us so people like me can learn from your experience!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/28/09 03:52 PM

 Originally Posted By: 88grandmarq
Thread sealer would be better than RTV.

check on E-bay for the head bolts. Most parts stores sell replacement head bolts in sets.


Thanks 88grandmarq.
Our UK stockists are having trouble even finding a listing for these cars, never mind the parts ! Even rockauto dont list the shorter ones.
Anyone know what other vehicles these fitted?

Thanks.
Andy.
Posted by: 89LTDBoy

Re: New big ford owner in UK - project resto/lowrider - 10/28/09 07:44 PM

 Originally Posted By: andyfanshawe
 Originally Posted By: 89LTDBoy
Did you flush the engine when you changed the radiator? The coolant passages look pretty nasty...



Hi 89LTDBoy.
The engine coolant was flushed for days and days, with hosepipes and coolant flush chemicals. It was filled with fresh coolant 4 times and run up till warm and then dropped out again. Couldn't really do much more!

Andy.


Ah, just wondering. It's interesting to see how much crud is left behind even after flushing, and exemplifies how important regular maintenance is.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/29/09 06:46 PM

Today was engine out day.
Heres the last bolt coming out, courtesy of my air wrench



I nipped out in my humble little Nissan Almera (rusty but faithful) and borrowed an engine crane



Now I was on my own, so i could either wait for my Wife and 2 sons to come back from their shopping trip and help, or just get on with it. Sod it, just do it!







Into the garage it goes





Heres a quick glimpse of my camaro that had to be partly put out of the garage to create some space!



And another of it watching closely!



Heres a sad looking engine bay



Next is onto the engine stand and stripdown begins.

Andy.

Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 10/29/09 08:22 PM

Man, I wish I had your drive to get stuff done!

Alex.
Posted by: RustyRodder

Re: New big ford owner in UK - project resto/lowrider - 10/29/09 11:41 PM

wow, you move fast!

bet your neighbors love all this!


nince camaro- guy i know from another site has a silver/blue one in spain...88 with an IROC front, if i remember right.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/30/09 06:36 PM

Hi rustyrodder.
I've got to move fast with this. Car needs to be fully finished by next May. Frame off, media blasted, rebuilt, put back, engine built, tranny checked, air suspension designed, built and fitted, door handles gone, wood off, trim off, front and back bumpers modified, prepped and painted!!

Hi GMGuy.
I have got a lot of energy!


Started on engine resto today.
Starter motor first. This is an ugly mess.



Removed top cover and it had just started to rust through with all the coolant spraying on it. Now thats what you call preventative maintenance. If any water had gone through there, well,......end of starter.



Internals look very clean.



Media blasted it and then put a layer of fibreglass matting on it. Then etch primed it and white primed. Top coats tomorrow.





Media blasted the starter and etch primed and white primed.







Top coats tomorrow. Bright red starter and silver cover. The white primer will make the colours pop! i like bright engine bays!

Andy.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 10/30/09 09:29 PM

That engine lift, even broken down, fits in that little car? Andy, you are quite resourceful!

How about a pic of the sign on your garage door? It looks like it might be funny...
Posted by: ElBlue89

Re: New big ford owner in UK - project resto/lowrider - 10/31/09 02:08 AM

 Originally Posted By: Al Von
That engine lift, even broken down, fits in that little car? Andy, you are quite resourceful!

I thought that was cool too, then I remembered what my bf told me about the little hatchback civic he used to have... he'd use that car to transport long pieces of steel tubing, because with it stuck through the back it fit and stayed in place better than in the bed of his truck. Kinda funny when you think about cargo space!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/31/09 03:25 AM

Hi Elblue and Al Von,
The crane folds flat and with the back seats folded down, fits in easy. The front passenger seat has to slide forward a bit, but I can get a driver and a passenger in as well. Considering i bought that car (10 years old) for about $700 it goes pretty well. Its a parts fetcher! Gets knocked about a bit.

I'll get a photo of the sign for you. Top bit says "Dads Fixit Shop"

Andy.

PS Hey Elblue, that stock car of yours? Isn't it used any more? It isn't just parked up now is it?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/31/09 06:14 PM

Today was cleanup and part stripdown. This engine is covered in oil!

On the stand:


After about 3 hours degreasing the exterior



When I tipped the engine upside down, the debris that came out of the cooling system via the holes in the top of the block by the cylinders was incredible. Loads of compressed air and a serious mess though!

Time to remove the timing cover and water pump. I have a 2/3 legged puller that hooks around the outside of the harmonic damper but that is not wise, so I ground the arms down with my air grinder and went in through the slots with the arms turned the other way round



Worked a treat!

This is a first view of the timing chain. Oily but hardly any play. Notice the block is thoroughly degreased.



Now the good news! This engine has been apart before. The wear in the cylinders is minimal. Timing chain is very good. Oil tight crank seal. Hmmmm. Sump off tomorrow and we'll check out in there. But this engine may need just fresh gaskets, cleaned oil pump screen, new oil etc. It sounded good before, burned no oil and was firing on all 8. Apart from spraying everything with coolant and oil that is!

More photos tomorrow of the bottom end.

Next few weeks then:
1) Finish engine off and cylinder head recondition and paint and assemble on the stand.
2) Design bodyshell brace and stand and drop frame out from underneath.
3) Media blast or use surface processing (http://www.surfaceprocessing.co.uk/index.html) to clean it up.
4) Weld up any areas requiring attention on the frame and the body when access is good. Needs new inner/outer rockers at least.
5) Replace all suspension bushes and pipes on the frame-including the hard to get to rear shock upper mounts.
6) Renew all body to frame bushes and hardware and replace frame.
7) Refit body and trans and suspension and fire up.
8) replace heater core and weld up passenger A pillar where stress carck is near upper hinge (can do that while dash is out)
9) Get car back up and running and weld all door handles and locks up.
10) Design, build and air suspension
11) Paint (2 tone-colours not finalised yet-Chip Foose where are you?)
12) 20" wheels fitted to now lowered shell.

All to be done by next May!
Phew! Thats my winter sorted out!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/31/09 06:35 PM

Forgot to post photos of the sexy red starter and silver cover! Front bit os starter will be painted silver tomorrow.





Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/01/09 06:04 AM

Bad news now!

Costs so far
1. Car purchase price £2500 ($4100)
2. Train tickets to collect it £45 ($74)
3. Proper thick shop manual £24 ($40)
4. PCV grommet £17 ($29)
5. Radiator £142 ($234)
6. plugs, filters, plenum gasket, red cap, thermostat, valve cover gaskets, dizzy cap, rotor etc £158.37 ($261)
7. Wheel cylinders £54.05 ($89)
8. Degreaser and carb cleaner £16.30 ($27)
9. Oil and carb cleaner £25.30 ($42)
10. EVTM (electrical and vacuum troubleshooting manual) £14.89 ($24.49)
11. Engine stand bolts and copper grease £12.39 ($20)
12. Heater matrix £76.64 ($127)
13. Engine gasket set £140.99 ($233)
14. Head bolts £ not sure yet
15. Core plugs £ not sure yet

Total so far of £3226.93 ($5331)
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/01/09 08:01 AM

Started at 6am this morning! Progress will slow from tomorrow because Iam back at work!
At the moment I am waiting for paint to dry.

Timing case prep for paint today.

Started out looking like this


3 and a half hours later and a lot of sore fingers! bare alloy-



Now i may be a pen pusher but my hands are pretty tough, but even mine are now suffering.

Painted silver



Timing marks before



After



Water pump prepped and painted red next.

Heres my sign in the garage



Must change that to read "repay with CASH" for parts!!

Andy
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/01/09 09:48 AM

Waiting for more paint to dry!

Water pump before





1 hour and a bit later



Looks clean in there



In etch primer grey



White primer



Red next.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/01/09 11:25 AM

water pump is now red



While that is drying, its oil pan off time. State of the oil pickup screen will be interesting.

First view inside the pan

Not much debris.

First views of the bottom end





Andy.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 11/01/09 04:17 PM

Considering the 'Z' in Specializing, I'm guessing that sign wasnt 'Made in England', haha! Thanks for posting a pic.

You certainly do nice work, Andy, and thank you for chronicling your build. Hopefully, it will turn into a sticky!

You have made quite the investment in that nice car, even with the exchange rate.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/02/09 01:55 PM

 Originally Posted By: Al Von
Considering the 'Z' in Specializing, I'm guessing that sign wasnt 'Made in England', haha! Thanks for posting a pic.

You certainly do nice work, Andy, and thank you for chronicling your build. Hopefully, it will turn into a sticky!

You have made quite the investment in that nice car, even with the exchange rate.



Thanks Al.
Bought in the UK, but definitely not made here!

Enjoying the build at the moment. Things will get interesting when the frame is removed and the welding starts. I enjoy my bodywork quite a lot

The rear inner wheel arch may have to come out and go further up to enable the wagon to go down low. May have to be mini tubbed!

Back at work today, so not much done. But got in at 2:20 pm and started preping the oil pan for paint. Finally got it ready at 4:30 pm. Plenty of rust on it, but none that has gone through. But it was close.





In grey etch primer



And finally in its silver





The hair dryer is there to get the metal good and warm from the inside! Better not tell my Wife though!

Andy.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 11/02/09 07:01 PM

That hair dryer/wife comment reminds me of one of the positives of not having a wife right now:

I can run my '70 Cadillac pie-pan hubcaps through the dishwasher and they come out SPARKLING! And then back on my Caprice wagon...
Posted by: ElBlue89

Re: New big ford owner in UK - project resto/lowrider - 11/03/09 12:30 AM

 Originally Posted By: andyfanshawe
PS Hey Elblue, that stock car of yours? Isn't it used any more? It isn't just parked up now is it?

Hey, the stock car is my boyfriend's. The racing season is over for the year here and the car is parked in the back of the garage for the winter. That photo was taken at the beginning of the season, and after a summer on the dirt track it isn't so straight... I believe the plan is to rebody it and have a small kink in the rear frame straightened for next year.

By the way, a friend of mine has that same "Dad's Fixit Shop" sign in his garage. Not sure where he got it.

Looks like ya got lots of elbow grease into cleaning that beast!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/03/09 05:38 PM

 Originally Posted By: ElBlue89
 Originally Posted By: andyfanshawe
PS Hey Elblue, that stock car of yours? Isn't it used any more? It isn't just parked up now is it?

Hey, the stock car is my boyfriend's. The racing season is over for the year here and the car is parked in the back of the garage for the winter. That photo was taken at the beginning of the season, and after a summer on the dirt track it isn't so straight... I believe the plan is to rebody it and have a small kink in the rear frame straightened for next year.

By the way, a friend of mine has that same "Dad's Fixit Shop" sign in his garage. Not sure where he got it.

Looks like ya got lots of elbow grease into cleaning that beast!


You mean someone else has one of my signs! Oh dear!

yes theres been a lot of elbow grease, and by the looks of things with the stock car, I won't be the only one!

More updates:
Core plugs installed



I removed the oil pump pickup and screen to check for blockages.



Clean as a whistle!

Masking the block for paint





Gone red at last





I'll start putting it all back together the next few days.

Andy.
Posted by: mikei1983

Re: New big ford owner in UK - project resto/lowrider - 11/04/09 07:46 PM

Awesome work. Just wondering (you may have already said it) why you are going with red.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/05/09 11:26 AM

 Originally Posted By: mikei1983
Awesome work. Just wondering (you may have already said it) why you are going with red.


Hi mikei1983
Why is it red?
The interior is maroon leather (dark red!), part of the cars paint scheme will most likely be red, most of the cars I build end up red, I like bright cheerful engine bays, and I like red In summary, red is brilliant

Andy.



Posted by: Ethan

Re: New big ford owner in UK - project resto/lowrider - 11/05/09 03:15 PM

Wow, I just spent an hour reading this whole thread. What an awesome project! Andy, I'm picturing you as Ed China from Wheeler Dealers.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/06/09 03:05 PM

 Originally Posted By: Ethan
Wow, I just spent an hour reading this whole thread. What an awesome project! Andy, I'm picturing you as Ed China from Wheeler Dealers.


Who?

Your car makes mine look a bit sick though!

Okay, lets get this engine back together

Finished starter motor


New crank seal in timing cover


Heres the timing cover bolted on, and you can just see the elusive oil pressure switch reinstalled



Another view of the cover and pump


And another showing timing marks


Oil pan on next and harmonic damper and pulley paint.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/08/09 04:48 AM

Long day yesterday.
Managed to prep and paint the engine mount brackets, the harmonic balancer and the crank pulley.

Heres a shot of the engine mount brackets with 1 about ready and the other not!


Degreasing the balancer and the crank pulley before the 4 hours of prep work started!



One or two of the harmonic thingymajig undergoing work





Crank pulley





Oil pan on at last





Now, this bit got filthy and interesting.
For those that have followed this thread from the start, you will remember that I spent hours and hours with a hosepipe flushing the block and heater core through with water and then with chemicals to clean the cooling system. Then ran the engine up 4 times with fresh water each time. Was it clear? I thought it was, until I ran the pressure washer through the freeze plug openings. Look at the colour of the water that came out!



Bit clearer now


Tell you what, taking photos and pressure washing at the same time makes for interesting states of wetness and awkward stances-trying to avoid the inevitable splash back!!

Don't know what happened on this photo, but you can see the colour of the water on the floor-good job my Wife was out with the kids!



Valve regrind/lapping in next. Joy.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/08/09 12:46 PM

Now then, thinking forward to the air suspension. I'm going to need plenty of space above the wheels/tyres when the car goes down to the floor, so heres a mod I will do to the rear.
Hopefully the diagram will tell the story.



Front suspension will be shockwaves from airride technologies. I will modify the frame slightly when it is out to get it lower at the front.

Andy.
Posted by: Yoder

Re: New big ford owner in UK - project resto/lowrider - 11/08/09 05:31 PM

AWESOME!!!
Posted by: Roo

Re: New big ford owner in UK - project resto/lowrider - 11/09/09 03:11 PM

Ey up Andy. Didn't realise you were over here as well.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/09/09 03:46 PM

 Originally Posted By: Roo
Ey up Andy. Didn't realise you were over here as well.


Hi Roo.
Certainly am! You are in the sunny bit though, and i am right up at J29 of the M1!
Nice cars you have there. Do you do your own spannering?

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/10/09 01:38 AM

Valve lapping in time.
Here's a first view of an inlet valve and the seat have i spent a few mins lapping it in





Now thats not a valve that has done 165k miles. These have been before.
Notice the milling marks on the head surface also. This has been skimmed before. No way am I going to risk having it skimmed again. This would be taking it too thin for the waterways. It checks out very well for flatness with no pitting or scoring at all.

Exhaust valve



Looking clean also. May have hit lucky with these heads!

Andy.
Posted by: Codyy

Re: New big ford owner in UK - project resto/lowrider - 11/11/09 01:18 AM

Wow just read the entire thread and I'm enthralled! Can't wait to see the final product!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/11/09 01:29 AM

Thanks guys, I'm seriously looking forward to removing the frame and starting some bodywork! I enjoy the mechanical side and the electrics, but the welding and painting is something else!
Think I need therapy!!
Certainly after lapping valves in for hours yesterday, i need some destress technique! Only 10 more valves to go, then its painting the heads time.
Keep following along.

Andy.
Posted by: 88grandmarq

Re: New big ford owner in UK - project resto/lowrider - 11/12/09 08:46 AM

 Originally Posted By: andyfanshawe









Just so you know....the large groove in the harmonic balancer is NOT the TDC mark. TDC is the 0 mark on the balnacer with the rest the numbers stamped in.
Posted by: 88grandmarq

Re: New big ford owner in UK - project resto/lowrider - 11/12/09 08:47 AM

andy.... I sent you a PM about cylinder heads.

check it out.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/12/09 10:57 AM

 Originally Posted By: 88grandmarq
 Originally Posted By: andyfanshawe









Just so you know....the large groove in the harmonic balancer is NOT the TDC mark. TDC is the 0 mark on the balnacer with the rest the numbers stamped in.


Thanks 88grandmarque.
I assumed it was until I prepped it for paint and some marks and numbers magically appeared under all the rust! Some very comprehensive BTDC and TDC marks! I marked the balancer with a centre dot at the point where I want the engine to be when I put it all back together.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/13/09 05:05 PM

After numerous boring hours lapping valves in and degreasing surfaces and changing 2 core/freeze plugs, the passenger side head is ready for paint





Etch primer on



Heres a photo of the plate blocking the exhaust passage in the head for the old thermactor system



Finally in red



Then installed the harmonic damper and crank pulley. Looks good now!



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/18/09 05:07 PM

Finally got the heads on and torqued down!



Now I've got 20 head bolts rather than 19 and a sheared one!

Onto the intake:
Heres the filthy thing





Then it was stripdown time. 3 of the injectors wouldn't come out of the intake at all. It took an hour of persuasion to get them loose! Not sure if they'll work again though!!

Here it is ready for media blasting





Here it is degreased and media blasted ready for etch primer tomorrow





Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/19/09 04:41 PM

Managed to etch prime the intake.
I am always amazed at what appears under the grease and oil and corossion.
These letters appeared:



Just to the left of the FORD logo is a circle with 1989 written in it. Really hard to see in the photo, but neat nevertheless!







Better get this engine together and finished and plan to get the frame removed asap.

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 11/20/09 05:12 PM

nice.

Alex.
Posted by: 88grandmarq

Re: New big ford owner in UK - project resto/lowrider - 11/21/09 11:54 AM

 Originally Posted By: andyfanshawe
Finally got the heads on and torqued down!



Now I've got 20 head bolts rather than 19 and a sheared one!

Andy.


I hope you used sealer on the shorter bolts that go on the lower side (under the exhaust manifold)
those bolts go directly into the water jackets.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/21/09 04:07 PM

Thanks 88GM.
I certainly did. I'm a veteran of many small block chevy and windsor/cleveland engines , so wouldn't miss that one!!


Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/23/09 04:02 PM

Final few engine jobs before we plan to get the frame down and out.

Heres the AC support rod primed before it goes black


Heres the intake coolant pipe painted black and the water pump pulley after 1 hour prep!



Installed on the engine. Poor photo-sorry! Doesn't do it justice. Chrome valve covers ordered.



Onto the exhaust manifold/headers. The studs are well rusted and I may as well change the 02 sensors so out they come. Sensors came out easily, but the studs wont. So, heres a procedure to guarantee their removal! Call is stud removal 101!!

Clamp in vice


Cut top of both studs off ..................



so I can get a deep reach hex socket on (14mm)



Warm around the stud with an acetylene torch (not too much though).........



and at the same time use a breaker bar and a bit of gradual persuasion. As soon as it starts to move, remove the heat and employ the good old 1/2" ratchet



Heres the manifold awaiting prepping for por15, with the threaded holes still intact



And heres the old studs.



Just got to order the new ones now!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/23/09 04:33 PM

Now the interesting bit starts.
The frame will be removed with the car outside the house-half on the road and half on the pavement! I'm on a very quiet road, so should get away with it!! All work to be done outside!

The plan is to support the transmission (like this).....................




raise the car up on 4 railway sleepers under the wheels, remove the trans and prop and fuel tank (my Wife wants the fuel!). Remove all seats to loose as much weight as possible. remove battery and anything else that can be removed easily to save weight.

Then design and build a cradle that will sit on uneven ground to hold the car aloft. I'll post up the design soon. Then remove steering intermediate shaft, rear axle and front suspension (may be difficult and dangerous with the weight of the engine and trans not there). Pull the frame out, put it on the garden on stands (got to work outside you see), strip it of any pipes etc, cut out and weld up any corrosion, get it media blasted and paint.
Then move back to the shell and replace the rocker panels and inner rockers with fresh steel-paint and rustproof. Media blast any corrosion that will be difficult to get to with the frame on, then reinstall the frame, all suspension components with new bushes, and all running gear. Fire engine up, and then strip out the dash and passenger front door. repaire stress cracks on upper hinge area and paint. weld up all locks and handles, remove all wood effect stickers and drive to the bodyshop and get it painted. Tow bar fitted, stainless exhaust designed and fitted, glass limo tinted, stereo replaced by mp3/hard drive one, and we are cruizin!
All before the end of next april!!! Car shows to get to!!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/26/09 03:18 PM

Heres a box of injectors waiting to go off for ultrasonic cleaning. I wont do this until the engine is going to go back in because of the risk of sticking pintles after cleaning and lpng term storage. Oh, and a couple of O2 sensors.



Heres the remnants of the exhaust header studs. Into the bin we go.



Heres the design of the cradle that will sit under the rockers and support it while the frame is removed. May put 1 more under the front and another under the rear, but with slightly different design.



I plan to build this in 2 weeks and get it under and the frame out by the start of my xmas vacation. Media blasted, modified, painted and back under 2 weeks later!!

All working outside-in the lovely UK xmas weather.

Andy.
Posted by: TheTank

Re: New big ford owner in UK - project resto/lowrider - 11/27/09 12:26 AM

nice build
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/28/09 04:15 PM

 Originally Posted By: TheTank
nice build


Thank you.

I'm now fed up of mucking about with the engine and bits, I can finish that off when the weather is so bad that I can't work on the frame.
In the meantime, prep for frame removal.

While tidying up to create some space, I dug out the old exhaust system that was on the car



As you can tell, the cats are still on it, but there is no support for the exhaust except for the 2 studs on each side where they bolt to the headers! Thats a lot of weight and leverage.

I now need the car up in the air on safe stands so i can remove the fuel tank and transmission and driveshaft. So onto railway sleepers it goes.





This is where the car will stay even when the frame comes off! I've warned the neighbours already!

There's loads of fuel in the tank so I used my power probe to run the fuel pump via the fuel pump test circuit connector on the LH inner fenderwell



Heres a pipe I connected from the fuel line to the tank of my daily driver. 20 mins later and the tank is dry.



As soon as the floor dries out a bit, I will remove as much as I can from the car to cut down the weight, but still leave it looking decent so as not too attract too much attention.

Heres a first view of a frame to body bolt, nut and washer!



Andy.
Posted by: Cowtown Cowboy

Re: New big ford owner in UK - project resto/lowrider - 11/28/09 07:33 PM

I hope your bolts come out easier than mine. Half of them either broke off or the stamped nuts inside the body spun out.
Fortunately Ford stamped dimples in the floor pan that are exactly over the nuts. Made it real handy for cutting holes with a holesaw.
Also you'll probably want to remove the front clip as an assembly before removing the rest of the body. It is easy to do once the inner fenders are out of the way.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/29/09 05:17 AM

Thanks cowtown cowboy.
your resto is damn fine to read about! Hows yours going?

At least you are working inside!!

I'm going to leave the front clip on and support it on a frame. I can't have a partly dismantled car standing outside for any length of time. This has got to be done fast and efficiently and back together. I will modify the frame for air suspension, but that shouldn't take long.

I'm going to strive to remove all bolts intact!! Should be fun.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/29/09 06:16 PM

Pouring down today, so couldn't do much outside. So, I had a look at the seized AC compressor.

Had to pull the field coils off with a puller



after removing a sad looking hub



This is the view when it was removed (or when part of it came loose!)





Don't think I can fix that!

And, just to add insult to injury, when the centre shaft of the compressor is turned it is really rough. So thats the end of that then!

Put that to one side for the moment and its onto the power steering pump cleanup and bracket paint.

Heres the pulley being removed



And with it off



Clean up and paint time next.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/03/09 04:29 PM

As promised, prepped and painted the power steering pump (red) and bracket (silver).



Got home from work today and it was actually dry but very cold (3 degrees). But I can easily cope with that as long as I stay dry, So, underneath and remove the transmission. And, boy was that heavy. The heaviest trans I have ever shifted. Especially on my own. Couldn't even take a photo since I was a bit busy and manily covered in trans fluid! And I had to cut the top line through with a hacksaw because I couldn't shift it. I am going to replace them with kunifer 10 anyway.



While I was under there I had a quick look and photo of the frame on the passenger side rear near the axle. And I'll tell you, it is rusty!



Heres the end of the trans x member



So removing the frame is a damn good idea before it is too late!

Fuel tank out next, then seats, then fabricate the support frame and get it all supported under the rockers and its down with the frame.

More photos to come.
Andy.

PS Wish I had cowtown cowboys workshop!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/05/09 01:48 PM

Onwards and upwards then. Prepping for frame removal.

Fuel tank removal next.
Does anyone else have this build up of water in the fuel filler neck opening?



By the way, how does the gas tank filler neck come out of the opening? Won't go out forwards or backwards!!

Anyway, after not much struggle at all, the tank gave way



Bit of a rusty mess, but we'll see if it cleans up.

Heres the straps and pins-also rusty



I received the deox c rust removal crystals in the post a couple of days ago, so lets try it out. Supposedly amazing stuff. See http://www.bilthamber.com/deoxc.html for full impressive details.

Heres the bottle



Pouring into a bucket of hot water



Heres the rusty power steering pulley before it goes in



And here it is in the mixture



Leave it for a couple of days and I'll post the results.

Heres a photo of the rusty frame now its visible without the gas tank being there.



Andy.
Posted by: pantera77

Re: New big ford owner in UK - project resto/lowrider - 12/05/09 03:48 PM

That rust doesn't look to bad, mostly surface.
And there should be a little tube in the gas filler neck opening that lets water drain out, unless wagons didn't have them?
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 12/05/09 06:50 PM

Wagons definitely have the drain hose, it ends in the fender well, to the rear of the tire. Its probably clogged with road debris.

And the filler neck is a just a slip fit into the tank, through that thick rubber grommet.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 12/06/09 09:32 AM

 Quote:
I received the deox c rust removal crystals in the post a couple of days ago


Phosphoric acid? Known on this side of the pond as Naval Jelly (for the gel. Also comes in liquid and crystal form).

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/06/09 04:25 PM

Thanks guys.
The crystal is phosphoric acid and I found the tube!

Found the drain tube for the gas filler door and stuffed a screwdriver up it! Did it drain the water out? Err.....no.



So, stuck the airline up it and blew. Did it work this time? Err......yes it did as all the water shot out and landed on top of me!

Heres proof that it now operates as it should.



Back to the frame removal.
Popped off to the local steelstockists and bought £100 worth of 8cm box section and 50mm angle iron for the body supports.



I then went inside the car to remove the seats and the passenger carpet was wet. Can't blame the heater core for this, so its up with the carpet and have a look and dry it all out.



So I went off to check the drain holes at the base of the windshield.



More on that later.

Here's the air compressor for the self levelling rear suspension



Thats going and be replaced by a more modern equivalent with air springs and a digital control system. I may even incorporate the rear ride height sensor into the new system.

I like the way someone has replaced the tired and split rubber mounts with a tie wrap!



Onto the steering disconnect. Simple, undo the pinch bolt at the firewall and slide the shaft forward and thats it. No its not. Would the intermediate shaft slide? No way. So, undo the pinch bolt at the steering box and unbolt the box itself and remove the shaft, This time it worked.
Then onto the bench to unseize the sliding joint and regrease and clean up.



Here it is all freed up, cleaned and gaiter resecured.


Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/07/09 04:11 PM

This is the heater fan removed (very tight space). You can see where the water has entered through the plastic grille above and gone into the left hand section that is visible through the hole where the fan used to be. This is where its supposed to go. There is a drain hole in that LH section that was blocked. So the water spills over into the RH side and into the cabin. You can see the rusty heater flap hinge.



This is the rusty stud and nut that I have had to nibble away with a die grinder to get the plastic vent off. I have now sealed the vent down with black RTV sealant so water doesn't enter there at all. I'll see what happens, but it seems to be dry inside now after a lot of rain. I'll replace that stud when the dash comes out for the heater core replacement.



By the way, what is that brown horseshoe shaped bracket for in the front left of the picture? Is it to scrape off the skin off your hands and fingers? 'Cos if it is, it works!!

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 12/07/09 04:45 PM

The finger scraper grounds the hood.

Alex.
Posted by: pantera77

Re: New big ford owner in UK - project resto/lowrider - 12/07/09 05:49 PM

I wish i had half as much motivation as you do to work on my car!
Posted by: White Falcon LS

Re: New big ford owner in UK - project resto/lowrider - 12/08/09 08:28 PM

Andy,

I've only just seen this thread, and read through all your posts. What a remarkable effort! These cars are as common as hen's teeth in the UK, and I'm sure this will turn out even better than your Camaro! \:D All the best of luck! I'm looking forward to your updates.

Are you planning an LPG conversion as well, or will you keep running it on petrol? Not sure what the prices are where you live, but I know up in Glasgow it's around £1.04 per litre on average! Even if it's a weekend driver, it can get costly rather quickly!

By the way, I would highly recommend Mobil 1 0W-40 for your engine. Would do beautifully for 15,000 miles (if you drive that much!) or 1 year. It's quite pricey over in Halfords, etc. but when I was in the UK, I used to pick up 4 litres for £19 at Costco. I remember buying nearly 200 quid worth, minus a tenner, of oil and getting some stunning looks from people. Opie Oils has it going for £42.29 for 5 litres, but Costco has some brilliant offers if you have one near by and have a membership.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/09/09 02:45 PM

 Originally Posted By: pantera77
I wish i had half as much motivation as you do to work on my car!


Nice one! Plenty of motivation here I can tell ya!

My Wife says if I haven't finished it by the end of April she is going to buy a Chrysler Voyager to pull our caravan!! Nooooooo!!

I've got 2 weeks off at xmas, so I'll be outside come rain or shine.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/09/09 03:49 PM

 Originally Posted By: White Falcon LS
Andy,

I've only just seen this thread, and read through all your posts. What a remarkable effort! These cars are as common as hen's teeth in the UK, and I'm sure this will turn out even better than your Camaro! \:D All the best of luck! I'm looking forward to your updates.

Are you planning an LPG conversion as well, or will you keep running it on petrol? Not sure what the prices are where you live, but I know up in Glasgow it's around £1.04 per litre on average! Even if it's a weekend driver, it can get costly rather quickly!

By the way, I would highly recommend Mobil 1 0W-40 for your engine. Would do beautifully for 15,000 miles (if you drive that much!) or 1 year. It's quite pricey over in Halfords, etc. but when I was in the UK, I used to pick up 4 litres for £19 at Costco. I remember buying nearly 200 quid worth, minus a tenner, of oil and getting some stunning looks from people. Opie Oils has it going for £42.29 for 5 litres, but Costco has some brilliant offers if you have one near by and have a membership.


Hi.
Thanks for your comments. Not putting LPG on it. I'm still not a fan of that. If I can't afford to run it on petrol I will sell it!!! It doesn't do that many miles anyway, pulling our caravan around the country to various shows and seaside resorts. Probably about 1500 miles ish.

It'll never be like my camaro but it should look quite radical. Theres no way my Wife will let me spend all that money and time again on another project like that. That was a one off-never again.
I'll keep you posted on the updates. Many more to come.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/09/09 05:08 PM

After 4 days in the deox c rust remover solution,





Notice that the rust has been removed right inside the "loop".

Quite impressed by the results. Still need seriously cleaning and prepping though. I also noticed that any slightly weak paint is also removed by the solution.

Here's a fan heater drying out the interior after the leak cure (hopefully)



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/10/09 01:25 PM

Support frame time.

Start with a length of 80 x 80 by 3mm box section, and add 2 50mm angle iron on the end for stability.
Hope you guys in the US like my welding mask design!



Put under the car and weld in a vertical support with a notch for the rocker panel spot welded flange.



Add diagonal supports for front/back and side to side loads





Other side



Front is a bit different. The rocker panel flange is very close to the frame side member so I welded in a section of angle iron at the top of the vertical support.



Then ran out of time and argon/co2!!

Finish it off and fully weld tomorrow.

Andy
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 12/12/09 05:36 PM

Nice welding helmet, Andy. Is that a bit of sunshine in pic #4?

Nice job, I hope this thread becomes a sticky!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/13/09 05:22 PM

 Originally Posted By: Al Von
Nice welding helmet, Andy. Is that a bit of sunshine in pic #4?

Nice job, I hope this thread becomes a sticky!


Hi Al.
Sunshine? In fact it was!! A rare glimpse.
Nice to see you have recovered from the marmite tasting!! I have never actually tried it.

Thought the welding helmet would please!

Still struggling with the cradle.
Here is the rear framework



I will now sleeve a smaller tube into the 2 verticals and get an adjustable support (like an axle stand). Shall I buy some or make some? All stockists shut and I haven't got time to spare, so lets make some

Start with the identical tube that the verticals are made of and cut them up to remove 4 9mm strips of material.



Then weld them back together



Still not managed to finish weld everything, so I will continue this tomorrow, and try to sit the rear of the wagon on its new stand.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/15/09 02:39 PM

Here's the final design of the rearmost stand with adjustable verticals and fully welded.



Just got to fully weld up the front support and then unbolt and drop everything!!

In the meantime, I've been thinking. I don't like the fuel filler neck where it is, so....what about relocating somewhere else? But where?
What was that car where the fuel filler cap was behind the rear light unit? Be a reasonably simple job to pivot the light unit and reroute the tube to exit just behind. Hmmm......

Andy.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 12/15/09 03:37 PM

Some mid-50's Cadillacs had the fuel filler behind the left tail light, as well as '55-57 Chevies.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/20/09 03:38 PM

Not posted for a few days but been seriously busy with the car in the background.

Front suspension removal today. Even though it is 2 degrees and snowing on and off!



But how to compress and remove the spring without causing major damage to the car, me, passing animals or nearby houses?
The car is now not heavy enough to compress the spring, so lets remove the wheel first and have a look - good view of the support structure also!



Remove caliper and disc. Cut through the drop link with my air saw, Loosen and remove top swivel ball joint nut and hit with a hammer! Keep out of way while doing it!



Of course the spring wont fly out because the shock will fully extend and then stop.

Then climb into the engine bay with the famous air saw and cut the stud off above the seriously rusted nut. Then stand on the engine x member and cut vertically down through the shaft and nut and wait for the spring to pull it through the hole.



This was followed by a big bang and a jolt through the car while i was stood on it!

Here is what happened



The spring won't come out because the shocker is stopping it, but the tension is off the spring.

Shock removal and out it comes. The shocker has seen better days



Sway bar removed



Then it started to snow really heavy..........



so it was time to pack up and resume later...or tomorrow. Rear axle next.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/20/09 03:53 PM

Notice I have put the front wheel back in place on top of 2 railway sleepers so it looks reasonable to the neighbours!!!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/21/09 02:31 PM

Todays task (in the snow) was to remove the rear axle. Nobody available to help so I took it steady!

The back right shocker with integrated air bag is in a bad way, but all bolts came undone easy. Not bad after 19 years. I left the upper trailing arms and shox's in place hanging from the frame.


Then I had the task of dragging the axle out from under the car, around my Wifes car and across the sidewalk and down the path to the back of the house. Luckily the snow helped make it easier and I then put it on a small wooden trolley to prevent scratching the blocks on our path. That thing is heavy!!

Here it is on the patio awaiting a bit of a clean up and paint.



Only a few more minor pipe clips to undo, pull handbrake cable through the front frame under the firewall, disconnect a few brake pipes to the M/C and its frame bolt removal time. Then frame out.

Plans include welding repairs to it first, then off to be checked for straightness, then off to be media blasted and powder coated in true overhaulin' style! I will route the air lines for the rear airbags before it goes back.

Then its inner and outer rocker panel repair and the frame goes back and everything goes back in. Then its bodywork time, and finally air suspension and wheels/tyres install.

Just one question....how heavy is a bare frame? Can 2 of us lift it?

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 12/21/09 05:00 PM

Ironic, you have more snow than we do.

Alex.
Posted by: 04clone

Re: New big ford owner in UK - project resto/lowrider - 12/21/09 05:08 PM

 Originally Posted By: andyfanshawe
Just one question....how heavy is a bare frame? Can 2 of us lift it?
All the car shows i've watched over the years i've never seen 2 guys lift a frame
Posted by: Cowtown Cowboy

Re: New big ford owner in UK - project resto/lowrider - 12/22/09 09:40 AM

2 strong guys should be able to lift the bare frame, but 3 would be more comfortable. I had no problem picking up the back of mine and wheeling it around like a wheelbarrow on the front wheels by myself.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/22/09 02:25 PM

Thanks cowtown cowboy.
Hows your resto going? Looking forward to your next photos.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/22/09 03:07 PM

Anyway onto todays jobs.
I know what happens this time of year (seen 48 of them!), things are wanted (desired even?! ) and everywhere's shut! So thinking ahead....bought some MIG welding wire, some 1.6mm thick steel (for sills etc), some 3 mm plate (for frame) and some more angle iron for more bodyshell bracing. Oh, and a 21 mm combo spanner from Halfords!! Mine has gone walkabouts :dontknow:

Front and rear bumper removal first then. Heres a view of the front bumper bolts



Bit rusty but nothing that an air ratchet and plenty of lube won't sort!

Here are views of the front and rear bumpers removed.





Heres a thought. Have a look at the distance between the chrome bumper and the bodywork. Theres a white filler panel there. Is it me, or does the bumper look like it doesn't reach far enough down the side of the body?



May fit it closer to the bodywork and loose the filler panel. Anyway, thats in the near future.

Than had to do xmassy jobs that didn't involve car work (plumbing parts for sink repair!). On my return it was dark and all neighbours tucked away cosily in their houses, so it was into the garage to do some work in there.

Lets strip the front suspension down. I pulled the LCA and knuckle off together, so first job was to break the lower ball joint taper which was easy for one but took a bit of time for the other one!! A big hammer always works well!

Then just enough time to press the ball joints out of the arms. Now i have a big vice and it should cope with this (done it a few times before on my camaro).

Heres the setup:

Heavy curved piece of steel, LCA, 32mm 3/4" drive socket and another socket to press. And a big hammer to hit the vice handle



Heres the 2 offending ball joints (one worn, other not bad, but they are both going in the trash) and the tools needed to remove them



A final shot of the wagon in the snow with all wheels balanced in place under the arches to give the impression of completeness (before the bumper came off)?? Keeps the neighbours happy.



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/23/09 11:41 AM

Final prep for frame removal today and probably xmas eve also.

Lets try to loosen all the frame to body bolts and see how many shear/spin or do other awkward things!

7 bolts per side, making 14 altogether (can you tell i am a maths teacher?!).
2 have sheared (the same one on each side ironically- the one nearest the front wheel under the firewall) so they won't cause a problem for frame removal. But I will have to remove the sheared remains when the frame is clear.





The one at the furthest rear on the drivers side has spun the captive nut inside the body. So this is the hole I will have to cut to get access



All the rest have come out easily. So overall pretty good.

Another little discovery under the rear carpet



A bunch of crayons! May use them to design the paint job!

Yesterday I ordered 2 lower ball joints, 2 upper ball joints and an upper A arm bush and shaft kit. Oh and 2 drop links. I'll post the cost up later. Needless to say the shaftkit is coming from New Jersey and will take a couple of weeks to arrive in the UK.

By the way, anyone know where I can get some body to frame bushes? RockAuto don't even list.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/23/09 02:19 PM

Thanks gator.
I'll look into it.

Prepping the suspension parts for paint. Here's one of the spindles. greasy rusty thing it is



After about an hour scraping/degreasing/chipping flacky rust off



Its now gone in the derusting solution for a day or two.

Here's a sight you don't see everyday. A big heavy car supported on a bucket!



Andy.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 12/24/09 10:17 AM

Hi Andy,

On the rear bumper, I have thought about removing the filler and tucking the bumpers, but I found it easier to simply buy an '88-'91! IMO, the '88-'91 is the perfect Box, combining the boxiness with smoothness...

The wagons all used the same rear bumper, 79-91, even though in 88, Ford smoothed the sedans, fitting the bumpers flush to the body.

Nice work, Andy! You are very clever and persistent.

Merry Christmas
Al Von
PS: Yes, I somehow survived my adventure with Marmite. Now the jar is on the shelf in my garage, with the other gasket-holding materials!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/25/09 01:03 PM

Rear frame support built



and one spindle in derusting solution



Andy.
Posted by: larryo340

Re: New big ford owner in UK - project resto/lowrider - 12/25/09 09:54 PM

Looking real good so far, are you going to powercoat them or just paint them?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/27/09 02:39 AM

More progress-this is the spindle as it came out of the solution and after a bit of extra cleaning, and its new silver paint





This is the acess hole cut out to reveal the spinning captive nut. I have already cut the cradle clear and bent it back so I can get a spanner on it.



It sheared off anyway, but at least the frame can come down now. I was also mistaken earlier on when I said there were 14 frame bolts. There are in fact 16, as I found out when the frame wouldn't come down!

Heres the frame coming clear and being dragged out the front. And, as usual, I had to do it on my own!



Frame stripdown now, welding repairs, off to be media blasted and powder coated and its everything back on and replaced.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/27/09 02:47 PM

Heres the frame on the drive in front of the garage



2 of us moved it with great difficulty up the garden and leaned it on our tree for the cutting and welding to start



That frame is heavy!

Heres the corner that has been plated before that will be done properly this time.



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/28/09 05:17 PM

Frame welding today.
Heres the frame corner that is just behind the front drivers side wheel.
As you can see it has been plated.



Whats the betting that it has been welded over rusty steel?
Here it is after the plate has been cut off



There you go then! I was right! The usual shop stuff doing the job wrong but in the quickest way. If I was a shop owner, would I plate over rust for a quick buck, or do it properly?

Anyway, here it is in various states as I gradually cut away the rot to good steel.
Note the corossion on the inner wall. This is no doubt due to water lying in there.







A slightly different view



Then my air saw packed up! Can't believe it. Have to get one tomorrow.

In the meantime, lets get the suspension arms ready for media blasting.

Heres the LCA ready to go



How to remove the top bushes in the upper arm when thet are as rotten as this when coolant has been spaying on it for years!


Set fire to the rubber,



knock the arm through and push out the shaft. Then press out the remains of the bush.



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/30/09 03:15 PM

Day off yesterday getting a new air saw and doing mundane things as the rain pors down.
Today wasn't as bad so I got back to work.

Finally cut out the last of the rot in the corner of the frame with my new airsaw



First repair section fabricated out of 3mm plate and clamped in place



Welded in



and a nice finishing touch-re profile the elongated hole



If the weather holds out a bit tomorrow (some chance), I will finish off this side.

All the blasting/powder coating places are not answering my calls. so all must be shut until the 4th january. Typical. Holidays to do jobs, but can't because everywhere's shut. And they all open up when I am back at work.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/31/09 01:22 PM

Finally finished welding one side









The other side is just as bad so another few hours repeating all this!

I have set up the wagon where I want the wheels to be - roughly.
What do you think of this?





Thats what I call low!!
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/01/10 05:29 PM

Over to other side of frame today, so flipped it over (easier said then done I can tell ya!).

Looked far better than the other side, so only a bit of work then? Err........no!

Looked suspicious so off came the front section to reveal....................



So a good half hour later with a cold chisel, an air saw, a air die grinder and a big hammer and all major corrosion is gone



Finish this off tomorrow.

In the meantime its thinking out loud time...........

Most places are back at work on monday - including me - so I have to decide what to do with the frame.

Media blasting is only half the story. In fact its exactly half the story. What about the inside? The important half?
I am going to get a price for media blasting and powder coating and then another quote for chemical dipping and electrostatic coating and possibly powder coating. I'll report back on the costs.
This has got to be right, no point in building a car on a dodgy frame is there?

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 01/02/10 12:07 PM

Nice to see somebody else thinking about the inside of the frame.

Whats your thoughts on adding a drain hole to the corners now that you have been upclose and personal?

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/02/10 01:18 PM

 Originally Posted By: GM_Guy
Nice to see somebody else thinking about the inside of the frame.

Whats your thoughts on adding a drain hole to the corners now that you have been upclose and personal?

Alex.


Hi Alex.
Now thats a damn good idea. I'll get them drilled tomorrow when I finish welding the other side. I can also get to the other side of the hole to deburr it if I am careful with my die grinder.

Thanks for the advice. That one simple hole could make this frame last years longer. And when it gets full of chemical stripper, it has to come out somewhere.

Nice one.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/03/10 10:57 AM

Sunny but cold day today, but I must get the welding on the frame done.

Drag welder out of the garage in position and look at this for a winter sight!



Simple weld up of the corner



and its on to a weak spot on top of the frame that is rusted and thin. Directly under a body mount.



But how to get the hole back in the right place? Make up a template



then bend it back out of the way, do the repairs, fold it back and cut the hole out! Simple!







Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/03/10 11:13 AM

Heres a strong piece of angle iron clamped across the rails to prevent twisting while welding



Heres the finished hole



Andy.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowri - 01/03/10 04:03 PM

Nice work, Andy! And you have the advantage of 220V house electric to run the welder on!
Posted by: MR_CLEAN

Re: New big ford owner in UK - project resto/lowri - 01/03/10 04:59 PM

Very nice work! Ive done a fair bit of welding lol Thats quality work there! Cheers!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/03/10 05:16 PM

Final photo after a long but fruitful day today.

Here's a photo of an engine mount complete and the other with the rivets drilled out and the clamshell split.



Now I can clean it up properly and put some paint on.

I have also put in the acid bath the upper trailing arms for the rear axle.

Photos of that later.

Back to work tomorrow in the snow and ice, but I'm sure I can squeeze some time in tomorrow somewhere.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/04/10 04:04 PM

Contacted Surface Preparation Ltd http://www.surfaceprocessing.co.uk/index.html today for a quote on chemical cleaning/stripping of the chassis and Electrophoretically coated. Cost for all this is £1300 ($2100).

This will produce a chassis that will need a further coat of paint to finish, but will last years!

An alternative is hot dip galvanising which will probably make it last 25 years +. I'll get the cost of this next.

A lot of money though!

Andy.
Posted by: simontemplers

Re: New big ford owner in UK - project resto/lowri - 01/05/10 06:33 PM

Could you get a late crown vic and use the chassis axles engines etc. Are they the same chassis 77-02 and you would get all mods rear disc brakes 4.6 engine etc.
I bought a 3 year old cv taxi for $1000 no rust but 300000 miles had £1600 in it in the uk after taxes paid. Sold it to film prop company. Must be plenty others about rolled cop cars etc
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/06/10 09:45 AM

Hi Simon.

I think you misunderstand.
The chassis is sound. It needs rust removal techniques inside and out. No big deal, just finding the right people and the right price. Certainly doesn't justify ripping everything out and replacing the lot!!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/06/10 04:16 PM

Interesting developments on the chassis front.
If the chassis is chemically stripped down to bare metal inside and out it is £480 + VAT. Then it needs treating inside and out. Another £670 + VAT will prime it eltropheretically. Then it has to be powder coated or painted which will be another few hundred if a good job needs to be done. Plus transport to and from there which could be £200. This will head us off into the £2000+ region and a bit silly.

On the other hand there is a top galvanising firm nearby (less than 10 miles) that I have heard good things about. Guaranteed good work and a friend of a friend! Derusting phosphoric acid first and all the trimmings. The frame won't need painting after this and will last between 34 and 150 years (according to the tech write up).

I will get a price on this tomorrow hopefully and post it up.

Andy.
Posted by: simontemplers

Re: New big ford owner in UK - project resto/lowri - 01/06/10 05:12 PM

No the reason i said this is because you were considering so many mods maybe rear disc brakes etc. Also the cost of Surface preparations then it would still neep powder coating.
I thought using a late CV say a taxi you would get all modern mechanics but with the boxy shell. That way you would get best of both worlds.
The taxi i got was $1000and only 3 1/2 years old Mechanically it were fine many new bits but the body was battered. The chassis frame were like new.
Either way im sure it will look good. I remember seeing your Camaro at Menwith Hill i were in the Caprice cop car.
By the way if you get bored you can do the Caprice up next if you wish \:\)
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/07/10 02:56 PM

Had a chat to the owner of the galvanising firm and he advised that I didn't have it done. When I asked why. He said that it will be dipped in a container of molten zinc at 450 degrees and it will most likely twist. Might not, but might.
Well I can't replace the chassis if it does, so I agreed it may not be the wisest move!!

So, it was off into the garden to have a look at the chassis and a deep think! Looking inside the chassis, it is surface corroded in only a few places. And all those are accessible to a media blaster. So, I contacted a media blaster and powder coater for a quote. I am still witing for that, but have now resigned myself to the fact that it now won't be rust stripped on the inside. But it will be heavily rustproofed with Dintrol 3125.

In the meantime I have loads of work to do on the car outside but cannot because it is way below freezing most of the time. Piggin' frustrating.

Heres a view from my eldest sons bedroom window at the snow laden frame leaning against our tree! Awaiting something to happen!



Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 01/07/10 06:04 PM

I have never heard anyone on this side of the pond ever consider galvanizing a frame. Plus, any future weld repairs are going to need to have it all ground off anyway to safely weld it.

Mostly, people "over here" go with powder coat, anti-rust paint (por-15 for the more extreme folks, zero rust, or just plain regular off the shelf rust paint for most people), or self etching primer + auto paint after a stripping.

Can't say there is a wrong way, just whatever your budget will allow.

Here in the rust belt, oil spraying is popular to keep rust at bay (reapply yearly), something you might be able to do to coat the inside of the frame rails, get one of those old style garden sprayers mix some kerosene or diesel with oil so it sprays and douse the inside of the frame. Now, since you have some sort of draconian regular auto inspections, this might not be an option since it does drip.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/09/10 04:49 PM

Thanks GM Guy.

All good thoughts. We have a product called Dinitrol 3125 rust proofing wax that has been proven to keep rust at bay and protect against further rusting. Works especially well inside box sections like frame members.

Interestingly one of my neighbours said who am I doing all this work for? When I answered "myself", he said, no you're not, it will be the next and subsequent owners that benefit, so don't go too far down the perfectionist route!!
Bit pessimistic but true.
Won't stop me doing a damn good job though-for me or any other future owners!

Still waiting for a quote, so its onto the suspension component prepping for paint.

For any non believers of the deox-c acid crystal rust remover stuff (or naval jelly type of stuff in the states), here are a couple of photos of the rear axle upper trailing arms. They went in rusty lumps and came out looking like this





The rubber bush is untouched.

Even the nuts and bolts are clean and rust free. And this is an acid bath outside in a plastic container with an inch of ice on the top! Can't wait to see what it can do when it gets warmer and more active!

Andy.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 01/11/10 07:56 AM

keep going just wish i had the time and money and waiting ability to do all that to my car
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 01/11/10 10:40 PM

Those control arms came out nice.

Your neighbour has a valid observation. But then, if you ain't going to do it right, don't do it at all.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/12/10 04:33 PM

Quite right Alex. We are on he same wavelength!


Fuel line reconstruction now. They are all very rusty and there is no way I can exactly reproduce them.

First I located some exact diameter pipe (5/16 and 1/4") then put on a one way circlip (thats what I call it anyway) and pushed it onto the tube to make the stop to prevent the fuel connector being pushed off under pressure

Heres the new and old end (black tape on the end to prevent scratching)



Heres the first section bent to match the section from the fuel filter back



Now got to repeat this for the rest!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/15/10 03:24 PM

Frame booked in to be media blasted and powder coated. But in the meantime I have to mock up and pre assemble the fuel and brake lines before it goes.
So, more pipe bending!

I bent up the main 8mm fuel line on the passenger side in kunifer 10. Difficult to photograph but heres an attempt





I'll try and photograph the whole line tomorrow in daylight.

Onto the 6mm vapour line on the passenger side. This line is loooong and needs to be bent in one piece if possible. This is the front of it with the flare bubble going on (swage)



This is the state of the main fuel line after being sprayed with coolant for a long time.





I wouldn't like to trust these for much longer. Doesn't bear thinking about - gas being sprayed out right next to the exhaust.

More complete photos tomorrow with new P clips holding the lines to the frame.

Had a brilliant price from RockAuto for the rear self levelling air shock absorbers. $80 for the pair! I was quoted 4 times that from a place in the UK!! So they are on their way from the states.

Andy.
Posted by: PseudoBoat

Re: New big ford owner in UK - project resto/lowri - 01/16/10 01:11 PM

Your new lines look distinctly copper-like. Are they in fact copper? I have used copper to replace my lines in the past, and it's worked fine, but always wondered if it was in fact a poor choice. Anyone have any opinions/knowledge on the subject?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/16/10 01:53 PM

 Originally Posted By: PseudoBoat
Your new lines look distinctly copper-like. Are they in fact copper? I have used copper to replace my lines in the past, and it's worked fine, but always wondered if it was in fact a poor choice. Anyone have any opinions/knowledge on the subject?


Kunifer 10. A copper alloy. Used them for years in the UK.
Tried and tested. No opinions needed.

Andy.
Posted by: pantera77

Re: New big ford owner in UK - project resto/lowri - 01/16/10 01:55 PM

 Originally Posted By: PseudoBoat
Your new lines look distinctly copper-like. Are they in fact copper? I have used copper to replace my lines in the past, and it's worked fine, but always wondered if it was in fact a poor choice. Anyone have any opinions/knowledge on the subject?

Copper works fine. It's whats underneath my car right now.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/16/10 02:51 PM

Heres a couple of photos of the main fuel line and the vapour line installed on the passenger side.





Heres the bolts holding the line clamps down after a few days in the acid bath.



And now a request. The connectors to the tank and the filter have little o rings in them (2 per connector). Shown here in a couple of bad photos! Anyone know where to get them from? Anybody got some lying around they wouldn't mind sending on?!





Return line bent up today in one full section. Photo tomorrow in the light.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/19/10 05:52 PM

Finally finished the lines on the drivers side (5/16 fuel return and 3/16 brake pipe). You can just about see the black line also. This is the airline for the self levelling rear suspension shock absorbers (see below).





Going to media blasting next few days. I'll try to get some photos. Quoted £280 ($458) for blasting and powder coating.

Rear shox arrived today from RockAuto.



Be a good addition to airsprings!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/19/10 06:23 PM

Managed to locate 2 part body mounts on ebay US for $7 plus $28 shipping !



If anyone has any of these or can recognise them as being from something else, please let me know!

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 01/20/10 04:51 PM

You'll be wrapping the copper on final installation right? (Galvanic Corrosion if/when the frame coating wears away).

Alex.
Posted by: lincolnmania

Re: New big ford owner in UK - project resto/lowri - 01/20/10 06:47 PM

 Originally Posted By: andyfanshawe
Managed to locate 2 part body mounts on ebay US for $7 plus $28 shipping !



If anyone has any of these or can recognise them as being from something else, please let me know!

Andy.


that is a lower body mount........good luck finding a complete set of body mounts, i gave up and started using universal energy suspension body mounts and having custom spacers made up......so far have changed the body mounts on around 6 box panthers.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/23/10 04:59 PM

Okay, frame ready to go to be media blasted and powder coated.

So now the body has to be ready to accept it. All ares that are not accessible when the frame is back in must be checked.

But, the 2 sheared frame to body bolts first.
Heres an offending bolt well rusted in



Warm it up with an acetylene torch, stud remover on, turn it with every confidence of it coming out and.......................



it sheared off further up!!

So, there was no other way than to drill and retap. Job done.

The inner sills (rockers) have looked dodgy for a bit, so lets see.

Heres a view of the rear of the drivers rocker panel with a clip for the stainless trim. thats the first to go then!



Looks a bit rusty around the wheelarch area.
Heres a series of photos as I delve deeper in!

View from inside the wheelarch


View from underneath



Put my hammer through this one!



More cutting out





Heres a interesting view down the inside!



Looks bad, but.......................now this is where i was really surprised......... I blew compressed air down the sills to dry them out, and this is how it looked



The outer panel is hardly touched but the vertical inner one is rotten for about 30 cm back. I have welded many lower panels up but have never seen an outer panel survive. The rust is only surface and very minimal inside. Interesting.

Anyway the rust goes up higher so i need to cut out a bit more in the top corner and into the floor. But it is not that bad at all. Makes a change!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/24/10 04:32 PM

I took the decision today to remove the last section of the outer rocker/sill to get access to the rusty section further up. I can then weld the section back later.



Heres a close up view of the rusty inner panel at the top



This is it all cut back as far as I can without major surgery



I will media blast the top section where the rust is next, then weld in the new inner panel.

Heres a view from the back



Heres my wooden support rod!!



The inner panel is 3mm thick, so into the garage to cut some. Found some 1.6mm and some 3 mmm but no 2mm. Typical. So, progress halted until I can get some.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/24/10 05:27 PM

 Originally Posted By: Bluemobile
Nice job. Just out of curiosity, how heavy is the body itself? how did you lift it up off the frame? Does a regular jack work? Did you gut the interior before lifting?


Hi bluemobile.
Not sure how heavy the body is! The body was jacked up with 2 trolley jacks a bit at a time and more and more wood put under the tyres. i raised it high enough so the frame could be lowered out from underneath on the trolley jacks.

Then I lifted it up a bit higher at the back and made the stand adjustable so I could slide it down out of the way while the rocker panel welding was being done.

As stated above, the frame was then lowered out from underneath and dragged out!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/26/10 04:06 PM

Got 2mm plate now, but by the time I get home from work its dark, so don't really want to weld it until the weekend when I can actually see what I'm doing.

The van arrived to pick up the frame yesterday. He said a week to do it, but I asked if he could keep it 2 weeks!! Give me chance to get the body ready for it.



Heres a couple of photos of the inner sills/rockers undergoing surface rust removal. Only got so far. Now need the spot welds media blasting to complete it.



You can just see the seat belt mount renforcing plate in this photo that is rusting. That needs to come off, be reconstructed and welded back.



Onto media blasting the rear of the drivers side inner wheelarch and the connecting floorpan.







Only slight pinholes in 3 places. Nothing a spot of MIG weld won't solve!

Blasted really well, but creates a bit of a mess to say the least!!

Heres one old and one restored engine mount



Heres the drivers side one with the rivets drilled out and getting ready for the acid bath.



Seriously looking forward to getting the frame back in its new BRIGHT RED powder coat, and doing some welding!

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 01/26/10 05:03 PM

We're looking forward to seeing it.

While you've got the rocker corner cut out, good oppertunity to spray some rust paint in there.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/27/10 01:34 AM

 Originally Posted By: GM_Guy
We're looking forward to seeing it.

While you've got the rocker corner cut out, good oppertunity to spray some rust paint in there.

Alex.



Hi Alex.
You are quite right. It will be drowned in dinitrol 3125 and then heated so it flows out of all the seams. I have also drilled three 1" diameter holes under the ally trim panels on top of the rockers to help get the fluid all over.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/27/10 01:33 PM

Received the 2 lower body mounts and exhaust manifold studs today, so parts are starting to come in thick and fast.

Good time to express my thought on this build while I am on a rare sit down and relax session! Kids watching tv, Wife at work and too late to work outside.

This build has been the toughest one I have ever attempted. For a variety of reasons:
Its winter and I'm working outside!
Parts are difficult to get (sometimes impossible!)
Short and adventurous build time.
Only good time is weekends in the daylight, and even then its raining or snowing and I am prevented from welding.

So all in all, its a really tough project but still enjoyable. Even though I am exhausted sometimes. Thinking forward to the time when the frame goes back and everything starts to be reassembled. Should look really good. Heres hoping it may actually work!

Thanks must go to my good lady wife who has to take over all the chores, looking after the kids, tidying up after me when I come in filthy and stinking to death, visiting my parents, helping with the kids homework, avoiding car parts stored in the house, ...................while I try to complete this build of what she calls an ugly car!! But i know it won't be when its finished . Whether she actually drives it is, at the moment, unknown!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/30/10 03:20 PM

Right, lets get this rocker panel complete.
Inner one fabbed and clamped and welded on both sides and etch primed and painted red for corrosion protection









Outer panel media blasted and stainless trim holes welded up 'cos I'm not using them anymore!



Wheelarch lip reduced in width



Welded in and thoroughly rustproofed inside





Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/30/10 03:32 PM

Remember this seat belt reinforcing panel?



Looks rough on the bottom?

Here it is removed





and the panels it was welded to







marked for cutting out



and cut out



New panel cut and in





Am I glad I shifted that. When the frame is in, access is impossible.

New one made up and welded tomorrow and its off to the other side. Of course, that will be nowhere near as bad as this side!!!! Ha!!!!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/30/10 04:55 PM

Heres an idea.
Behind the rear wheels is a quarter panel that is almost straight from top to bottom! Shouldn't it follow the profile that the doors do as they go down to the rockers?

So, bend along the red line and push the bottom of the panel in towards the middle of the car.



How far can I go in without going to close to the frame?

Time will tell.
Andy.
Posted by: pantera77

Re: New big ford owner in UK - project resto/lowrider - 01/30/10 05:29 PM

Man I wish I had 1/10 of your fabrication skills! My idea of fixing rust is pop riveting some sheet metal over it.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 01/31/10 09:53 AM

 Originally Posted By: andyfanshawe
Heres an idea.
Behind the rear wheels is a quarter panel that is almost straight from top to bottom! Shouldn't it follow the profile that the doors do as they go down to the rockers?

So, bend along the red line and push the bottom of the panel in towards the middle of the car.



How far can I go in without going to close to the frame?



Interesting idea. Have a good look for what undersides will potentially get exposed. As It sits right now, my exhaust pipe is hidden from view, but if the rear portion was folded in, the exhuast pipe and underbody would come into view.
Will you be match the angle on the bumper ends, since it lines up with the lower rocker.

Heres a pic I've got to give you an idea of spacing. If you need another angle let me know.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/31/10 02:23 PM

 Originally Posted By: Bluemobile
Are you gonna do the same in the front? The header panel is made of fiberglass and won't be as easy to fabricate.


Hi Bluemobile.
Don't know about the front yet. I know the bottoms of my fenders at the front re held together with bondo!!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/31/10 04:26 PM

 Originally Posted By: GM_Guy
 Originally Posted By: andyfanshawe
Heres an idea.
Behind the rear wheels is a quarter panel that is almost straight from top to bottom! Shouldn't it follow the profile that the doors do as they go down to the rockers?

So, bend along the red line and push the bottom of the panel in towards the middle of the car.



How far can I go in without going to close to the frame?



Interesting idea. Have a good look for what undersides will potentially get exposed. As It sits right now, my exhaust pipe is hidden from view, but if the rear portion was folded in, the exhuast pipe and underbody would come into view.
Will you be match the angle on the bumper ends, since it lines up with the lower rocker.

Heres a pic I've got to give you an idea of spacing. If you need another angle let me know.

Alex.


Hi Alex.
Mine doesn't look like that!



Not a good picture and taken upside down, but my rear inner quarter is very close to the rail (finger width) on the pass side. That is where the spare wheel is kept, so I could easily relocate the spare (or remove it altogether) and join the bottom of the outer to the bottom of the inner.

Have you a photo of the other side on yours?

Thanks.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/31/10 04:54 PM

I need some paint to go on the underside of this wagon. Something that will be tough and long lasting, seals in and neutralises any minor rust that is left behind, is a good colour and sticks really well. Oh, and must set/dry in very low temperatures.

After a bit of research, I came up with this



http://www.rust.co.uk/epoxy-mastic.cfm

This is supposedly the best on the market. £110 to my door for 5 litres and 2 pack (paint and hardener) and in an aluminium colour.

Will dry to a rock hard finish down to -10 degrees C.

I want the whole of the underside to be painted in this stuff eventually. Should look nice and bright under there!

Should be arriving mid week. Will report back.

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 01/31/10 07:04 PM

Mine is an '89 Sedan. So no floor cubbies. Forgot about that.

Alex.
Posted by: pantera77

Re: New big ford owner in UK - project resto/lowri - 01/31/10 08:52 PM

 Originally Posted By: andyfanshawe
I need some paint to go on the underside of this wagon. Something that will be tough and long lasting, seals in and neutralises any minor rust that is left behind, is a good colour and sticks really well. Oh, and must set/dry in very low temperatures.

After a bit of research, I came up with this



http://www.rust.co.uk/epoxy-mastic.cfm

This is supposedly the best on the market. £110 to my door for 5 litres and 2 pack (paint and hardener) and in an aluminium colour.

Will dry to a rock hard finish down to -10 degrees C.

I want the whole of the underside to be painted in this stuff eventually. Should look nice and bright under there!

Should be arriving mid week. Will report back.

Andy.


Sounds like good stuff. I've had good luck with por-15, stuff works amazing.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/01/10 04:05 PM

Thanks guys.

Did I say that the passenger side would be better!!! Well I was wrong. Very very wrong.

This is the first view inside the rockers/sills



The rust has spread up into the bottom of the C post and the metalwork right under the back door. The outer rocker, even though it is galvanised, is also seriously weakened.

Heres the bad rust areas ringed



Further down the inner rockers towards the front is also bad.

This will take some time to repair-but I have 2 weeks! The frame is arriving tomorrow in its new powdercoat so it looks like it will be back on the garden until the rust repairs are done.

What is amazing is the amount of rust metal that has come out of the rockers. I'll get a photo tomorrow.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/01/10 04:21 PM

 Originally Posted By: pantera77
Man I wish I had 1/10 of your fabrication skills! My idea of fixing rust is pop riveting some sheet metal over it.


Hi pantera77.
Thanks for the compliments! trouble is I end up doing harder and harder projects that cost more and more money!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/04/10 12:13 PM

Heres a few shots of the frame after media blasting and powder coating













And the final one of the glorious colur coat of bright red! Although it looks orange in the photo.



Before anyone asks why red? Well, I'm not going through all this work to powder coat a frame black so you can't see it when its in! I want it to be painfully obvious that its there!! Cant wait for annual inspection time! And its my favourite colour of all time!

Before anyone criticises the colour, ..................I don't care!!!

Andy.
Posted by: Cowtown Cowboy

Re: New big ford owner in UK - project resto/lowrider - 02/04/10 01:09 PM

Good on you!
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 02/04/10 01:18 PM

I like it. Will the underside of the body be a different color so the frame will really stand out?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/04/10 03:18 PM

 Originally Posted By: Jeff2
I like it. Will the underside of the body be a different color so the frame will really stand out?


Yep.
2 part epoxy mastic in a nice silver!
So it will stand out!

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 02/04/10 04:26 PM

OOoohhhhhh.... =-)

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/05/10 03:33 PM

After 3 days of snow and rain, I got my chance to start the rust repairs on the passenger side.
Wonderful!!

Now I can't get any body panels for this, so whatever I cut out I have to weld back. Or make a new panel from flat steel. What I plan to do is a combination of the two. Remove panels as clean as I can, replace the rusty bits on those panels, then weld them all back in. Simple eh?

But first lets find the true extent of the damage

Heres an explanatory screwdriver jab!

Gone through here



and here



Heres the back of the panel in the last photograph. You can see why it corrodes-a double skinned panel that collects moisture behind



This is interesting. There is a black foam material that is inside the panel. When this was squeezed (by my chisel!) water came squirting out. No wonder it is rotting from the inside down



Hers a peek inside at the extent of the rust. Doesn't look too bad now! yeah right!



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/05/10 03:50 PM

Heres what I plan to do

Cut out this panel cleanly with air saw and drilling out the spot welds



This will leave the way clear to remove this bit nice and clean



That will leave the rocker/sill completely clear for me to remove the last section of it



I can then repair the inner rocker panel and then weld the new repaired panels back!

This is a view of the rust remains that have come out of the rockers and cut out already! These used to be good clean steel!



Andy.

Repair/remake all panels
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 02/05/10 04:46 PM

 Quote:
This is interesting. There is a black foam material that is inside the panel. When this was squeezed (by my chisel!) water came squirting out. No wonder it is rotting from the inside down


Welcome to the evil of building cars for the stupid buying public. New cars come with even more foam crapiness hidden in panels all for the sake of noise control.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/06/10 10:36 AM

Here we go then with a systematic removal of panels one by one to see where the rust ends!

First bit off in the corner nice and clean



Rounded corner bit next. Here it is with the spot welds drilled and ready to cut along the black line


Wonder how bad it is under here?





Not bad for a change.

Rocker marked for cutting



And out we come



I can see whats happened here. Water has got onto the foam that was inside the panel and run down into the rocker panels gradually rotting it out.

The inner panel is rotten where it is welded to the box section under the floor. So that needs to come out as well



At last, good metal! Here it is cleaned up and media blasted, ready for reconstruction



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/07/10 05:39 PM

This is the back of the outer rocker with the inner rocker cut off.



You can actually see where the water has entered at the top and run down and spread out. The bottom of the outer rocker panels are almost rust free.

In my opinion this is entirelty due to the water being held by that black foam stuff that is injected in for sound deadening. I will make sure this foam is removed from the other side and thoroughly rustproofed also.

This is where I think the water is entering. Through this plug.



Check yours guys!

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 02/08/10 04:56 PM

Can that piece of foam be grabbed and pulled out in one piece from the plugged hole?

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/09/10 04:07 PM

Hi Alex.
Unfortunately not! Its stuck really well to the metal. Like chewing gum. Really hard to shift even witha sharp knife through a hole cut in the inner wheel arch.

Been trying to think of a way to shift it. From filling the cavity with petrol and setting fire to it!!! (Don't!) to blowing compressed air into the cavity and drying it out. On regular intervals. Although its taken 20 years to take its toll!!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/11/10 05:02 PM

Had a few days off due to the weather and working. But had a chance tonight to cut the new inner sill (rocker) out of the correct 2mm plate steel and drill it for plug welding. Here it is clamped in place





Welded in



I have a week off from tomorrow so should get quite a bit done. Unfortunately I have been let down by a chap in the states who has failed to ship some spacers for the new poly body to frame mounts. This will put me back about 2 weeks. Disappointing.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 02/12/10 05:02 PM

Have you got all the buiscuit pieces? What kind of spacers? This side of the pond we reuse the hard parts from the old bushings.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/12/10 05:43 PM

 Originally Posted By: GM_Guy
Have you got all the buiscuit pieces? What kind of spacers? This side of the pond we reuse the hard parts from the old bushings.

Alex.


Hi Alex.
Hard parts are all okay. No biscuit pieces available. All parts obsolete. Searched for weeks and weeks.
Using poly bushes from energy suspension but needs spacers to make them fit the holes in the frame.

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 02/13/10 09:20 AM

I can't picture what you are referencing.
Which biscuit? Spacers?
If you got the poly pieces, and the hardware, you are set. Not all poly pieces fit perfectly, center them and tighten down the bolts and they won't move. The ones for my Nova where first production energy suspension, the thickness was fine, but it wasn't the tight fit that newer pieces have but they have not budged in the 15 years they've been on the car.
Gotta run. I'll see if I can dig up some pics later...

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/14/10 05:25 PM

 Originally Posted By: GM_Guy
I can't picture what you are referencing.
Which biscuit? Spacers?
If you got the poly pieces, and the hardware, you are set. Not all poly pieces fit perfectly, center them and tighten down the bolts and they won't move. The ones for my Nova where first production energy suspension, the thickness was fine, but it wasn't the tight fit that newer pieces have but they have not budged in the 15 years they've been on the car.
Gotta run. I'll see if I can dig up some pics later...

Alex.


Thanks Alex.
I didn't realise the poly bushes would work if they weren't an exact fit in the hole. The spacers filled in the gap. That little bit of info should save me a whole bunch of time! Thanks.
Those pice would be nice.

Anyway, further progress made yesterday and today.
Etch primed and painted the inner sill/rocker red!



Heres the old inside of the outer sill/rocker



and the partially blasted and rewelded one!! You can see the patches butt welded in.





Here it is sealed, etch primed and painted red inside.





Here we are clamped ready for welding



and finally welded in



and painted white temporarily



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/14/10 05:44 PM

How about this for progress!

Before



After





The brown stuff inside is dinitrol 3125 rustproofer and to make it get into all the seams I heat it with a hot air gun until it drips out everywhere.

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 02/15/10 09:49 AM

As long as the poly bushing is resting on the mount you'll be fine. If its something that you think would nag at you down the road, make a bunch of metal slugs/washers with the hole size you need and weld them into the original hole. Or tack them into place on top of the mount.

Alex.
Posted by: DetroitP71

Re: New big ford owner in UK - project resto/lowrider - 02/15/10 09:26 PM

Don't finish it to quick!
It will be winter here for a while we need something to keep us entertained. It is a real joy to read your posts.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/18/10 04:01 PM

Thanks guys. I'll do my best!

Phew. Feel knackered after a few days so called holiday! I actually work harder in my hols than when I'm at work!

Anyway, where did I get to? Oh yes, the c post rust.
Here is the bottom of the C post clamped into place



Welded





Primed ready for a spot of filler and paint



Now onto the final bit of welding (or so I thought) before the frame goes back, which is the inner rocker/sill. I know its rusty inside because I've seen it when looking down, but how bad?

So 1 long cut later and the bottom bit is gone





Looks a bit dodgy at the front, so out with my chisel and oops!



Here is the inner panel cut out a bit more so I can see inside and the true extent of the rot



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/18/10 04:13 PM

Now I really need to cut right to the front, but I can't because the body is being supported there. Hmmmm? I know, I'll media blast the inside as much as I can and then rustproof it till I can get the frame on then remove the fender and cut off the base and reconstruct.

Heres an interesting shot from the inside looking forward towards the front passenger wheelwell



The bolt is the fender bottom one.

Doesn't look too bad now but will still need reconstructing at some point.

While the camera was there, heres a shot the other way inside the rockers towards the rear passenger wheel



Still some more work to do then!!

Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 02/19/10 10:25 AM

This is all very informative. I've noticed rust spots starting to bubble through on my 91 Crown Vic in the same spots that you're finding are rusted nearly through. \:\(
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/20/10 12:21 PM

Time to tidy up that inner panel and make a replacement to butt weld in.
Before that its cheer me up time!

Here are the red powder coated upper A arms for the front suspension. Look sexy!





Okay, thats remotivated me, so lets make a new inner rocker (sill) panel. This has got to be accurate since it will be butt welded all the way round







I have had to make it in 3 sections because I didn't have a single sheet long enough! I will weld them together first on the bench and then weld them in fully.
The bottom will then be cut level.

I need to treat the inside of the rockers first.

Andy.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 02/23/10 01:41 PM

8pg of posts

remind us of what color the frame was going to be?

and them is some fine control arms
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/23/10 03:49 PM

 Originally Posted By: Justin McCarter
8pg of posts

remind us of what color the frame was going to be?

and them is some fine control arms


Hi Justin.
Going to be a lot more than 8 pages by the time its finished!

The frame is bright red! Exactly the same colour as the control arms! And under a cover on my back garden awaiting a warm day so I can uncover it and photograph it.

Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 02/24/10 10:08 AM

Keep those pictures coming. I don't know about anyone else, but when this is all done, I'd like to see this thread become sticky. This is really turning out to be a step-by-step "How to restore a Box" guide. \:\)
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/25/10 05:08 PM

Finally got the inner sills/rockers welded in, but not before I painted the sides that will not be accessible when they are in



Heres a few views of the welded in panels-ready for grinding, sealing and painting







The white streaks are paint trails when attempting to get paint inbetween the joints - successfully!

Heres an imortant step. Rustproofer poured into the panels and heated up till it flows out of all the joints and drips onto the floor



You can see the brown fluid on the bottom of the welded seam



You can also see a nasty rust spot under the passenger door! Thats on my list!

Heres a photo of one of the new poly body to frame mounts that arrived yesterday



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/27/10 04:59 PM

Forecast is not good for the next few days, but I don't care! I need to get the frame back as soon as possible so I can get this car to the bodyshop.
So its finish off a little bit of welding and prep the underside for its new silver paint!

This involved removing all seam sealant to check underneath for rust and wire brushing and surface rust removal-all on the passenger side.

Heres a few photos going along the rockers and towards the back. i feel quite proud of this. The view before it all started was horrendous. The view now is fantastic.
Apart from the brown surface rust, it is now clear and green! Or is it..............

Front



Going further back








Heres the rear seat belt reinforcing plate that is concealed above the frame when it is in



Only surface rust which will disappear under the media blasting! I will pour rustproofer in behind it before I seal it off.

This is directly above the rear wheelarch



and just a bit further back



This is where it gets interesting!
Heres the frame mounting point just behind the rear wheels. The black lines are metal fatigue cracks. It is not down to corossion. It is exactly the same on the otherside. Hmm, design flaw?



Heres 1 more views of the back



Still some rust removal to do, but we are almost there.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/27/10 05:11 PM

Thought i would try out this rustremoving gel



Here it is applied where the middle seatbelt reinforcing plate was (and will be again!)



I will post another photo up tomorrow after it has done its work!

Some nice little jobs to do here.....
All the seat belt bolt reinforcing plates and the seat bolts reinforcing plates are rusting and so is the steel underneath. Like this one



Very simple to remove - 4 spot welds drilled, chuck plate in acid bath for a few days, media blast and paint rusty steel on car, weld panel back and repaint everything.

Its all in the details!
Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 02/27/10 11:28 PM

 Originally Posted By: andyfanshawe

This is where it gets interesting!
Heres the frame mounting point just behind the rear wheels. The black lines are metal fatigue cracks. It is not down to corossion. It is exactly the same on the otherside. Hmm, design flaw?


Two theories,
First, frame flex, and in turn, trunk floor flex, which twists around the more solidly affixed body mount.
Second, how where the old bushings? If any of the forward bushings where rotted out then the weight of the body and contents would be concentrated on the lone rear mounts.
A third theory I suppose, whoever owned the wagon at first carried a lot of cargo, putting added stress on the rear mounts, starting off the cracks, and then just subsequent normal movement carried it on.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/28/10 05:01 PM

Hi GM Guy.
Thanks for that. Want to see the real reason? Read on...

Media blasted and seam sealed loads of welded joins today. That stuff is smelly and "harmful" so it was out with the air fed mask and get stuck in.

I got everything set up to go underneath, set myself up underneath and got comfy and......... forgot my masking tape to get a smooth edge! "Sod it" said I so I just put it all on and I will clean up the edges tomorrow. It will also give me a chance to see how well it has stuck.





Just got to weld up the metal fatigue cracks and we can start painting the passenger side.



But something is not quite right. The capive nut is spinning and the metal seems thin and weak. But it welded up okay with no burning through so it can't be thin due to rusting.

Theres no alternative but to open up the panel and have a look inside.

Where to drill though? Difficult to assess where the hole needs to be on the inside of the cargo area. So lets take a guess................here (black spot)



Here we go then



Heres the view .........



Just can't see what is happening apart from rust!

So another hole drilled and here we are



The captive nut cage has broken free on one side and the nut has slipped out under it.

It looks as if I have no option but to remove the panel that I have drilled completely and replace the panel where the captive nut is. And all other panels that need patching around it! Then weld a new inner panel in.
This will put me a few days behind, but needs to be done. And I am assuming the other side will need doing also.

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 02/28/10 07:34 PM

 Originally Posted By: andyfanshawe

It looks as if I have no option but to remove the panel that I have drilled completely and replace the panel where the captive nut is. And all other panels that need patching around it! Then weld a new inner panel in.


Your not going to try dicking around with another captured nut are you? Drop a 1/2" bolt through the hole and put a rubber plug in the hole you drilled. With some luck, your double hole corresponds to a standard oval plug size.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/28/10 09:38 PM

 Originally Posted By: GM_Guy
 Originally Posted By: andyfanshawe

It looks as if I have no option but to remove the panel that I have drilled completely and replace the panel where the captive nut is. And all other panels that need patching around it! Then weld a new inner panel in.


Your not going to try dicking around with another captured nut are you? Drop a 1/2" bolt through the hole and put a rubber plug in the hole you drilled. With some luck, your double hole corresponds to a standard oval plug size.

Alex.


Hi Alex.
No, I can rescue the captive nut cage dead easy. Its the corrosion around it that I want to cut out. The metal is very thin and once the frame is in I have no chance of doing it.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/01/10 11:06 AM

 Originally Posted By: GM_Guy

Your not going to try dicking around with another captured nut are you?
Alex.

Did you really mean that to sound how it did Alex?
"Dicking around"? Not too impressed by that.

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 03/01/10 05:18 PM

Guess that must be one of those phrases with two different meanings on each side of the ocean.

Over here: Dicking around = wasting time with/mucking about with.

In this case: trying to rebuild it as built, as opposed to doing the obvious and much less work version that'll work as good or better.

I think I can guess what the phrase means over there from what you quoted, but enlighten us.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/02/10 01:52 AM

Hi Alex.
The meaning or implied meaning is not pleasant.

The panel inside is rotten. No getting away from the fact that if it is left holes WILL appear directly round the frame mount. Yes I could just replace with a nut, but what good it will do will only be short term.
I'll post some more photos up with the inner panel removed to show how bad it is.
I want no regrets with this. No thinking "I wish I had done this and that" when the frame goes back. If that means a few more hours work to get piece of mind, then so be it.

I am sure the phrase "taking a short cut" applies over there, but that I am definitely not doing.

Besides I enjoy doing it!

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 03/02/10 05:20 PM

10-4. When I read you needed to fabricate a new interior panel, thats what I was homed in on as it looks to be in good condition, save for the holes you needed to drill. Fixing rusted bits is a given at this point.

So, will google.co.uk give me the proper UK meaning of what I typed?

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/02/10 06:16 PM

Digging deeper then.............
Heres the dodgy frame mount revealed after i cut out the panel in front of it



Heres a closer view. You can just see where I welded the cracks up from underneath



So my decision to remove was correct. There is a bit of rust there that needs stopping.

Right. Lets media blast and see what happens



The corner looks very rusted and in fact went through when I prodded it! The lap joint under it will need cutting out and replacing too.

Heres the panel I cut out with the cage on it



Underside of it



Lets get welding then and reinforce that area better........

Andy.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 03/03/10 01:07 PM

I like how he says what were doing like the old show "The new Yankee work shop" or Bob Vilia from this old house

I hope he isn't expecting us all to be there when he lowers the body to the chassi, but i'll be there in spirit.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/03/10 03:59 PM

 Originally Posted By: Justin McCarter

I hope he isn't expecting us all to be there when he lowers the body to the chassis


No, I'm raising the chassis to meet the body.

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 03/03/10 07:31 PM

It'll be an uplifting experience, I'm sure...

Alex.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 03/05/10 01:15 PM

so do you guys always type your name like that or does it do it itself

Justin, aka the driver of that bas asd Crown Vic in Lima Ohio. .. quote"That car isn't a manual hes just forcing up shifts. but i've been wrong before."
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/05/10 04:52 PM

Here's the corner cut out where the rust is





Here's a panel fabricated with a Step (or joddle) in it that you can just see



In place



This is a close up view of the underside of the captive nut for the frame bolt. You can just see cracks all over. This is very weak and contributed to the metal fatigue cracks on the hatch floor that I welded up. So my decision to remove a perfectly good outer panel was well and truly justified.



I am going to strengthen up the area to prevent further cracks and weld back the exterior panel. Thats tomorrows job.

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 03/05/10 05:44 PM

 Originally Posted By: Justin McCarter
so do you guys always type your name like that or does it do it itself


I sign what I write. Good ettiquette that seems lost on "todays" generation that can't be arsed to sign their words, and you gotta address them with their sill myhandlenameistoolong.

Alex.
Posted by: RustyRodder

Re: New big ford owner in UK - project resto/lowri - 03/05/10 11:37 PM

I agree, not to mention the basic grasp on the english language tends to be lost. I don't ask for perfect language, but please know the different 'there's and the difference of your and you're.


Alex.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowri - 03/06/10 07:54 PM

Indeed!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/07/10 04:50 PM

Had a sneak peek at the frame today since it was sunny!



Finished welding in the repairs to the frame mount on the right and closed off the panel with my spot welder





The seat belt reinforcement panel here is rusty



Here it is removed. Too much rust underneath.



Cut out the rust and plate made up to fit with a joddled edge. The numbers are for my good lady wife to push the panel with a pry bar while I weld it from underneath! I tell her the number and she pushes there!





Over to the other side. Which I am expecting to be just as bad.



In fact it was far worse



Heres a view from the other side to show how far the rust has gone



More welding to do then!

Andy.

Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 03/08/10 12:33 PM

 Originally Posted By: GM_Guy
 Originally Posted By: Justin McCarter
so do you guys always type your name like that or does it do it itself


I sign what I write. Good ettiquette that seems lost on "todays" generation that can't be arsed to sign their words, and you gotta address them with their sill myhandlenameistoolong.

Alex.




Sorry for the improper English. So then I may assume the answer would be you type it in your self.

Andy nice picture of the frame. I'm looking forward to a web page for that car such as Supermotors, cardomain, etc. As well as a two or three page special in a magazine.

and i know i am to not to speak like that

Justin.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/09/10 03:14 PM

Cutting deeper to try and get to the end of the rust.
Heres 2 photos to show the extent of the rust.
The black lines are where the panels have been cut or is about to be cut





Replacement panels have been made already and hopefully will be tack welded in tomorrow.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/10/10 03:28 PM

Lets try to get this corner finally welded up so I can paint the underside and get the frame back!

Heres the last cut on the black line shown above



First panel made and tacked in place. Very very pleased with the fit considering it is going to be butt welded



Trial fitting the front section. Yet another good fit! Bit of luck eh?!



Different view



I have designed these panels so I can have maximum use of my spot welder and get zero distortion and weld it FAST.

The frame bolt hole will also be reinforced by the addition of a 1.6mm panel welded on top-just as I did on the other side.

Quite surprised how well these home made panels fit. I must be getting good! How long to get these skills? Started bodywork when I was about 19, and I'm 49 now. Thats 30 years practice. WOW!

I absolutely love doing this type of bodywork!!!
Anybody want theirs doing next?

Andy.

Posted by: Cowtown Cowboy

Re: New big ford owner in UK - project resto/lowri - 03/10/10 03:39 PM

Sooooo, coming to Canada any time soon?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/10/10 03:39 PM

Does this annoy anybody else as much as me!!



Guess whats coming out next!!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/11/10 03:53 PM


Heres the corner coming together.
The spot welder makes things very easy.









Andy.
Posted by: guumer

Re: New big ford owner in UK - project resto/lowri - 03/11/10 07:57 PM

come to Canada and fix my 04
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/12/10 11:57 AM

 Originally Posted By: Cowtown Cowboy
Sooooo, coming to Canada any time soon?



Hi CC.
Looking at your projects, I think you could teach me a thing or two!! ;\)

Andy.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 03/12/10 12:54 PM

well my 1990 could use some touch ups
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/12/10 02:30 PM

Oh dear, what happened there?

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/13/10 03:23 PM

Welded in all the panels this morning but also had to patch a rusty and thin spot above them in the corner (went through with the media blaster). Quite difficult to cut it all out up there, but my trusty air saw came to the rescue again!



I had to peel back the cargo area panel in the front corner and hold it up with a screwdriver so I could weld it.



Any panels I won't have access to when it is all finished I etch primed and painted red (avoiding any flanges I need to spot weld soon) to prevent corossion inside



I had to cut a good corner out to get access a few days ago



This now needs closing off, so I made up a panel with a step/joddle and an overlap to try these new modern adhesives that some manufacturers use to bond panels on. Supposedly stronger than welding and seal the joints at the same time.

Heres the panel



and heres the glue



Heres the new corner panel in place





Lets see how strong it is in a few days.

I used the same adhesive to bond a 1.6mm reinforcement panel to the top of the frame mount hole but will still tack it into place tomorrow to prevent shear fractures (twist).

Compere the view now to what it was a few days ago





Bit better!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/14/10 05:45 PM

Managed to persuade a straight piece of steel to curve into the right place!









Andy.
Posted by: School_of_Burn

Re: New big ford owner in UK - project resto/lowri - 03/14/10 10:55 PM

looks like you have had to do a lot of welding and fixing. looking good. ive thought about redoing the factory wheel wells with some aftermarket tubs to make any future wheel changes easire seeing as the shape of the stock ones gave me some trouble when i mounted 20"s to it.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/15/10 02:39 AM

 Originally Posted By: School_of_Burn
looks like you have had to do a lot of welding and fixing. looking good. ive thought about redoing the factory wheel wells with some aftermarket tubs to make any future wheel changes easire seeing as the shape of the stock ones gave me some trouble when i mounted 20"s to it.


Hi.
Good thinking.
I'm going to do a similar thing,but only change the outer half of the inner arch



The top of the arch on the wagon is very high so shouldn't need much changing.

Andy.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 03/15/10 02:01 PM

 Originally Posted By: andyfanshawe
Oh dear, what happened there?

Andy.

https://www.crownvic.net/ubbthreads/ubbthreads.php?ubb=showflat&Main=90096&Number=1240486#Post1240486

this one has more back ground
https://www.crownvic.net/ubbthreads/ubbthreads.php?ubb=showflat&Main=89667&Number=1239845#Post1239845


She still is in dis repair, rr quarter panel looks like a golf ball, and the header panel and fenders are 2nd hand some green,Dk blue, purple color shifting paint.

Along with your post, good idea to get rid of that water standing
spot.

Justin.
Posted by: School_of_Burn

Re: New big ford owner in UK - project resto/lowri - 03/16/10 11:31 PM

 Originally Posted By: andyfanshawe
Hi.
Good thinking.
I'm going to do a similar thing,but only change the outer half of the inner arch



The top of the arch on the wagon is very high so shouldn't need much changing.

Andy.


the angel of the inner is what i had the problem with. glad to see you have a plan for that too.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/17/10 03:08 PM

Onto seat belt reinforcement panel replacement.

In the rear seat area the metal around the seat belt bolts is not good, Can't risk this, so out they come

Heres one already marked for cutting, with slots cut with the cut off wheel to get the air saw through





Heres my favourite tool of all time!!



Out it comes



Heres one I cut out earlier





New plate being joddled



Ready to media blast the rusty plate and weld on and weld back in



Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 03/17/10 05:00 PM

Coming along nicely Andy.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/17/10 05:26 PM

Thanks Alex.
It will be when the underside is painted - hopefully this weekend. Then the frame can go back - at last. And the assembly starts.
Still a long way to go though.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/18/10 04:27 PM

Managed to weld all 3 plates in













Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/21/10 06:15 PM

Anyway, final bit of structural welding done today on the seat belt bolt reinforcing plates.
Media blasted them all and welded them back in,







This was the one above at the start



Then repaired the drivers and passenger front seats reinforcing panel.



Not bad since this is how it started out!



First coat of silver epoxy mastic 2 pack paint went on with a brush. Bit of a poor photo but I'll get better ones tomorrow.



Andy.
Posted by: Tim825

Re: New big ford owner in UK - project resto/lowri - 03/22/10 11:40 PM

Looking good!!! Andy, I must say you are one of the best metal fab guys I have seen in quite a long time and considering it is not your "day job" makes it even more impressive. I hope you have continued success with your project and it all turns out this good.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/25/10 04:49 PM

Thanks Tim. Much appreciated.

Thanks rayc!

If you are changing a diesel engine on a range rover, you can't be that bad yourself!

Heres the LCA's blasted and etch primed. Don't want to powder coat these because they will be modified soon.





Heres the transmission x member media blasted and etch primed!
You can just see the wagon in the background awaiting its frame! Only a couple of days away before it is reunited.



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/27/10 08:05 AM

Finally uncovered the frame and installed all the brake, fuel and air lines.
All we've got to do now is carry it to the car!!













Andy.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 03/27/10 11:52 AM

Hope that tree between the frame rails in your engine space is not a premonition of after the first two weeks.

Justin.
Posted by: School_of_Burn

Re: New big ford owner in UK - project resto/lowri - 03/28/10 12:31 AM

 Originally Posted By: Justin McCarter
Hope that tree between the frame rails in your engine space is not a premonition of after the first two weeks.

Justin.


lol thats bad.

but its looking great and that frame is crazy good looking
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/28/10 03:03 PM

Today is frame back day. So some muscle is needed. While I was waiting for all 3 helpers to arrive I did a few jobs.

First was to burn the centres out of the LCA bushes so I could collapse the outer shells and remove them.



Next was to paint the pins that go through the fuel tank straps. They have been in my acid bath so are rust free. A magnet comes in handy



The front core support to frame mounts have a spacer above them. They needs cleaning up and painting so I started prepping them and made a surprise discovery! They are adjustable!



Very clever bit of design.

Here's one of them etch primed and painted red to match the frame



Then it was time to get the car ready for the frame to go under. It needs to be slid in so something slippy like sheet plywood would be good. Our bedroom door has 2 of these sheets so out it comes and is stripped down! Hope my Wife doesn't notice! I'll put a better one on in the next few days. Heres the bedroom door gone!!



and here are the panels under the car







Here are the poly bushes ready to go



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/28/10 03:03 PM

Muscle arrived so here we go!

Had to carry it over some bushes!





and over some steps!





and under we go













Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/28/10 03:11 PM

Then they all left me on my own - even my Wife!
So up it went on my own!

Took about 2 hours to carefully get it into place. Nobody told me two of the washers in the new poly mounts wouldn't go through the holes! So a slight mod was needed.







Heres a few photos of the frame all bolted in! 6 months of hard work to get to this stage!















Andy.
Posted by: mikei1983

Re: New big ford owner in UK - project resto/lowri - 03/28/10 04:11 PM

Looking good. I didn't realize it has been 6 months already. I need to step up the pace!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/28/10 05:48 PM

 Originally Posted By: Bluemobile
Awesome! How are you gonna do the rest of the body work with frame in place? If you plan on painting the undercarriage, wouldn't you get over spray on the frame?


I have already painted the areas around and on top of the frame so wont need to go anywhere near the frame again.
The epoxy mastic paint I am using needs to be brushed on to be effective on lightly rusted areas. No spraying under there.

The car is parked on a public road and needs to be mobile soon. Its tax (permission to use it on roads) runs out soon and it needs an annual inspection before I can get it taxed again. Otherwise it will get clamped.
I will do the exterior bodywork when it is back running but will make sure the frame does not get any overspray on it.

Keep watching and you will see!!
Thanks for the question.

Andy.
Posted by: mbood82

Re: New big ford owner in UK - project resto/lowri - 03/28/10 06:23 PM

Is that why it appears to be sitting on it's tires again here?



I noticed that when you posted it before and it looked like it was already back together again... I assume you didn't want to attract attention?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/29/10 01:20 AM

Correct!

Andy,
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 03/30/10 08:01 AM

The police, "Is that a cross member behind that tree?" -"No it cant possibly be and stop making guesses at whats under that tarp he's just been making a deck and moving it around every now and then. Next your going to say that coffee table is held up by a ford LTD engine assembly"



Justin.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/03/10 03:14 PM

Thanks guys.

Little progress made in last few days due to...how shall I put it.......interesting challenges at work. Thats all I've got to say about that.

Anyway, time to complete the front suspension so I can get this car back on its feet.

Heres the LCA's with all new bushes and ball joints pushed in





Now, a long time ago (well, last october), I spotted that the drop link bushes holes in the LCA's were elongated, so its now time to sort them out.

Here's one of them.


Cut a copper plate out and clamped it to the bottom to stop any excess weld buildup





Then weld it up



and grind/file it back



The quick ones amongst you may have spotted something strange about the above photos!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/03/10 03:22 PM

Painting time.





Leave them to dry for a few days and its onto the upper arms.

Heres the shaft kit and bushes



Heres the drawback in powder coating-scraping it off!



Shaft painted silver, and the upper control arm securing nuts while I have the silver paint out

before


after




New ball joints bolted in and we are done,







Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 04/03/10 07:24 PM

Fantastic.

Which bushing did you end up using?

 Quote:
Our bedroom door has 2 of these sheets so out it comes and is stripped down!


ROFL! Did your wife notice? =-)

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/04/10 01:22 AM

Hi Alex.
I used the energy suspension bushes and did exactly what you said. Centralised the frame and tightened them all down firm. Hopefully the frame won't move.

My good lady wife wants a new bedroom door anyway, so I got permission to remove it!!

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 04/04/10 09:59 AM

It won't move. The bushing will squeeze into the gap. Firm? Squish them tight. The metal sleeve in the bushing is your stop (be it rubber or poly). Tighten that thing down fully.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/04/10 05:18 PM

Thanks Alex.
Rest assured they are tight! Thanks for your advice on those earlier on. saved me a few dolllars and time.

Okay, my job is clear now. Get the front and rear suspension in so I can get this car on its feet and get the trans and engine in. But I can't get the front springs in because there isnt enough weight there without the engine and gearbox in.
So, I can either make a spring compressor or have some fun and fit airbags to the front temporarily and have a play with the ride height and still be able to get the car on its feet with the bags in and pumped up!
More importantly I can get measurements for the shockwaves to be ordered and made up.

Heres the suspension temporarily in



Here are the airbags I just happen to have lying around from another project!



Here's the airbag installed.



I now need to plumb them in and its onto the rear axle.

Andy.
Posted by: The_Punisher

Re: New big ford owner in UK - project resto/lowri - 04/04/10 07:35 PM

Wow, very nice....
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowri - 04/04/10 08:57 PM

Awesome. I love watching the progress on this build.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/07/10 05:51 PM

Keep watching....................loads more to come!

Boring but important bits now. Cleaning and painting.

Brake discs/rotors first. Media blasted and painted.



Heres one of the rear drums



Taped off for media blasting



And media blasted



Photo of the red painted one tomorrow.

Back axle next. I'm going to prep this best I can without media blasting and paint it with epoxy mastic paint.

Heres the rusty thing



and about halfway through prepping



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/08/10 05:40 PM

Finally finished prepping the back axle. Only took 12 hours! Wish I'd had it media blasted now.

But thats too easy!!!

Removed the halfshafts and discovered a Limited Slip Diff. Bonus. Didn't know it had that.

Also took off the backplates.

Bit of painting later and here we are





If you look carefully under the diff, you will see a plastic bowl with a big split in it. It didn't have that split until the axle fell off the stands! guess where all the oil went that was in it? Yep, on my Wife's beloved patio. Oops! And I've still not put her a bedroom door on yet either!

While the brake backplates were off, guess what I did?.............



The diff cover was also a bit sad, so media blasted and a bit of contrasting silver paint



Now a few days off on our short easter hols in the caravan, and then I'm going to put it all together! Am I seriously looking forward to that.
1 week to get the engine, trans, driveshaft and axle in and all associated pipework/wires/fluids etc, plumb and bleed brakes, strip and paint the fuel tank, find or make a suitable TV cable and fire it all up.

Phew!
Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 04/09/10 04:38 PM

 Quote:
guess where all the oil went that was in it? Yep...


A prime example of 'what looks like a simple project turning into a much bigger project'. =-)

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/12/10 06:30 PM

 Originally Posted By: GM_Guy
 Quote:
guess where all the oil went that was in it? Yep...


A prime example of 'what looks like a simple project turning into a much bigger project'. =-)

Alex.


That is so true!!

Now its time to get this car back on the floor.
First job is to strip the rust off the rear floor area where the gas tank will reside, and paint it with epoxy mastic paint.
Heres a couple of photos to show how far back I baremetalled with an angle grinder and a media blaster.





Heres the same bit painted with a thick coat of epoxy.



Rear springs next. These will only be temporary (until airbags go in) but they can't look bad, so media blasted and painted.



Oops! I have accidentally painted my Wife's bird feeder silver as well. Oh dear!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/13/10 05:51 PM

Try to finish off the axle today, and install it. Then front rotors fitted, all wheels on and supporting frames removed. Well thats the plan!!

Heres the final moments before the axle is sealed off.





2 trolley jacks and some assistants (My Wife and 2 sons) got the heavy axle to the car.





Here it is installed with new shocks









Onto the front suspension and rotors installed. No calipers just yet. Need to be stripped and painted.



How can 2 simple parts like these 2 bump stops be so gratifying to fit!!



And yes I did get the supports removed, but it was too dark to photograph. I'll post them tomorrow.

Sure looks pretty under there now!!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/13/10 06:05 PM

Heres a nice before and after shot! Makes it all worthwhile.





Andy.
Posted by: 04clone

Re: New big ford owner in UK - project resto/lowri - 04/13/10 07:10 PM

Looks great man!
Posted by: pantera77

Re: New big ford owner in UK - project resto/lowri - 04/13/10 08:32 PM

Those look like the old style tabs on those trac-loc clutches. I bet it's dead as can be, although there's only one fun way to find out.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/14/10 01:13 PM

 Originally Posted By: pantera77
Those look like the old style tabs on those trac-loc clutches. I bet it's dead as can be, although there's only one fun way to find out.


Thats cheered me up ;\) Hope my good lady Wife doesn't see this-divorce is getting closer the more money this car swallows up!! Another future job to do

Might try that fun way when its all back together!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/14/10 05:46 PM

Should have been putting trans in today, but I have loads of parts lying around the house and garage and car and shed and loft.................that are getting in the way. And annoying my Wife. So, lets get these fitted.

Seats first.
Carpet out and vacuumed floorpan and carpet. The floorpan is in good shape, with no holes. Just surface rust. I'll derust it and epoxy paint it during the summer.









Carpet back in, then bolted the passenger seat back in.

Onto drivers seat next. But hang on, when it was in the car it wasn't working properly. The 6 way power seat wasn't doing what it should be doing. iirc it was trying but straining and tipping and making noises, but not doing much.
Lets have a look.



Turn it upside down.



Quick look around and have a look here



Now that would explain the noises. But why has the weld broken? Didn't take long to find that every pivot point on one side of the seat had seized solid. Took about an hour to strip the seat and took considerable force to unseize it. In fact it was unbelievable to see how stuck they were. A big hammer wouldn't shift them!

Heres a couple of views of the unseized pivots and the broken one clamped up ready for welding.





Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/15/10 05:48 PM

Welded the seat frame mechanism,



Tested the 6 way movements and it is fully functional!! Thats what I like, a dead cheap repair!!

Onto the transmission now.
Before it is fitted I need to make a couple of new plates for the top of the trans x member to frame mounts. The old ones have rotted and come off the rubber.
Made these out of 3mm steel plate



Next is the trans to cooling pipes. I had to cut one of them at the trans because I couldn't get it undone. Nows a good chance to make a new one out of new pipe.

I had to cut the top one in this picture back in october



Heres the new one made at the side of the other one that I will reuse but cleaned up (that was a bad sentence!).





Final job is to clean up the trans and give it a coat of silver to freshen it up.
3 hours later and seriously sore fingers, and we have a prepped and masked transmission



Silver paint later and it looks smarter



Try to put it in tomorrow. Then get ready for engine in.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/15/10 06:02 PM

Forgot to add! Had the injectors cleaned by stripping out the filter baskets from the top of each one, removing the plastic base and spraying fluid backwards through them and then dipping them in an ultrasonic bath.

New filter baskets and bases and spray pattern tested okay for each one!

Heres a boring shot of the new injectors waiting to go in.



Couldn't get any shots of the cleaning process since a local shop did it!! Sorry to all. $60 for all 8.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/16/10 04:16 PM

Bit of a get bits in today!

Trans in first





YeaH, yeah, I know the trans pan is filthy but it won't be soon!!

Heres a good view of the new trans cooling pipe



Heres one of the plates I made for the frame to trans x member rubber mount yesterday. You can just see it on the top



Then I finished off the front brake pipes. Here's one that I made to go from the master cylinder to the passenger side front wheel, attached to the new flexy pipe. Alongside it is the old pipe from the master cylinder to the drivers front wheel (used it as a pattern to make the new one).



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/16/10 04:48 PM

What about some comparison photos? Bit of a motivator eh?

Rusty driver side frame corner and new one











Passenger side with some of the rust cut out of the frame, and the new repairs







That's well and truly sorted them out then!! The frame is now full of rustproofing fluid and the all importanat drain holes in the corners.

Andy.
Posted by: 99_03PantherS

Re: New big ford owner in UK - project resto/lowrider - 04/18/10 11:18 AM

This is just amazing. This should be the "Panther of the year".
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/18/10 04:09 PM

Ought to be the "pain in the ass panther" of the year!!

Right, its about time that engine went in,....

Had to move my Camaro out of the garage to hook up the engine to the cherry picker



You can just see my poor chevy abandoned outside!!



This is where its going!



The floor isn't level so one of the legs has to go on some wooden blocks





Here's a comparison shot of before and after





Andy.
Posted by: 99_03PantherS

Re: New big ford owner in UK - project resto/lowrider - 04/18/10 07:28 PM

Looks brand new!
Posted by: Gordonfan24

Re: New big ford owner in UK - project resto/lowrider - 04/19/10 07:36 PM

Great build! Keep up the good work!

Nice Camaro, too.

I do have one question. You were putting parts in a bucket of some solution/fluid to get the rust off. What exactly was that substance? And do you have pictures of the container? I would like to look into that for the suspension parts on my '97.
Posted by: mikei1983

Re: New big ford owner in UK - project resto/lowrider - 04/19/10 11:02 PM

Looking good Andy!

Do you doing the body work too?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/20/10 01:11 AM

 Originally Posted By: Gordonfan24
Great build! Keep up the good work!

Nice Camaro, too.

I do have one question. You were putting parts in a bucket of some solution/fluid to get the rust off. What exactly was that substance? And do you have pictures of the container? I would like to look into that for the suspension parts on my '97.


Thanks.
The rust removing solution is called deox-c.
Made by Bilt Hamber in the UK. I think your US equivalent is called naval jelly?
See http://www.bilthamber.com/deoxc.html

The crystals are dissolved in water with a ratio of about 1:20 and can be put in any container. I used a big plastic box. Here is the container in action.



Hope this helps.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/20/10 01:12 AM

 Originally Posted By: mikei1983
Looking good Andy!

Do you doing the body work too?


Hi mikei1983.
Yes, I will be doing the bodywork also!

Andy.
Posted by: Colt45

Re: New big ford owner in UK - project resto/lowrider - 04/20/10 02:46 AM

Great build, great build.
I can't wait to see it finished.
Posted by: Gordonfan24

Re: New big ford owner in UK - project resto/lowrider - 04/20/10 08:30 AM

 Originally Posted By: andyfanshawe

Thanks.
The rust removing solution is called deox-c.
Made by Bilt Hamber in the UK. I think your US equivalent is called naval jelly?
See http://www.bilthamber.com/deoxc.html

The crystals are dissolved in water with a ratio of about 1:20 and can be put in any container. I used a big plastic box. Here is the container in action.

http://i167.photobucket.com/albums/u141/andyfanshawe/derust.jpg

Hope this helps.
Andy.

Thanks! That's exactly what I am looking for.
Posted by: mikei1983

Re: New big ford owner in UK - project resto/lowrider - 04/20/10 09:17 PM

If I only had the motivation...... lol!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/21/10 04:56 PM

Here is a photo of the wagon actually stood on its own feet rather than stands under the sills!



Heres the engine in and partly assembled





Fuel tank needs to be cleaned up and prepped for epoxy mastic paint that is supposed to seal any rust or pinholes or defects permanently.

Fuel tank before




Nothing too bad at all but needs prepping. I have new seals and locking plates for the pump and sender so I will media blast around there. The inside of the tank looks immaculate.

Heres the tank being stripped. I am using an air grinder to get minimum sparks!! All holes have been sealed so no vapours are escaping.







Heres the deox c gel that I am using for rust removal.



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/21/10 05:10 PM

Found this under the carpet. It says ELEC OK on it, has a time on it, but no date.



I assume this is a sheet left over from the original factory build. Has anyone seen anything like it before?

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 04/21/10 05:34 PM

That sheets likely from the seat manufacturer, the factory "build sheet" is an 8 1/2 x 11" sheet of paper with codes for the various parts going onto the vehicle, ie: tire size, trim color, trim type, which has zero correlation to the door jamb codes for the same components.

Alex.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 04/22/10 07:49 AM

And where do i find this 8.5x11 sheet?



Justin.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/24/10 05:02 PM

To further the tank prep, I media blasted the top of the fuel pump and top of the sender unit to make sure it is all clear when they are pulled out





Here's the fuel pump appearing into daylight



Inside of the tank looks perfect.

Sender unit removed and rustproofer sprayed around the hole



New O ring and clamp plate installed



Both tops of the sender and pump heavily rustproofed during and after installation. They are not going rusty again!
Then a further 2 hours to degrease and panel wipe the tank ready for paint.

Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/24/10 05:09 PM

Here's the media blasted exhaust manifolds.



And the new studs being installed but not before a quick retap



O2 sensors in, all masked off and high temperature paint applied



Onto the plenum. Lets go really bright! 1 hour prep and were are away with etch primer and a white primer to make the red topcoat "pop"!









Install that tomorrow.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/25/10 12:50 PM

Bit more progress today. Only got 2 weeks to get this thing MOT'd!

Dipstick tube painted bright red but with the bracket that bolts to the headers painted black as if it has been burnt!!



Trans pan seriously cleaned up - about 2 hours to do it! Then painted the sexy red.



Here is a view of the pan dropped off the trans



This is a pleasing view. No debris in the pan at all.



New filter



Finally finished painting the tank with epoxy mastic.





Finally a view of the engine bay with the red plenum! Thats BRIGHT!





Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 04/25/10 02:05 PM

I've been enjoying this thread too. Andy, are you still married after all this? Did you meet that April deadline? (Or was it May?)

You claimed to be a backyard mechanic, but I can tell you I could only dream of doing the things you have done. Perhaps you can show me how to rebuild an AOD-e transmission next? This is about the only thing that will kill my '92.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/25/10 04:05 PM

Hi enslow.
Am I still married? Just...! I have a lovely and understanding Wife, but even she says no more projects like this.....or find a new lady. Thats quite a dilemma, 'cos I could get a new project AND a new Wife - at the same time!!
Probably have no money to do it with though!!

I am not a mechanic by trade, but have been wielding spanners since I was 17, and I'm now 49.
One of my mottos is "just get stuck in". I do dread certain jobs and certainly don't know how to do certain things, but that doesn't stop me. I will learn it no matter what.

Interestingly, the only thing I haven't done is to rebuild an auto tranny but I have all the how to DVD's and manuals!

If mine broke, I would try to follow the dvds/books and have a go.

Rather than dream about doing these things, why not have a go? Start simple and work up.

Thanks for following though.
Andy.
Posted by: mikei1983

Re: New big ford owner in UK - project resto/lowrider - 04/25/10 10:07 PM

Andy,

Not only are you a good Mechanic, fabricator, and body repair. You seem to be a motivation speaker too (for automotive stuff)!

As far as the new lady and project (but no money) hhmmm... that could be a BIG dilemma, but remember you can always make more money..lol...

Good luck with your time line, looks great!
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 04/26/10 01:02 PM

 Originally Posted By: andyfanshawe

One of my mottos is "just get stuck in". I do dread certain jobs and certainly don't know how to do certain things, but that doesn't stop me. I will learn it no matter what.

Interestingly, the only thing I haven't done is to rebuild an auto tranny but I have all the how to VHS and manuals!

If mine broke, I would try to follow the vhs/books and have a go.

Rather than dream about doing these things, why not have a go? Start simple and work up.

Andy.

That hit me right here.

On the other hand what was the name brand/ temperature range you used for your headers? The only thing I'm second guessing would be your fuel rail connection points on the high pressure side when you used those one way tooth spring clips.

About your transmission problem when and if it occurs use this video as well as your DVDs to help further acquaint you with the inner workings of the automatic transmission.

http://www.youtube.com/watch?v=pbVY5teBzlg

It really helped me clear up some of the gray areas for me when my motor blew, but I already installed the T5.


Justin.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 04/26/10 08:55 PM

 Originally Posted By: andyfanshawe
Hi enslow.


Rather than dream about doing these things, why not have a go? Start simple and work up.

Thanks for following though.
Andy.


Yeah, how much simpler could it be than to start with Ford's electronic 3 speed + overdrive?

I tell you, I could use your welding skills on my wife's Lesabre. The rockers go on these cars. These one's aren't bad structurally, so I'll just keep up the POR-15 treatements and try spraying rust inhibitors into the insides of the rockers for now.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/27/10 01:03 AM

Heres the new trans pan installed. Looks far better than before!





Right. Game time.
Guess the 2 things I was painting on top of this board!....



Andy.
Posted by: mbood82

Re: New big ford owner in UK - project resto/lowrider - 04/27/10 05:48 AM

diff cover and a dog bone? \:D
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/27/10 11:03 AM

 Originally Posted By: mbood82
diff cover and a dog bone? \:D


Diff cover correct-but I haven't got a dog! Nice try though.

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 04/27/10 04:48 PM

If you're up for practical jokes, once the project is over re-hang one of the overspray doors in the bed room.
Nice job so far Andy. Looks great.

Alex.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 04/28/10 10:42 AM

It's probably his floor jack or something stupid like that. My family has been out here for a few generations now, but we still have a tad of that British sense of humour.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/28/10 12:06 PM

 Originally Posted By: enslow
It's probably his floor jack or something stupid like that. My family has been out here for a few generations now, but we still have a tad of that British sense of humour.


No. Its an engine part! Nothing stupid.
Someones got it on one of the other forums.

Andy.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 04/28/10 12:53 PM

Engine part eh. Intake manifold upper!! I WIN!! and the diff cover.


Justin.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/28/10 03:44 PM

Brilliant

Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 04/28/10 09:23 PM

Wow. I wondered, but I didn't think the upper intake had such a small mounting surface. And my Dad had an 87 Crown Vic, we just never took it off.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/02/10 04:24 PM

Not posted recently due to a lot of boring fitting up to the engine. But here are the highlights!

Fuel tank first.
I painted it very successfully with silver epoxymastic paint after days of preparation. Then I remembered that the straps that hold the tank in were also silver, so I painted the tank red!







Looks good!

Then I completely covered the top of the fuel pump and the top of the sender unit with didnitrol 3125 rustproofing fluid. They are not going rusty again!

Heres the tank installed-not a good photo but I like the contrast between the red tank and the silver straps



Before I put the tank back, I even removed the studs that the top of the tank straps bolt to, cleaned them up and reinstalled them with plenty of rust proofer before securing the tank with nylocs.
Here's one of the studs being cleaned up in the vice



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/02/10 04:30 PM

Rear self levelling height sensor next.

Heres a series of photos to show its progress. Note the sticker that I had to mask off carefully!













and the finished product!





Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/02/10 04:41 PM

Steering box next.

Heres the mucky beast with the pitman arm puller on waiting to do its job!



Cleaning up and painting time





Here it is installed with all the other steering components just cleaned up. I will paint them later in the summer. One outer tie rod is on the limit of its wear, so I will replace it soon.





The bottom of the core support looks ugly with surface corrosion, so I'll tackle that later this summer also.

Heres an interesting find. The steering box splines have grinding marks on them. No doubt due to someone wanting to replace it and not being able to get it off, so cracked open the grinder!! Went a bit too deep!



Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 05/02/10 06:35 PM

 Originally Posted By: andyfanshawe
 Originally Posted By: pantera77
I wish i had half as much motivation as you do to work on my car!


Nice one! Plenty of motivation here I can tell ya!

My Wife says if I haven't finished it by the end of April she is going to buy a Chrysler Voyager to pull our caravan!! Nooooooo!!

I've got 2 weeks off at xmas, so I'll be outside come rain or shine.

Andy.


Got any pictures of that Voyager? ;\)

BTW, care to come to Vancouver for a vacation? I've got a Buick Lesabre to work on! The body's in nice shape except for the rockers.
Posted by: sanco

Re: New big ford owner in UK - project resto/lowrider - 05/03/10 05:14 PM

wow i dont hang out too much in this section of the forums but man you sir have done an amazing job with the car!!!!! i just went through the whole thread and this is just amazing! excellent work!!!!
Posted by: kustomizingkid

Re: New big ford owner in UK - project resto/lowrider - 05/03/10 07:28 PM

Just read through all this, amazing amazing work!!!
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 05/05/10 12:26 PM

 Originally Posted By: andyfanshawe
Heres an interesting find. The steering box splines have grinding marks on them. No doubt due to someone wanting to replace it and not being able to get it off, so cracked open the grinder!! Went a bit too deep!

Andy.


Grinding a cut into the old pitman arm then driving a chisel to break it loose, is one of the practices we teach here. For when the Advanced Auto parts store rental puller doesn't always work alone.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/06/10 05:42 PM

 Originally Posted By: enslow
 Originally Posted By: andyfanshawe
 Originally Posted By: pantera77
I wish i had half as much motivation as you do to work on my car!


Nice one! Plenty of motivation here I can tell ya!

My Wife says if I haven't finished it by the end of April she is going to buy a Chrysler Voyager to pull our caravan!! Nooooooo!!

I've got 2 weeks off at xmas, so I'll be outside come rain or shine.

Andy.


Got any pictures of that Voyager? ;\)

BTW, care to come to Vancouver for a vacation? I've got a Buick Lesabre to work on! The body's in nice shape except for the rockers.


Any pictures of the voyager?
Afraid so!



I didn't finish by the end of April, so, yes, I had to buy one!

Andy.
Posted by: mikei1983

Re: New big ford owner in UK - project resto/lowrider - 05/06/10 11:42 PM

So when you going to "start" working on the Voyager?..lol...
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/11/10 05:42 PM

Sorry guys, not been on much. Work is getting busy-exam season just starting.

Anyway, you will all be pleased to know that the engine fired up and ran, but a bit rough! Was eventually traced to a loose connection to the coil and timing was 20 degrees out! Many little leaks but all sorted by tighteneing up various fasteners.
Now its all the fitting up of front calipers, bleed brakes out, front sway bar, front shox (front springs put back in place of airbag temporarily), front and rear bumpers, last bit of cosmetic welding and its off for its annual test.

When it passes, its bodywork time.

I have a graphic designer coming to photograph the car in the next few days to design a paint job. I'll keep you all posted of the different designs.

Andy.
Posted by: 04clone

Re: New big ford owner in UK - project resto/lowrider - 05/11/10 05:58 PM

Cool! I've been following since the beginning. What a transformation.
Posted by: mikei1983

Re: New big ford owner in UK - project resto/lowrider - 05/11/10 10:39 PM

Andy,

Is the voyager getting done after the wagon is finished..lol!!!
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 05/12/10 09:52 AM

I know I'm not the only one who checks this thread every day. We're all waiting for the next set of progress pics. \:\)
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 05/12/10 12:06 PM

Exactly. Just becuase we're not writing anything doesn't mean we are not watching.

Alex.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 05/12/10 07:16 PM

For the Voyager, I want to see a lowrider, black paint, hood scoop. I'm sure Andy has the skills to modify the front end to accommodate a Hemi V8 and glass packs.

I still can't believe the progress Andy makes on his cars. I'm lucky if I can get the oil changes completed in between the silly stuff like replacing a side view mirror, window regulators, preparing for the smog tests....

BTW, my wife has not given me permission to tell you why I needed to change the side view mirror.
Posted by: mikei1983

Re: New big ford owner in UK - project resto/lowrider - 05/12/10 10:47 PM

Oil changes, whats that.... lol.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 05/14/10 12:37 PM

I'm reading up every day as well. I wonder when my prize is coming for guessing what he painted.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/15/10 05:00 PM

Trying to catch up now.
Front calipers (new) painted.


Front sway bar painted


Front springs painted


New drop links


All installed




Heres the EGR completely clogged


Sway bar


Heres the sticking rear fold down seat locking mechanism being cleaned and freed off


All brakes bled out, all suspension bolts tightened....and a serene view of the wagon waiting for its first test drive!



Andy.
Posted by: Ethan

Re: New big ford owner in UK - project resto/lowri - 05/15/10 06:19 PM

Looks awesome Andy! Although, you did forget to paint your tie rod ends
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 05/15/10 09:15 PM

That sway bar endlink (drop link) bolt doesn't have enough thread on it to be of much use (like the stock endlinks). Your endlink bushings need to get compressed somewhat for them to be effective. As it is, the sway bar is just along for the ride until a significant amount of lean gets put into the car. Shim it wish some extra washers and you'll be good. (Poly urethane bushings you want to tighten so they bulge out a bit as well to take out any slack).

For the doubters, go for a spirited drive and then shim it and compare on the identical drive.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/16/10 03:55 AM

 Originally Posted By: Ethan
Looks awesome Andy! Although, you did forget to paint your tie rod ends


Well spotted!
Thats a future job, 'cos this car needs its annual test otherwise it will get clamped and towed within a few days
So, I am making a couple of shortcuts until it gets its pass. Then they will come out again and be painted.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/16/10 03:56 AM

 Originally Posted By: GM_Guy
That sway bar endlink (drop link) bolt doesn't have enough thread on it to be of much use (like the stock endlinks). Your endlink bushings need to get compressed somewhat for them to be effective. As it is, the sway bar is just along for the ride until a significant amount of lean gets put into the car. Shim it wish some extra washers and you'll be good. (Poly urethane bushings you want to tighten so they bulge out a bit as well to take out any slack).

For the doubters, go for a spirited drive and then shim it and compare on the identical drive.

Alex.


You are quite right Alex.
Surprised me when I fitted them. And they are stock repalcements.
I will try what you said though.
Thanks.
Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 05/16/10 09:51 AM

Stock = floating sofa feel for the stereotypical bluehairs, wouldn't want to compromise that with some end link bolts that allow you to snug it up properly now...

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/16/10 04:08 PM

2 12 hour + days and its bumpers back on today, but have a look whats under the silver foil





and thats with it cleaned up! So major scraping and rustproofer sprayed around.

So thats about it for the first stage of its resurrection. All that remains is to fire it up and see if it moves and stops!

Heres the first photos of its new position for a few days while I do a bit of cosmetic welding.





I only turned it around, but what a fantastic feeling! First time in 6 months it has moved under its own power after an extensive rebuild. And nobody was there to see it...except me.
I don't care. I know what has gone into this car. And I know whats to come.

Every single day through the long cold winter in sub zero conditions-with spanners frozen to the floor and water running out of my shoes. No excuses, no sitting in a warm comfy chair, no complaining about how cold or wet it is outside. I didn't realise how lonely it was until the last few days when other people are outside because the weather is better.
This feeling is something else.

Heres where it was!





Has it really been that long? This has been hard, and I mean one of the toughest I have ever attempted. The rest won't be easy but the results will start to show.

Thoughts turn to the next project....................................but for now, thanks to all that have been following along. Your inputs have been invaluable.

Now lets get some paint on this thing and bring it to life! :hat: :hat:

Andy.
Posted by: hungrymonkey

Re: New big ford owner in UK - project resto/lowri - 05/16/10 07:31 PM

I am wondering if you are the first person to ever do a complete frame off restoration of a mid 80's crown vic station wagon.

Thank you for the pictures and inight.
Posted by: Yoder

Re: New big ford owner in UK - project resto/lowri - 05/16/10 11:10 PM

I've been following this build...er...rebuild from day 1. I very much look forward to seeing the next phase. Andy ,you do very good work and are to be commended on a job very well done so far. BTW...Red and Silver looks good too.
Posted by: jgvic

Re: New big ford owner in UK - project resto/lowri - 05/17/10 09:42 AM

WoW!! amazing rebuild!!! Just like you said it, lots of time and patience. Keep up the good work. \:D
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 05/17/10 04:44 PM

Awesome!

Alex.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 05/17/10 08:43 PM

If I had the money, I'd fly over there and have a pint with ya. Well, first of all, I don't have the money anyway, and second I'm not much of a beer drinker. I'd probably get through half the pint and say that's enough.

Just the same, I wish I could go over and shake your hand! Amazing work!

If I had done the same, our neighbours probably would have called the city and forced me to get rid of the car. That's just the way it is here.
Posted by: hungrymonkey

Re: New big ford owner in UK - project resto/lowri - 05/18/10 07:57 PM

lived in suffolk and norfolk for a few years. I do miss cask ales.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/19/10 01:15 AM

 Originally Posted By: enslow

If I had done the same, our neighbours probably would have called the city and forced me to get rid of the car. That's just the way it is here.


Hi enslow.
I suppose I have been really lucky. All the neigbours are good and understanding. Although listening to an air saw going full belt for 30 mins non stop must have been annoying! Oops

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/21/10 04:59 PM

Right, I'm back.
Lets sort this mess out



Heres the bit I cut off months ago that has been waiting patiently to be repaired and returned to its home.

The black line is where I will cut it and join a new section on.



Heres the panel cut and a new section made up and clamped ready for welding



Heres the new section spot welded in place. Notice the shrinking hammer marks on the lip because I had to shrink it to get a slight curve on it





Here it is in place ready for welding





Welded and primed and painted white temporarily





Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/21/10 05:17 PM

Right, lets close it all off

Heavy rustproofing first



Panel made up and painted on the inside with a hole for more rustproofing



In place waiting for the MIG torch



Andy.
Posted by: GlockElbow

Re: New big ford owner in UK - project resto/lowri - 05/21/10 08:17 PM

Andy,

This is just amazing work. I spend a lot of time in the UK, at least a week every month. I've never seen a Panther on the road there. I hope I get you see yours one day.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/21/10 11:55 PM

 Originally Posted By: GlockElbow
Andy,

This is just amazing work. I spend a lot of time in the UK, at least a week every month. I've never seen a Panther on the road there. I hope I get you see yours one day.


Hi.
Whereabouts in the UK do you visit? I am located in Derbyshire, smack bang right in the centre of the UK.
If you get anywhere near, let me know. We could meet up!

Whats your job?
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/22/10 05:06 PM

Heres the drivers side undergoing repair. This is the "sponge" pulled from the top hole in the picture. This is the stuff that holds water and then tips it down the inner rocker and rots it out. So in the bin it goes.



Heres the closing off panel ready to be welded



Andy.
Posted by: GlockElbow

Re: New big ford owner in UK - project resto/lowri - 05/22/10 07:13 PM

 Originally Posted By: andyfanshawe
Hi.

Whereabouts in the UK do you visit? I am located in Derbyshire, smack bang right in the centre of the UK.
If you get anywhere near, let me know. We could meet up!

Whats your job?
Andy.


I spend a lot of time in London. If I get lucky I get to travel outside of London, but it's been a while since I've been north of London. Recently it's been more like Swansea, Portsmouth, Southampton, and Brighton. Last year I was in Coventry, Notthingham, Leeds, Manchester, Sheffield, and Birmingham so who knows.

I'm responsible for the pre-sales technical consultation for multimedia software and hardware.

If I my job takes me anywhere near Derbyshire I'll let you know. I'd enjoy buying you a pint and seeing the results of all your hard work!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/23/10 12:35 AM

Hi.
Be fantastic to meet you. Sheffield is about 10 mins away from us.
And I'd buy you a drink!

If you type S432DT into google earth, you will see exactly where we are.

How do you find the UK driving compared to the US style?

Andy.
Posted by: LysanderMB

Re: New big ford owner in UK - project resto/lowri - 05/23/10 05:21 AM

Andy -

Just catching up with your progress. Amazing!

EBay sent me a notification last month (I'd forgotten I'd set it up) and I got over excited in the heat of the bidding and now I'm the proud owner of a 1991 Country Squire in addition to my 1985... Masses of stuff to fix on the 'new' one but the bodywork is in pretty good shape and it has rear shoulder belts so my son's car seat will go in the back. Guess I'm the only man in England with two Squires!


1991 behind the tree, 1985 in front.

Lysander
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 05/23/10 09:01 AM

Welcome aboard Lysander.

Alex.
Posted by: GlockElbow

Re: New big ford owner in UK - project resto/lowri - 05/23/10 10:59 AM

 Originally Posted By: andyfanshawe
Hi.
Be fantastic to meet you. Sheffield is about 10 mins away from us.
And I'd buy you a drink!

If you type S432DT into google earth, you will see exactly where we are.

How do you find the UK driving compared to the US style?

Andy.


It'd be fanstatic to met you too. The volcano in Iceland has put a cramp in my traveling. I hope to be back on the road soon.

You've asked about one of my favorite topics,I love to drive. I enjoy driving in the UK, but it's a lot of work for me. Starting with the obvious driving on the left side of the road isn't as hard as I thought it would be. The first time was intimidating, but it gets easier everytime I do it. It's only confusing when the road is narrow with no center line. What is hard suprised me, I struggle to stay in my lane. As soon as I stop concentrating I drift to the left. Driving in heavy traffic is much easier. Everything is slower and I just have to follow the car in front of me.

That's the obvious, but the subtile stuff is what's interesting.

In comparision to US drivers, drivers in the UK do not accelerate from a stop nearly as fast. Makes sense when fuel is $8.00/Gallon US. Even when I'm driving a tiny diesel I'm not putting my foot down hard on the accelerator.

How speed limits are posted took me a while to get used to. In the US speed limits are posted, in the UK you're expected to know what the speed limit is based on the type of road you're on. Last year I drove from Heathrow to Aberystwyth in an Audi A5. Sixty mph on wet twisty Welsh roads not much wider than one lane was some of the hardest driving I have ever done.

Wow, my perception of what a big car is gets reset everytime I drive in the UK. The Audi A5, Vauxhall Insignia (2011 Buick Regal) and Ford Mondeo where huge cars in the UK. The Ford Focus and VW Golf felt normal sized. The Ford Fiesta and Peugeot 206 didn't seem that small to me. When I get home I'm stunned by how small the Focus looks. Driving your US cars in the UK must be a challenge. There's no way a Crown Vic fits in a single UK car park space.
Posted by: LysanderMB

Re: New big ford owner in UK - project resto/lowri - 05/24/10 05:31 AM

I've driven all types of cars in both the UK & the US and they are certainly very different experiences. I never did get the hang of stupid 4-way stops. (For the non-Americans, everyone has to stop, whether or not anyone else is in sight, then whoever got to their line first has priority.) To a Brit used to 'give way' signs it is surprisingly hard to remember to come to a full stop when no other car is visible. I found it next to impossible to keep track of the order in which the cars had arrived at the junction. At least a British accent and driving licence seem to be a sufficient deterrent to prevent a State Trooper from issuing a ticket.... 4-way stops were especially irritating in a stick shift MGB, having to go up and down the gears at each block. You can see why nearly all US cars have automatic transmission! And why in stick shift Britain we have roundabouts (circles) where stopping is only needed if someone else has priority.

Driving a Country Squire in the UK is surprisingly easy. It is smaller than a typical delivery van and with far better visibility (so long the back isn't full of junk, I mean vital baggage). I've got quite good at parallel parking though most parking bays are exactly the right length and width so there is not much room to get it wrong. It is a good idea to keep an eye out for the back swinging wide - there is such a long overhang behind the back wheels that it is easy to whack sign posts etc if you're not careful. Don't ask me how I know this...

Lysander
1991 Country Squire
1985 Country Squire
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowri - 05/24/10 11:09 AM

 Originally Posted By: LysanderMB
Andy -

Just catching up with your progress. Amazing!

EBay sent me a notification last month (I'd forgotten I'd set it up) and I got over excited in the heat of the bidding and now I'm the proud owner of a 1991 Country Squire in addition to my 1985... Masses of stuff to fix on the 'new' one but the bodywork is in pretty good shape and it has rear shoulder belts so my son's car seat will go in the back. Guess I'm the only man in England with two Squires!


1991 behind the tree, 1985 in front.

Lysander


Cool twin Squires. You've obviously found the coolest Country Squire thread on this site.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/31/10 05:16 PM

Not been on much, but a lot has been done. A lot of little things to get the car through its annual test.

Here's the patch final welded



Heres the battery clamp spacers!! All they had to do was cut it shorter and rebend.



More photos of that soon

Heres the rust hole in the font of the rocker being repaired. All butt welded for accuracy.



Panel cut and just about to be offered into place



Tacked in



Fully welded



I have removed the number plate and moved it to the end of the bumper



Saturday is test day.

Andy.
Posted by: RustyRodder

Re: New big ford owner in UK - project resto/lowri - 06/01/10 11:49 AM

looks great!
Posted by: GlockElbow

Re: New big ford owner in UK - project resto/lowri - 06/01/10 10:30 PM

Good luck with your MOT!
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 06/02/10 12:21 PM

 Originally Posted By: Justin McCarter
I'm reading up every day as well.



Even though I'm sure I forgot most of what you did. Just don't make any references to previous steps.

Justin.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/05/10 12:12 PM

Heres the old and new battery hold down clamp. You can see the original battery must have been wider.





Well I made it to the test station with no funny noises or squeaks or rattles and it.............passed!!!





Heres the emission read out. CO and HC is okay but lambda is not. But it doesn't matter since the emissions are within specs for this year of car in this country.



Andy.

Now its serious bodywork time!!!!
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 06/05/10 02:53 PM

Yay!

Alex.
Posted by: LysanderMB

Re: New big ford owner in UK - project resto/lowrider - 06/06/10 03:53 PM

Well done for passing the MOT.

My '91 is in the shop getting a rebuilt tranny... apparently the forward (or was it front?) clutch has disintegrated. Not looking forward to the bill...

Can anyone Stateside help me track down some dark blue back rests for the fold down seats in the back? For some reason the car has the seat squabs but not the back rests. Anyone have any idea how much they might cost?

Lysander
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/07/10 12:49 AM

Hi Lysander.
Is this your new squire per chance?



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/07/10 05:37 PM

Oops! I've just spotted from the photos of the battery that I've fitted it the wrong way round!! Connected okay, but 180 degrees out!!

Bet you were all too polite to say

Andy.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 06/08/10 11:34 AM

I'm still waiting for my prize for guessing what it was you painted, no more free bees.

Justin.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/08/10 12:09 PM

You can have the satisfaction (and smugness) of knowing that you were the only one to get it right. That is not a freebee, thats priceless!!

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 06/08/10 05:09 PM

 Originally Posted By: andyfanshawe
Oops! I've just spotted from the photos of the battery that I've fitted it the wrong way round!! Connected okay, but 180 degrees out!!

Bet you were all too polite to say

Andy.


Just figured you wanted it that way. I've changed to a side terminal battery in mine since I hate top terminals. Makes sense not to have the positive terminal under the grounded support bar.

Alex.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 06/08/10 11:50 PM

I had a battery fail with side terminals once. The battery also had top terminals. What happened was that the internal connector to the side terminals inside the battery broke so I ended up converting to top terminals. I may have been unlucky, but the guy at the battery store said the internal connection to the side terminals of the batteries is not always very strong.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 06/09/10 04:44 PM

I only use AC Delco batteries, I have never had a failed internal bar on these. I'm sure that as long as king kong isn't ham-fisting my battery cables or bolts I'll be fine.

Alex.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 06/10/10 04:31 PM

Ive had two batteries go dead in less than a total 5 years next one is going to be for one of these.




Just may last longer .
we do need to stop we are starting to stray from the thread, but it would be half the length without us going out like this.


Justin.
Posted by: simontemplers

Re: New big ford owner in UK - project resto/lowrider - 06/12/10 08:46 AM

Are you off to Menwith Hill this year. Are you taking the Ford or the Camaro if you go?
Got my tickets this morning.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/12/10 07:18 PM

 Originally Posted By: simontemplers
Are you off to Menwith Hill this year. Are you taking the Ford or the Camaro if you go?
Got my tickets this morning.


Hi.
Yes, we are planning to go to Menwith Hill. Tickets are supposedly on their way.
The Camaro will be winging its way there. The wagon is undergoing more restoration work!

Weather permitting, we'll see you there

Andy.
Posted by: LysanderMB

Re: New big ford owner in UK - project resto/lowrider - 06/13/10 04:50 PM

Andy -

That is indeed my new Squire - the seller was very lucky it got into a bidding war at the last minute & I paid much more than I meant to... Just paid ££££££ for a totally rebuilt transmission & still have plenty to do before I can use it every day. The heater blows very hot whatever the setting, for example, even 'vent'. Grrr. On the other hand the body is in fantastic condition (I had a look at the underneath during my MOT) and it will make a great car - or so I tell my wife....

Lysander
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/16/10 01:04 PM

Hi Lysander.
Looks nice.
I used to regularly talk with the previous owner of your car and have a few photos of it. Would you be interested in them?

Good luck with it. They are quite easy to work on though.

Not had much progress with mine over the last couple of weeks. Really busy at work and its passed its annual test, so just waiting for my holidays to start the exterior bodywork.

In the meantime, I decided to upgrade the stereo to one that actually works and doesn't have a tape deck. Got this one quite cheap from a friend, and it has MP3 and plays the usual writable CD technology. Video out as well for future built in monitors.

Old connectors cut off and new ISO connectors wired in-using heat shrinkable sleeving of course



Heres the ISO connector in the back.



Intestingly, the wiring diagram on the unit itself was wrong!! Good job I spotted it first!

I even utilised the old rear "railing" system for it



Heres the new look. yeah I know it looks out of place but it sounds good!! May paint the surround black though.



Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 06/17/10 08:52 PM

Looks nice. If you can find it, you may be able to replace the ashtray with one from a 93+ which would have cupholders. I'm not certain, but I think it just might fit. I'm not sure if you would need the cup holder/ashtray + bracket, or just the cup holder.
Posted by: PseudoBoat

Re: New big ford owner in UK - project resto/lowrider - 06/17/10 11:58 PM

No it doesn't fit.

What you need are armrests from a 94 continental. Straight bolt on, with cup holders, and extra storage.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/18/10 01:04 AM

Thanks guys.
The chance of me finding any of those parts here in the UK is.....well.........nil!!

Good thoughts anyway.
Andy.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 06/18/10 12:44 PM

You know when its been the cars time when you cant find anything for her in the junkyard. Been that way for my 1990vic and brothers 95f150 for two months.

And much nicer than my radio install witch included blue wire nuts circuit testing and duck tape, how young I was didn't know of the 5$ harness kit at pep boys.

Justin.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/22/10 03:46 PM

Okay, before the big bodywork starts in my holidays (5 weeks), lets sort out a few issues.

Flashing airbag light first. Really annoying. Supposedly been on for years.

Flashing code 8, which is a ground problem to one of the front 3 sensors.

So, each one out and tested and bolted back down to clean metal





Front right and front left give good readings and are reinstalled. Ground circuit to PCM from both is fine.
So it must be the centre one then?
Heres a view of it removed



The steel has corroded and pushed away from the circuitry and has got an actual hole in it.

Heres a view from the underside and you can just see a gap where the steel has parted.



Whats the chance of water and pressure damaging the PCB inside?
And whats the chance of getting hold of another sensor like that?
Anybody got one lying around?!!

So, what other jobs need doing? After I fitted the stereo, the LCD clock is on full brightness and the stereo won't power down when the key is in acc or run????????

So, stereo out and wires checked. Must have been something I have done.

There is continual power to the yellow/black wire that comes from fuse 11 in the fuse box. This should be hot in acc or run, not all the time. So fuse pulled and guess what? Still power to the yellow/black wire!!! WTF?

According to the wiring diagrams I have (dealer), the yellow black wire feeds power to the power antenna (haven't got), amp for old radio (haven't got), and LCD dimming relay for old radio (relay removed) and new stereo (removed). But still power exists on the yellow/black wire!???????????

So, this offending wire is receiving no power from the fuse box (fuse removed), goes up under the dash and appears at the lcd dimming relay, the power antenna switch and the stereo. So it shouldn't have 12 volts to it. But it has!

The only possibility that remains is a melted wire within the loom. But how? So it looks as if the dash is coming out to remove all the old wiring insulation tape and check the entire dash loom for damage.

Oh well, more dismantling to do. At least its damn sunny here now, and far better than the -6 degrees I worked in during the winter!!

More to come..............................Seriously looking forward to the bodywork though.

Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 06/22/10 04:21 PM

That's weird what's going on with your stereo install. If you still have the Ford plug you cut off the car's wiring harness, you could double check the wire colors that way. Somewhere online I'm sure there is a diagram of which pins on that connector do what. The only thing I can think of is an error in the colors in the wiring diagram.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/22/10 04:33 PM

 Originally Posted By: Jeff2
That's weird what's going on with your stereo install. If you still have the Ford plug you cut off the car's wiring harness, you could double check the wire colors that way. Somewhere online I'm sure there is a diagram of which pins on that connector do what. The only thing I can think of is an error in the colors in the wiring diagram.


Hi.
I have the dealer wiring diagrams and have been checked and double checked. The new stereo plug has been removed and the wires are back to where they were before the install. No stereo plugged in. Got to be a melted/trapped wire somewhere! Not quite sure how, but the car has been rebuilt!!

Anyway it'll give me an excuse to remove the whole dash to do some more welding and change the heater core!!


Thanks for your input though.
Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 06/22/10 06:13 PM

 Quote:

And whats the chance of getting hold of another sensor like that?


I believe it is zero. There was a member here a few years ago looking for one. He may have found one on ebay, but for some reason I think the "fix" was pulling the airbag light and disabling the system.

Alex.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 06/22/10 06:22 PM

Any chance you can scan the air bag diagram? I can't find squat on the box air bag system.

If you are working off the full wiring diagram, pay special attention to tiny little references to connections to other wiring. Your power may be tied into something else as secondary power.
If you remove the airbag control module, does that phantom power go away? (air bag module holds a charge for while to power the system).

Alex.
Posted by: PseudoBoat

Re: New big ford owner in UK - project resto/lowrider - 06/22/10 10:08 PM

I grabbed a bunch at a wreckers until I found a good one. I may have some still ( I know I have some sensors, just maybe not the middle one ). I intend to go to the wreckers later this summer, so there is a good chance I could ship one to you.

I'm actually going to be in London in early July...
Posted by: pantera77

Re: New big ford owner in UK - project resto/lowrider - 06/22/10 10:28 PM

Pulling the air bag light = the worst noise ever.

You could throw a resister in there, or be lazy like me and put a piece of electrical tape over it.


Or fix it the right way.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 06/23/10 07:57 AM

Surely one of us in the US can find a decent one in a boneyard. My airbag light isn't on, so presumably all the sensors are still good. I figure if mine are still good, here in the rust belt, other cars ought to have good sensors too.

Unfortunately, I've got no time right now to head to the boneyard (even though I could use a few parts). My son is gearing up to work on his Eagle Scout Project and that is sucking up the majority of my free time. Hopefully later this summer I'll have more free time.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/23/10 04:37 PM

Wow, it would be seriously nice to have someone find me a good used centre sensor, but I wonder how hard it will be to repair. I'll find out.

But now, the wiring fault..........................
Well, finally solved it! What a stupid thing it was.
Almost embarassing, but not.
The fault was assuming. I know, I know, you should never assume.

When the factory wiring was checked out, it was fine. When the new wires were soldered in, it wasn't fine. So it makes sense that I had done something wrong. But I double and triple checked the wiring colour to colour and it was okay.

Have a look at this photo, especially the black tape just above my finger



Now I ASSUMED that the tape was just holding the wires together. After all, what stupid idiot would join a permanently hot wire to an accy feed wire?

Heres a photo of it with the tape removed



That is a professional crimped join/splice. And that is where the power was being transferred to the yellow/black wire. But why would it be there? Remember this is a new stereo with no hacked wiring.

A few mins later and the crimp was off, the wires heat shrink insulated and we are back firing on all cylinders! So to speak.

Just 1 crimp was causing the electric windows to operate without the key, the LCD clock to stay illuminated and the stereo to stay powered up with the key out without manually switching it off. Still can't believe it.

We live and learn!

Andy.
Posted by: interceptor1985

Re: New big ford owner in UK - project resto/lowrider - 06/23/10 04:49 PM

About that electrical box, if you can manage to find a way inside of it you can check for blown capacitors by looking for bulged rounded off tops, they should be flat on top. that's a normal common problem for circuit boards that have had some sort of short. And the reason its wrapped in steel is to avoid radio interference I think.

By the way, great eye on that wire, it would have slipped right past me!
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 06/27/10 11:56 AM

I believe all my sensors are intact, never did find out why my light was on but ditched the bulb and module years ago. so if you wanted mine then i guess i could test and send it over the lake or we could make it much easier by me and you finish every thing on your car except your air bag light. send the car over i could install the sensor and make shure the fix is good over a two year quality check and test and i'll be shure to get your car back to you when the check is over.

But seriously send me a pm with what you used for circuit testing and i'll let you know. More or less just reimbursement for shipping.


Justin.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/27/10 04:18 PM

Wow! Thanks Justin.
Let me get you a test diagram drawn out. Then all you need is a digital multimeter.

I'll arrange for the car to come over to you, or just the shipping for the sensor! Whichever is easiest :-)

Thanks again.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/28/10 03:07 PM

Tonight, I intended to start the process of removing the inner rear wheel arches and reduce the outer wheel arch lip in width and start reconstructing it all-including reprofiling the rear lower quarter panels.

BUT, got involved in servicing my dads car Enjoyed it too much though. Took me away from the jobs in hand!

Tell you what though. Went out in it yesterday to the local country park with my youngest son (7) and my good lady Wife. I drove, my Wife sat on the passenger front and my little lad sat inbetween us on the bench seat! Was fantastic. All 3 on one seat, and still plenty of room.

Now what car can you do that in these days? Eh? Those days are gone! But not for us :yay:

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/28/10 03:29 PM

Hi again Justin.

Here is a connector view of the centre front airbag sensor.



Sorry its slightly blurred!
Anyway, put a digital multimeter set on ohms, between connector 620 and a good shiney bit of the metal case. If it reads less than 1 ohm, chuck it in a box and tell me what I owe you for shipping!

Thanks.
Andy.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 06/28/10 09:04 PM

I'll check tomorrow, and i'm going to need a real address a bit more specific than UK. I have a shipping est that could be from 80$-170$.

One random address gave me a 4day shipping of 71$ and a 2day shipping of 49$, that would be for around Blackfriars st. Carlisle.


Justin.

Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 06/29/10 06:52 PM

Ship it as a international surface parcel with Canada Post (6"x5"x4" 1kg is $15). Shipping with things like fedex will hit Andy with extra charges from the shipper.

If not a lot is going over on the mail run, it'll get to andy within 2 weeks since they fill the space with the lower dollar options. It potentially can get to Andy as fast as express post.

Alex.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 06/30/10 12:31 PM

Justin is in the US, so he has two options. Drive to Canada to ship it Canada Post, or ship it US Postal Service. But you're right, UPS, Fedex, etc have inflated shipping costs, especially for international orders.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 06/30/10 05:09 PM

Oops. I was thinking of the Toronto fella who said he had some modules. The US has priority mail international (small packets upto 4 pounds for $13.45. (flat rate box 8-5/8" x 5-3/8" x 1-5/8")

[ http://www.usps.com/prices/priority-mail-international-prices.htm ]

Alex.
Posted by: drover54

Re: New big ford owner in UK - project resto/lowrider - 07/01/10 07:25 PM

Wow, i just finished reading through the whole thread... amazing job, your bodywork skills and fab skills in general are outstanding. its also nice to see someone else with red and silver as their favorite colors! everything else aside i am definitely subscribed to see the finished product of this project.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 07/02/10 08:58 AM

 Originally Posted By: drover54
Wow, i just finished reading through the whole thread... amazing job...


I check this thread every day. Makes me want to keep my Box running forever.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/02/10 03:23 PM

Fantastic to hear that my work is inspiring others. Thats what life is all about. And thats exactly why I am a teacher.

Here's a bit of mojo for me! A new set of rear light units for my wagon! $25 each. $20 shipping to the UK and a further $30 customs charge!!



Is it my age, or do they look sexy?!!!!!!!

Now must start the wood removal and get this thing in a state for paint. Been a bit lax lately. Been catching up on jobs that I didn't do over the long cold winter working on the wagon! Like servicing my Wife's Grand Voyager, my Dads Toyota Yaris and my custom camaro. All forgotten about since last october when it all started.............!

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 07/02/10 05:41 PM

Nice score on the lights, great price to. Are they OEM, or an aftermarket unit?

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/02/10 05:55 PM

Hi Alex.
Supposedly OEM!

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=390173986422&viewitem=

By the way, you were spot on about the body mounts not moving even though they aren't a perfect fit! Thanks again. Saved me a lot of grief.

Andy.
Posted by: larryo340

Re: New big ford owner in UK - project resto/lowrider - 07/02/10 06:51 PM

Hi Andy,

I've been following your thread, and you have done some extremely amazing work on that wagon

That tail light is a genuine Ford part, I also noticed that seller has brand new OEM side mirrors. I don't know if you need them, but they sure would look pretty \:\)
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 07/03/10 01:16 PM

 Originally Posted By: drover54
Wow, i just finished reading through the whole thread... amazing job, your bodywork skills and fab skills in general are outstanding. its also nice to see someone else with red and silver as their favorite colors! everything else aside i am definitely subscribed to see the finished product of this project.


Shure hope you remembered to use the restroom, call off of work, and eat four meals.

And for Andy reply quick because the one ground circuit checks out fine are their any other tests for the three other wires, because my air bag light was on for a reason. Before i send a possibly bad failed in an other way. And we need to still discuss the conditions for me sending you this sensor.

you must paint a mural on your tail gate of my car in its prime but with 18" mustang wheels parked in a field with a sonnet explaining how glad you are that i sent you the part and of the fact that your air bag light wont blink anymore, text needs to be all upper caps fading away at the bottom and thin at the top just like at the begging of all the star wars movies, and cut this out onto a strip of vinyl "CrownVic347ciT5" and post it to each quarter panel, and hood and roof just like a Nascar sponsor would get.


Justin.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 07/03/10 04:21 PM

What, out with the wood grain? I thought it looked so classy! Could you send it to me to glue onto my '92 Aero Grand Marquis? It doesn't matter if it comes off in a million pieces, it will give it a distressed look.

I should do a photochop and see just what it would look like.
(Note, please do not send it to me. My wife would never forgive me!)
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/05/10 04:45 PM

 Originally Posted By: enslow
What, out with the wood grain? I thought it looked so classy! Could you send it to me to glue onto my '92 Aero Grand Marquis? It doesn't matter if it comes off in a million pieces, it will give it a distressed look.

I should do a photochop and see just what it would look like.
(Note, please do not send it to me. My wife would never forgive me!)


Hi enslow.
Whats it worth to not send the wood grain to you !

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/05/10 04:49 PM

 Originally Posted By: Justin McCarter

And for Andy reply quick because the one ground circuit checks out fine are their any other tests for the three other wires, because my air bag light was on for a reason. Before i send a possibly bad failed in an other way. And we need to still discuss the conditions for me sending you this sensor.

you must paint a mural on your tail gate of my car in its prime but with 18" mustang wheels parked in a field with a sonnet explaining how glad you are that i sent you the part and of the fact that your air bag light wont blink anymore, text needs to be all upper caps fading away at the bottom and thin at the top just like at the begging of all the star wars movies, and cut this out onto a strip of vinyl "CrownVic347ciT5" and post it to each quarter panel, and hood and roof just like a Nascar sponsor would get.


Justin.


Hi Justin.
Thats a tough deal! Go on then I'll put your decals on my wagon. Small price to pay for such an expensive sensor.

Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 07/10/10 12:03 AM

5 days, no posts.... sweats, delirium, ...

I addicted to this thread.

OK, it above 30C here, that accounts for the sweats and delirium. But I'm still addicted.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 07/13/10 04:19 PM

still waiting on post of other tests before i send out the part.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/16/10 01:35 AM

Interesting developments on the airbag front

Heres a shot I took earlier on of a seriously corroded front centre sensor.



Heres the same sensor but with the metal peeled back



The silver circle is a rivet that should have been connected to the remains of the wire that is sticking out! So that is why the airbag ECU was detecting no earth through the circuit.

Here it is cleaned up a bit



So I soldered a wire to the little bit that was left and secured it back to the case with a self tapping screw.



The white stuff is a sealant to try to prevent it all happening again!

Then fully rustproofed (dinitrol 3125) and installed.

Guess what? After supposedly years of the airbag light being on, it actually went off!!

Too good to be true almost. Time will tell though.

Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 07/16/10 07:53 AM

Glad you found a solution to the air bag light problem that didn't involve postage across the Atlantic Ocean. That would have certainly involved extra time and money, even for a "free" part.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/23/10 05:50 PM

Here we go, 2 steps forward and 3 steps back.

First...............that code 8 for the airbag circuit front sensor, has now reappeared and turned into a code 9! Perhaps the heat from the soldering iron on the little bit of wire that was left has affected a solder joint on the PCB buried in the protective covering. The resistance across the firing circuit resistor is way too much. It was okay before the soldering. Whatever has happened either needs further investigation by trying to dig away at the plastic, gel covering, whatever its called. Bit like an archaeological dig-a bit at a time and with a lot of care OR loose the airbag and all associated components and wiring completely. 1990 airbag technology is a bit dated and worrying.

Secondly and more serious was the appearance of the oil pressure warning light after a run and a thoroughly warm engine. According to the manual thats 6psi or less - oops!. No problem, perhaps a faulty switch on the block. So, get an oil pressure gauge, make up an adaptor hose and wire it in temporarily.........



Fire it up and what do I see? 40 psi with a cold engine and 10W 40 semi synthetic oil.
As it warmed up I kept an eye on the pressure. When fully warm, the pressure was 5 or 6 psi. As I blipped the throttle the oil pressure went up to a max of 25 psi.
Now call me a perfectionist, but that ain't enough.
The engine doesn't rattle or smoke or misfire even when idling hot, but it doesn't inspire confidence!

During the winter when the engine was on the stand, the bores were well within spec, the cam lift was also within spec, but the engine was filthy inside and out. I removed and cleaned the oil pick up tube and cleaned as much as I could. When the decision came to rebuild or not, I knew the bodywork/chassis work would take a lot of labour and money so took a chance on renewing all the gaskets, core plugs, oil seals, lapping valves in etc. It wasn't burning oil before and was quiet, so a calculated gamble was taken. Leave the crank bearings well alone, save some money, put it back together, finish the bodywork/chassis welding, get it back on the streets, get it taxed (licensed) and insured and legal. Then sit back and assess whats next.

Well it looks as if the gamble may not have paid off. I don't think I have any choice than remove the engine again, strip it down and rebuild it properly. Not something I wanted to do, but that was the gamble, and if it needs to be done, so be it.

I'll change the oil and filter again to see what happens, but I am not expecting any change. I am assuming the clearences on the mains and big ends and cam are the main culprits for the loss of oil pressure.

Here we go again.....................

Andy.
Posted by: PseudoBoat

Re: New big ford owner in UK - project resto/lowrider - 07/23/10 07:43 PM

That engine will go a long time in that condition. You'll get a lot of responses about it with a lot of good advice. It's a common problem for these engines. I ran mine for over 100000km with that problem with no worsening. I just ran some additives for it and the light stayed off.

However you are a perfectionist. A perfectionist would pull the engine, send it out for boring, and all the other things they do to freshen a block. You will do the HO upgrade at least. You will run headers. Your oil pressure will be perfect. Just wait until the body is done. Your engine is fine for now.
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowrider - 08/10/10 07:31 PM

Please
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 08/10/10 08:30 PM

I hope the oil pressure issue hasn't got him soured on the project.

Alex.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 08/11/10 09:44 AM

he hasn't pm me about getting the sensor.
Justin.
Posted by: Cowtown Cowboy

Re: New big ford owner in UK - project resto/lowrider - 08/11/10 07:47 PM

If the crank is in good shape otherwise, just install new bearings. That's why they sell new ones after all.
Or a reground crank kit. Or for what a new cast crank is worth, it might even be cheaper to simply replace it. This is not the end of the world.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 08/13/10 09:21 AM

Hi all.
Thanks for the interest! No I haven't been put off by the engine. The opposite in fact. It's running very well at the moment so I have been putting a few miles on it.

Myself and the family have been holidaying around the country in our caravan pulled by our Chrysler Voyager (still american!) so not much has been done.

we are flying out to Gran Canaria next week for a few days so even less will be done!! The UK hasn't supplied much sunshine over the last few weeks.

As soon as I get back the rear inner wheel arches are coming out and be redesigned and the rear quarter will be reprofiled. Then the gas tank filler door will be welded up and relocated behind the rear light unit.
I then intend to work forwards removing the "wood" and repainting as I go.
When I have the bodywork done, I will then pull the engine and rebuild it!

Be patient!
Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 08/13/10 09:27 AM

Thanks for the update! What you're doing is just about every car lover's dream. I hope that some day I'll have the time and skills to do the same. \:\)
Posted by: FrostKnight

Re: New big ford owner in UK - project resto/lowrider - 08/17/10 08:08 PM

Amazing job Andy!! I myself am doing a overhaul on a 1990 crown victoria LTD.

Before



After





I still have lots to do to the car, including dying the top... This thread makes me want to get outside and continue to work on it!

Keep up the great work!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 08/29/10 06:01 PM

Hi Frostknight.
I hope I can get mine painted as fast as that! Keep us updated on your progress.

Right here we go again! Holidays over, but not back to work quite yet. No more excuses.

This is the bit I want to change. The straight section at the bottom of the rear quarter panel, and the trim and the removal of the badge and the removal of the red marker light. Oh and the fake wood!!





Heres the interior trim and the rear seats removed on the passenger side.



Heres a view of the inner wheel arch joining the outer quarter panel. Notice the rust starting to show through.





If the car was repainted, it wouldn't be long before that ate its way through. So I am going to remove the outer half of the inner wheel arch and try to detach the inner wheel arch lip from the outer wheel arch lip cleanly. Then reshape, medai blast and repaint.

This is the bracket on the drivers side that the rear seat back bolts to and pivots on. That is rusty and will be removed and remade. One of the speed nuts (as we call them) has already rotted through.



Ready for cutting!


Andy.

Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 08/31/10 05:29 PM

Right, if this thing is going to get a quality paint job, I don't want any rust bubbling through after a few months. So I need to dig deep and find any potential rust areas.

Rear wheel arch lips are notorious for corroding. So I need to remove part of the inner wheel arch and separate the inner lip from the outer one and have a look. Fun!!

Heres a view of some rust bubbling through at the bottom of the wheelarch towards the back.



Lets see how bad it really is





Now lets go inside and remove the inner wheel arch section.
Line marked for cutting



Starting the cut so the air saw can get in



Heres what my air saw did





Heres the state of the rear quarter panel after all remains of the inner one has gone





Its actually not too bad. A few pinholes but nothing that cant be saved with some media blasting and a small bit of welding.

These areas would have made a real mess of new paint after a few months.

Heres an interesting shot. Notice the rust creeping under the lower panel corner. Bet you can't guess what that would eventually do?!!



Blasting tomorrow.

Andy.

Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 08/31/10 07:05 PM

Glad to see progress reports again Andy. I don't know what we're going to do when you finish the car. =-)

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/01/10 05:33 PM

Hi Alex.
Funny you should say that because I've been offered a 1968 Impala!!

Anyway, back to the plot!
Whellarch lip repair and width reduction (sounds like cosmetic surgery!).







The wheel arch lip is way too wide, so here is my famous air saw in action again



Then I got involved in a friends rusty maxda mx5 rockers! Its sometimes not good to be the local welder/fabricator 'cos I get asked to do loads of jobs.

Anyway, reshaping quarter panel tomorrow (unless I get asked to do something else!)

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/02/10 04:52 PM

Today is quarter panel reshaping day.

Heres the panel under the rear bumper marked for cutting.



And heres the cut



Heres my friend Jay sat waiting to bend the quarter panel up. So this is the original shape



and this is the panel bent











I think it looks a lot better!

Andy.
Posted by: FrostKnight

Re: New big ford owner in UK - project resto/lowrider - 09/02/10 10:16 PM

Thanks Andy!

I'm currently wet sanding, and then polishing. Followed by 351w heads on the 302 block, 3.73 gears b303 ford performance cam and timing gears.

Your vic is looking good as it goes through its changes! I'm excited to see how this all progresses!

Keep up the great work! Take care of yourself!
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 09/03/10 12:57 AM

Andy, is anyone selling near you? I think I want to emigrate!

Oh wait, the annual cost of petrol is probably more than my salary. I think I'll stay.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 09/03/10 08:35 AM

I really like the rear quarter panel reshaping. It's something that's really subtle (especially if you're not familiar with wagons), but it really makes the body lines flow better.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 09/03/10 10:58 PM

x2


Justin.
Posted by: Yoder

Re: New big ford owner in UK - project resto/lowrider - 09/03/10 10:59 PM

GREAT WORK Andy, looks good. The panel reshape should have been like that from factory to begin with.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 09/04/10 01:51 AM

 Originally Posted By: Jeff2
It's something that's really subtle


Subtle is right. I totally missed the reshaping until I thumbed through this entire page. In fact, I thought the reshaped quarter panel was the original factory shape, what it should have been.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/05/10 02:31 PM

Thanks guys!
Heres the spare wheel well removed completely



And the cardbord templates of the panels to fill the gap





Now just got to make them out of steel







Now then, one of my friends (Chris) has done a sketch of a possible finished product......

Have a look at this:



Not a bad sketch is it! He says he is available for custom sketches on any car of your desire. Send me a PM and he will do you one for a small cost.

Interesting design though!

Andy.
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowrider - 09/05/10 07:00 PM

I really like the exhaust cutouts in the bumper.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 09/07/10 05:27 PM

I like the concept drawing.

Alex.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 09/08/10 08:58 PM

how about he does me a scetch and i'll send you that air bag sensor? and 15 pages on 50 replys a page woho


Justin.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 09/12/10 04:16 PM

Progress today for the first time in ages.

The task was to repair the rust corner of the wheelarch, finish the panel replacement where the spare wheel used to be and try to weld some holes up.

Heres the card template for the rusty corner and a black line where I am going to cut



Here it is removed and the offending rusty steel





New steel clamped in place for welding.





I spot welded the join down the quarter panel to prevent any distortion.



Heres the wheelarch lip in place ready for welding



and welded



to be continued..............................

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 09/12/10 04:27 PM

Cardboard template for bottom panel made



And panel transferred to steel



Welded in



Fully rustproofed by heating the panels and spraying dintrol 3125 in till it seeps through the joints



Finished arch waiting for prepping for paint



View from the outside to the inside!



Hole welding next. Copper plate clamped to the back of the panel to absorb the heat and prevent distortion







Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowri - 09/13/10 09:05 AM

Posted by: Super_Buffalo

Re: New big ford owner in UK - project resto/lowri - 09/18/10 10:55 AM

NEED MOAR!!!!!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 09/18/10 04:40 PM

 Originally Posted By: Super_Buffalo
NEED MOAR!!!!!


Okay!
Recent evenings have been wet and getting dark quicker, so not much progress till today.

Time to remove the "wood" from the rear quarter so I can do some more welding and get it prepped for paint.



This is me with a hair dryer and a wallpaper scraper!



All off-but not the sticky residue yet!





Cutting the light unit metalwork out



Ready to be welded up
-and you can see the 5 holes around it I had to weld up.


More tomorrow.
Andy.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 09/18/10 09:22 PM

Ahh that tape line is cheating, supposed to use a straight ruler and marker and roll the ruler over as you trace and hope to get a straight line.


Justin.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 09/19/10 03:25 AM

Time to start thinking about the lowrider part of this build.
Yes it will have air suspension but it really needs to be lower.

Now this will take a lot of work, and I certainly can't do this outside, but................cutout the floor and firewall where the frame is and lower the whole body down over the frame, and remake the floor and firewall. Probably have to lower the motor too!! Oh, and move the steering column, and wiper motor, and trans tunnel..................
That will give a nice stance, and combined with air, will make this wagon sit on the floor.
Hmmm........

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 09/19/10 03:44 PM

Today managed to make up the panel to fill in the gap where the side marker light used to be. Joddled it so it would sit flush and spot welded it in.







Completed panel



Just got the wheelarch lip to repair in 2 places and the quarter can can be prepped and painted. then its on to the other side.

Andy.
Posted by: LysanderMB

Re: New big ford owner in UK - project resto/lowri - 09/21/10 03:39 PM

Great progress Andy!

Part of me is sad to see the lovely wood being taken off but beauty is in the eye of the beholder. The look you're going for would be ruined by the wood, that is for sure.

Now that you've adjusted the rear panel, where are you going to put the spare wheel?
Posted by: DallasCV

Re: New big ford owner in UK - project resto/lowri - 09/21/10 04:32 PM

Are you thinking about modifying the stock bumpers to tuck them in? Get rid of the big safety shocks and section the bumpers so that tuck in like the early 70s cars did.
Just looked at your original pictures and I guess this year didn't have the really ugly bumpers...they did a better job of tucking them.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 09/21/10 05:57 PM

 Originally Posted By: LysanderMB
Great progress Andy!

Part of me is sad to see the lovely wood being taken off but beauty is in the eye of the beholder. The look you're going for would be ruined by the wood, that is for sure.

Now that you've adjusted the rear panel, where are you going to put the spare wheel?

How about this?

(Please don't hurt me!)
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowri - 09/21/10 06:47 PM

 Originally Posted By: enslow
 Originally Posted By: LysanderMB
Great progress Andy!

Part of me is sad to see the lovely wood being taken off but beauty is in the eye of the beholder. The look you're going for would be ruined by the wood, that is for sure.

Now that you've adjusted the rear panel, where are you going to put the spare wheel?

How about this?

(Please don't hurt me!)


Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 09/21/10 08:11 PM

Thankyou and here are your spare tires.
Spare tires? We don't need no stiking spare tires.





http://www.imdb.com/title/tt0071230/quotes?qt0371636

Justin.
Posted by: mikei1983

Re: New big ford owner in UK - project resto/lowri - 09/23/10 11:08 PM

The '302' stripe should rap off the finders, just like the 'BOSS' cars. Then drop the spare tire and just take your chances.

Depending upon the interior, and if he is not keeping the far rear seats, he could build a spare tire mount that almost like what they have for trucks...
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 09/25/10 05:35 PM

No spare tire + flat = breakdown truck (that I have already paid for anyway!).

Weekend again, so its bodywork time.
I need to finish the welding on the passenger side, so its rust removal time............

Heres the offending patches


If I hadn't removed the inner arches, this would never have been repaired properly and would soon breach the new paint. We've all seen this before - a rust repair that keeps on coming back. Well this one won't.









And finally complete ready for a bondo skim



Heres my garage extension in the shape of a gazebo!!



Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowri - 09/27/10 08:47 AM

Looks like progress despite the fall weather.
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowri - 09/28/10 07:14 PM

Andy,

You need to act quick. Here is another wagon for you to work on

FrankenVic Wagon



Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowri - 09/29/10 08:26 AM

While I appreciate all of the work which goes into a custom vehicle like it, I don't like the FrankenVic Wagon as much as a Country Squire. From what I've seen so far, Andy's only making the Country Squire better. \:\)
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/06/10 02:15 PM

Nice work on that frankenwagon though. Somebody has good skills.

Anyway, onwards, upwards and backwards!

Couldn't get the lower repair panel flat with a skim of bondo, so after a bit of investigational work, I found out that the wheel arch lip I welded in was slightly out of shape (not curved enough), so I had to cut the lip out agai, reprofile the panel and then weld a new lip in.....

Heres the lip cut out.



After loads of bondo skimming, panel beating sanding and priming, we come to this



Because I am working outside in the autumn, I need some protection. So here is my gazebo and a tarpaulin!!





Heres a couple of views of the inner wheelarch structure cut out and new flanges bent ready for the new inner section. Notice the accidentally cut upper panel that my air saw went through by mistake!! Welded back together though. Don't tell anyone.





Andy.
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowri - 10/06/10 02:23 PM

Thanks for the update. I'm sure many of us have been going through fabrication withdrawals in your absence.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowri - 10/06/10 04:13 PM

That rear side panel is looking good.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/06/10 04:48 PM

After mucho thoughto of a name for this vehicle, I have been introduced to its name (no, almost a slogan) by accident.

My eldest son (almost a teenager at the ripe old age of 12 years and 11 months) is undergoing diving lessons (swimming pool, diving board ones, not the underwater scuba type!) and he was finding it difficult to dive off the 3 meter board. I know how he felt, because I have been through all this when I was a mere pup. I said "trust me, just do it. Call it a leap of faith, it will open up new dives to you".

He wasn't quite sure what I meant about a leap of faith, so I tried to explain it. Something along the lines of, just step forward and trust in what will happen......

This sums up the wagon. So many people have said it is ugly, too big and a modern day dinosaur!! Don't forget us Brits are not used to such size and ..almost..., dare I say it.....arrogance in a car!

But I don't see it like that. It will look different, it will look lower, it will look a LOT better...TRUST ME...

So, there we go, LEAP OF FAITH. Now got to decide where to airbrush/signwrite the name on the finished car.
I quite like that. Not quite sure that my Wife does though - or even that I am still sane!

Andy.
Posted by: GlockElbow

Re: New big ford owner in UK - project resto/lowri - 10/06/10 06:38 PM

 Originally Posted By: andyfanshawe
LEAP OF FAITH.


I like it. I think it's going to take some faith to drive it in the UK. It will certainly take faith to fill it with gas at almost $8US a gallon!

I bet the average Brit is stunned when they see your wagon. I get comments about the size of my Vic when I give international visitors a ride and its just a sedan. These things are huge!
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowri - 10/06/10 06:44 PM

 Originally Posted By: andyfanshawe
So, there we go, LEAP OF FAITH. Now got to decide where to airbrush/signwrite the name on the finished car.


May I suggest, the front fender between the wheel arch and the front door edge. In the style that the old bombers would have near the nose of the plane.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 10/06/10 08:57 PM

 Originally Posted By: andyfanshawe
... So many people have said it is ugly, too big and a modern day dinosaur!!


We get that too. They may be dinosaurs, but the older ones are easier to mofidy and far more reliable then more modern cars. Also, the new bodies are swooped up at the rear making visibility very poor in the back. I drove a Toyota Corolla for 3 weeks a couple of years ago even my wife who hates large cars said my dinosaur was easier to see out of then the Corolla.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowri - 10/07/10 08:43 AM

I love my 91 Crown Vic dinosaur!

My brake lights were broken over the weekend (bad switch and no time to fix it), so I took my wife's car on a 6 hour drive I had to make on Sunday and I hated every minute of it. Her Pontiac Vibe is fun enough to drive around town, but on a long trip it's murder compared to the Crown Vic. Her car has lots of cabin noise plus it was being blown around by a nasty cross-wind the entire trip. The same trip in my Crown Vic would have been comfortable and quiet and with the extra weight and stronger power steering, the cross-wind would have been easy to deal with.

All in all, the Crown Vic is a much more relaxing car to drive on a long trip.
Posted by: LysanderMB

Re: New big ford owner in UK - project resto/lowri - 10/08/10 09:50 AM

Driving a Country Squire in the UK does get attention but for every disparaging comment there's a positive one. Filling up the tank isn't so bad compared to a Range Rover. And there are plenty of those around in the UK. You can't beat a big wagon for a long journey with a pile of luggage.

But remodelling a Squire is indeed a 'Leap of Faith'!
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 10/11/10 02:59 PM

Andy,

Here's something that should probably go straight to your trash bin, but who knows, you might find it interesting just the same. It is an emissions report from AirCare for an '87 Country Squire. I don't believe you have to worry about emissions where you are, but if you have access to a gas analyzer you could find engine problems before other problems arise. For example, high temperatures resulting in high NOx can burn out exhaust stem seals, a common failure on the early '90's Panthers.

The green trace is the vehicle speed. Both NOx and HC failed in this report. This report was for a 1987 Country Squire that failed both the HC and NOx.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 10/12/10 11:20 AM

 Originally Posted By: enslow
my wife who hates large cars said my dinosaur was easier to see out of then the Corolla.



and our mirrors are 3*4inch thats saying a lot.

Justin.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/12/10 03:20 PM

Thanks enslow. Makes interesting reading.

Now its time to start to reconstruct the inner wheel arch and tie the inner to the outer.

Heres a panel cut to fit



Heres the back view with the area painted that I wont be able to paint/treat effectively after its welded in. I've kept the edges clear of paint so it wont burn off and block the rust proofers treatments path. The holes are there for the adhesive to grab to.



Tack welded in.


Next panel made up and painted on the inaccessible side. Then areas scraped where the welds will be







Tacked in. You can just see the white adhesive squeezing out.




Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 10/13/10 05:21 PM

(Still following along).

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/15/10 03:07 PM

What about a 2 door wagon conversion? And I mean proper length (longer)front doors. Hmmmmm.............

Andy
Posted by: 124neta

Re: New big ford owner in UK - project resto/lowri - 10/15/10 03:56 PM

 Originally Posted By: andyfanshawe
What about a 2 door wagon conversion? And I mean proper length (longer)front doors. Hmmmmm.............

Andy


That sounds wicked. strip out everything else from the back and make it a two seater covered pickup!

I remember seeing this tread when it started, guess i dont check the box furums as often as i should, cause WoW! Great work.
Posted by: DallasCV

Re: New big ford owner in UK - project resto/lowri - 10/15/10 04:21 PM

They do it on a lot of the older cars...4 door to 2 door conversion. Just need a 2 door box doors and back window section. It's doable. Parts over there may be harder to find though. Basically you'd have to find a trashed 2 door box and get all the good stuff.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/15/10 05:19 PM

Nah. No chance over here for parts.
It would all be custom built from scratch.

Andy.
Posted by: PseudoBoat

Re: New big ford owner in UK - project resto/lowri - 10/15/10 06:36 PM

How about 2 door gull-wing? Or sliding van-style?
Posted by: DallasCV

Re: New big ford owner in UK - project resto/lowri - 10/15/10 07:07 PM

okay then maybe if you could just find the door panels...but the other way I've seen it done is to use your existing doors and graft them together...then move the 'B' piller back to where you need it. hmmm....panel wagon...
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 10/15/10 08:16 PM

For concept ideas, from a Trekie fan....
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/16/10 03:58 AM

All good ideas.....
What about throwing in something that it badly needs......a roof chop? That would be something else.
Now where could I get some glass from??.....

Andy.

PS I can see a new sketch coming on!
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowri - 10/16/10 08:15 AM

 Originally Posted By: enslow
For concept ideas, from a Trekie fan....



reminds me of this.
Posted by: LysanderMB

Re: New big ford owner in UK - project resto/lowri - 10/17/10 03:29 PM

Two doors would certainly accentuate the length. But I shudder to think of the work! You have plenty of US based followers and I bet one of them would find/give you a couple of doors. You could pay for the shipping easily enough.

Leap, Andy, leap!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/17/10 06:07 PM

Needed to finish the inner wheel arch yesterday and today so i can start to paint this thing

Heres a strange ugly bulge in the rear of the inner arch that needs to go. Notice the black marker line where it is going to be cut



And here it is ...gone...



Patch welded/glued in



The numbers on the panel is where I asked one of my young sons to press down in order from the inside while I tacked it from under the arch



Finish welding next and seam sealing and rustproofing. Then its epoxy paint underneath and final prep on the quarter for its temporary white paint.
Then its onto the other side.

Andy.
Posted by: simontemplers

Re: New big ford owner in UK - project resto/lowri - 10/17/10 06:36 PM

Are you only spot tack welding the plates or will you seam weld them?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/18/10 01:07 AM

 Originally Posted By: simontemplers
Are you only spot tack welding the plates or will you seam weld them?


Always seam weld.

Andy.
Posted by: simontemplers

Re: New big ford owner in UK - project resto/lowri - 10/19/10 07:09 PM

 Originally Posted By: andyfanshawe
 Originally Posted By: simontemplers
Are you only spot tack welding the plates or will you seam weld them?


Always seam weld.

Andy.

Sorry just wondered as photos just show spot welding then you say that you will seal it next.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/20/10 12:58 AM

Hi Simon.
I'll post some fully welded pics next.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/20/10 02:43 PM

While I am messing about with tedious welding, priming etc, I have had time to think about the front of this car.
To put no finer point on it, it needs redesigning. Too flat and too old fashioned.
What I would like is to produce a concealed quad headlight arrangement. Behind a phantom gille, or even better, behind a venetian blind grille. In other words, turn engine off and the grille closes up leaving it all black. Turn engine on and it opens up.
This may or may not involve scrapping the front nosecone/headlight panel.

Just a few thoughts for the time being........

Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 10/20/10 06:17 PM

What about a functional hood scoop done to match a phantom grille? Maybe fairly low profile?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/27/10 06:17 PM

Finally got to finish weld the inner arches and seal from inside the tailgate area.



I even managed to weld the inner frame to the inner arch. have a look here to see what I mean





Heres the welding under the arch



Nearly finished this side. Looking forward to doing exactly the same thing to the other side!!

Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 10/27/10 09:29 PM



Amazing. I do so wish you were my next door neighbour. But you wouldn't. I'd be pestering you for so much help, like fixing rust on my wife's unibody Lesabre.

My dad for years would repair rust holes by pop-riviting in metal, then using the coat of bondo. It actually worked well, but welding is so much neater and permemant.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 10/29/10 01:00 AM

either way its much better than what i saw at the scrap yard some t shirts then plastered then bondo then primer kinda 180deg from andy and about 120deg from me
Posted by: fordoldfart

Re: New big ford owner in UK - project resto/lowri - 11/01/10 04:43 PM

The old gentleman I worked with at the local salvage yard would cut out the holes or wrecked spots and weld in new panels with a acetlyene torch he was a master at this. But that was before spot welders and mig machines where readily avaliable to small shops and ordinary folks. Good work
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 11/02/10 11:12 PM

Andy,

What would it take for me to be able to cut out rusted sections and start welding in patches? I'm not sure if I see myself into replacing entire rocker panels, but maybe at least patch the ugly externally showing rust patches. I think I'd stick to flat sections, or sections that require only one bend.

Oh yeah, the car I'd be working on would be 97 Lesabre which is unibody, not body on frame like your Country Squire.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 11/06/10 05:06 PM

 Originally Posted By: enslow
Andy,

What would it take for me to be able to cut out rusted sections and start welding in patches? I'm not sure if I see myself into replacing entire rocker panels, but maybe at least patch the ugly externally showing rust patches. I think I'd stick to flat sections, or sections that require only one bend.

Oh yeah, the car I'd be working on would be 97 Lesabre which is unibody, not body on frame like your Country Squire.


Hi enslow.
I'm assuming you've got a welder and something to cut the rusty steel out with!
Just try it.
Whats stopping you? Have you any doubts?

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 11/06/10 05:15 PM

Had a lot of bad weather recently, so been very limited working outside.

Anyway I decided to remove all the bondo and paint I put on the wheelarch and try to panel beat it all into the perfect shape without using any bondo at all!!! This meant cutting out and rewelding some of the patches I welded in before!

Heres the wheelarch in as close as I can get after about 4 hours tapping!!



Heres a new lip going in after reshaping







Here it is finish welded. Just need to cut the lip to width now.



Andy.
Posted by: Russrad25

Re: New big ford owner in UK - project resto/lowri - 11/12/10 08:39 PM

Bump...I so want to see this get done!!!
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 11/13/10 08:26 PM

 Originally Posted By: fordoldfart
The old gentleman I worked with at the local salvage yard would cut out the holes or wrecked spots and weld in new panels with a acetlyene torch he was a master at this. But that was before spot welders and mig machines where readily avaliable to small shops and ordinary folks. Good work


i'm shure that would be the way i'd do it you use the same metal for filler the slow heating and cooling of welding with a torch leaves the medal softer to work with than mig tig. but like you said mig and spot are faster alone with out counting time it takes to smooth metal with a hammer than some bondo over ground down welds


Justin
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 11/15/10 09:38 AM

 Originally Posted By: andyfanshawe

Hi enslow.
I'm assuming you've got a welder and something to cut the rusty steel out with!
Just try it.
Whats stopping you? Have you any doubts?

Andy.


Well, first of all, I don't have welding equipment for two reasons. First of all I'm sure anything worth while using will test my budget. If it's something I'm going to try just a couple of times only to conclude it's better for me to leave it to the pros, I'd have wasted money. The second reason is that it's my wifes car! (Come to thing of that, your wife's Caravan = lowrider????)

From what you say, with the right equipment it's not a hard skill to learn for basic stuff. I might consider it sometime. Replacing the rockers on the H-body Lesabre is quite possible. You can buy new rockers for just a couple hundred dollars. It's the labour that puts the costs way high. Anyway, I should probably start this in a new thread and leave this to your Squire.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 11/24/10 12:23 PM

After long hours at work and crappy british weather=this is where I'm at...

Heres the finished wheelarch painted white temporarily (protection from weather) with its coat of epoxy primer to further protect it.






I will flat the epoxy back next spring.





Heres a view of the underside where the ugly spare wheel well used to be



More in a minute!
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 11/24/10 02:29 PM

And off we go to the other side.
Now when I bought the car, the owner said an exhaust shop had reversed the car into something and damaged the trim around the marker light. He also said the panel had not been damaged.

Heres a photo of the trim just after it was taken off



and another from the back



That is a mess.

So, was the metalwork damaged? see for yourself





You bet it was! Difficult to tell from the photos, but it was crumpled around the marker light and the body crease line.

Here it is again after a few hits with a hammer. The masking tape is to stop the british rain from gtting in!



Again, difficult to tell but the crease line is almost straight now, so the rest will follow.

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 11/25/10 08:04 PM

An archaeological dig around every corner.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 11/28/10 03:14 AM

I wouldn't suggest this for everybodies project, but given the quality, extent, and documentation of Andy's project, I would support giving him a separate section in the Box forum. One thread could contain all posts directly relevent to his rebuild, leaving other threads open for comments.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowri - 11/29/10 11:01 AM

I don't mind this all in one thread like Andy is doing now. It's easy enough to click through all the pages.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 11/30/10 03:07 AM

Don't think I'll be doing any work on my wagon today!!



Andy.
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowri - 11/30/10 05:24 AM

Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 12/01/10 04:35 AM

Don't think I'll be going anywhere again today! Snow 3 feet deep in places





My custom camaro is entombed in this garage!



Not even 4 x 4 's are moving today!

Andy.
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowri - 12/01/10 05:26 AM

Where are the snowplows???

I am surprised that you are allowed to park on the streets in the winter. Around here, the streets have to be clear for the snow plows.


We get that much snow here too, but our streets have never looked that bad.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 12/01/10 05:52 AM

Heres some more!

My small everyday Nissan Almera



Our Chrysler Grand Voyager



My woody wagon



Don't think we're going anywhere soon.

Andy.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 12/01/10 08:00 AM

ah my ram 1500 could make some head way in that snow, wish i had my 3wheeler still that could float on water and ride on top of snow where go carts and 4wheelers sank and got stuck
Posted by: Cowtown Cowboy

Re: New big ford owner in UK - project resto/lowri - 12/01/10 09:53 AM

Wow! I don't think we have that much snow in the mountains here.
Hopefully it's not cold too.
Posted by: larryo340

Re: New big ford owner in UK - project resto/lowri - 12/01/10 10:08 AM

Holy crap...I didn't know it snowed that much in the UK
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 12/01/10 11:07 AM

It doesn't normally! Nearly everything has come to a halt!!
I teach in an 11- 18 year old school and it was closed on tuesday and today, and will be closed tomorrow also.
Most likely friday as well!!

Damn good!
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/10/11 05:14 PM

Oh dear, I've been away too long!!

Enslow has given me a shout, si I had better update.

The weather has been so cold here, it has been impossible to do any work on the car since I now need to prep for paint and actually paint!! No mechanical work is neede on the car so its now to a point where nothing can be done.

So jobs, educating my 2 sons, looking after me elderly parents, DIY on the house, other car jobs....etc has kept me busy!

But the wagon is waiting patiently waiting for its next onslaught-which is coming soon.

Soon I will take each door off one by one and weld up the handles and locks and prep for paint inside my workshop where my custom camaro resides in hibernation.

But for now I needed to paint the inside of the quarter panel where it was all reshaped and welded to protect it from the crappy UK winter. So low temperature epoxy paint was applied inside. And created such a god awful smell inside that I couldn't have worked on it anyway!!







More to come - eventually! Sorry for the lack of progress. This will change soon.

Andy.
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 01/13/11 12:13 PM

i figured it was only the winter, just so you know i was going to post something just so people just knew you were still in business.

and do you want that air bag sensor
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/05/11 05:14 PM

Hi Justin.
Thanks for the thought.
Regarding the air bag sensor i think I will just remove the whole system and put a proper steering wheel on!!

I've had an airbrush artist working on my camaro today, and we had a chance to talk about the wagon.

He made an interesting suggestion. After removing the rest of the wood effect vinyl stickers and doing all the necessary repairs/mods, paint the wagon white, then airbrush the wood effect back on from the front but fade it out as it goes through the doors. In effect we have the old staying but evolving as we go along the vehicle!

Further back (back door?) we may paint woody woodpecker in pecking his way through the paint and the wood!

May be interesting!!!?

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 02/06/11 01:52 PM

 Quote:

More to come - eventually! Sorry for the lack of progress. This will change soon.


Its winter! Can't very well do much in conditions like that, I don't even change oil in winter, it can wait until the temps get closer to freezing and sunny outdoors.

Interesting idea with the woodgrain. I kinda like it.

Alex.
Posted by: BigMerc96

Re: New big ford owner in UK - project resto/lowri - 03/07/11 10:19 PM

Any updates?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/11/11 02:17 PM

Originally Posted By: BigMerc96
Any updates?


Hi BigMerc96.
No updates yet, but hoping to start again this weekend.
BUT.....now bear in mind this is the UK where US cars are quite rare..........I've bought a Lincoln Mark 8!









Watch this space.
Andy
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 03/11/11 03:04 PM

Oooooh... Nice car.

I'll take the Towncar in the back there though.
Posted by: BigMerc96

Re: New big ford owner in UK - project resto/lowri - 03/12/11 07:30 PM

ooh, I'm jealous of that mark VIII. Those are somewhat rare even in the states. They are really cool though.
Posted by: interceptor1985

Re: New big ford owner in UK - project resto/lowri - 03/12/11 11:25 PM

Need to hit them lights with some Polish;)
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 03/16/11 07:14 PM

575 posts and 178197 views i contributed.


Justin.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowri - 03/17/11 03:41 PM

Originally Posted By: Justin McCarter
575 posts and 178197 views


I know I check to see if there are any new posts in this thread every time I log in to CVN. With a view count that high, there must be quite a few people doing the same. cool
Posted by: BigMerc96

Re: New big ford owner in UK - project resto/lowri - 03/19/11 02:08 AM

I know I check it pretty frequently.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/21/11 03:26 PM

Hi all. I'm back woot

Had some sunshine today, finished work early, had a drive home in my gorgeous Lincoln mark 8 - does life get any better?!!

Ultimatum from my Lovely Wife..."get that woody wagon finished will you or else"..........Oh dear.

So, out with the hair dryer and scraper and hammer and dolly.

More "wood" removed and adhesive and 2 hours tapping and scraping and tapping and scraping, oh,...and levering and we have an almost straight rear quarter around the old marker light hole.







Bit more tapping, scraping and levering to do tomorrow and its light hole welding up time. Then its back to reshaping the lower quarter to match the other side and its inner wheelarch removal time.

Hopefully in no time at all, I can get the doors in the garage, get the handles and locks welded up, and all painted and we are getting somewhere near the final paint job.

Just a thought...........May, just may, put a quad cam 4.6 engine and box into it along with all the electronics. the one in my Lincoln is gorgeous!

Andy.

PS Good to be back!
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowri - 03/21/11 03:42 PM

Great work. Good to have the snow gone. Wish I could say the same. First day of spring and it's snowing.

Are you going to remove the bumpers and bring them in closer to the body to remove the gap?
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowri - 03/21/11 03:52 PM

Progress! I hope the weather cooperates and lets you get more done soon.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/21/11 04:36 PM

Originally Posted By: WSTRLNG
Are you going to remove the bumpers and bring them in closer to the body to remove the gap?


Yes, definitely.

Andy.
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowrider - 03/21/11 06:18 PM

Here...
http://cgi.ebay.com/ebaymotors/Crown-Vic...c1a518f03#v4-39

For when you get done with that one. grin

Posted by: 81ltdcrownvic

Re: New big ford owner in UK - project resto/lowrider - 03/21/11 11:31 PM

HEY Andy's back at it again!!! YIPEEE!!! Can't wait to see more of this stunner. Oh and BTW, do it with the 4.6 cammer, talk about alittle somethin extra! Looks good Sir, keep up the good work!! - Big John
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/22/11 05:22 PM

Thanks guys!

Here we go with my favourite tool! My neighbour hating, damn noisy but brilliant air saw!





Spot welding a closing panel in tomorrow.

Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 03/23/11 11:33 AM

Originally Posted By: andyfanshawe
Just a thought...........May, just may, put a quad cam 4.6 engine and box into it along with all the electronics. the one in my Lincoln is gorgeous!

Andy.

PS Good to be back!


I'm not sure about the quad cam 4.6, but I did notice that the 4.6 OHC didn't have nearly as much low end torque. You might actually prefer the torquiness of the pushrod engine. The 4.6 is a nice smooth and quiet motor though.

How about a blower?

P.S. I missed ya!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/24/11 05:36 PM

Originally Posted By: enslow
Originally Posted By: andyfanshawe
Just a thought...........May, just may, put a quad cam 4.6 engine and box into it along with all the electronics. the one in my Lincoln is gorgeous!

Andy.

PS Good to be back!


I'm not sure about the quad cam 4.6, but I did notice that the 4.6 OHC didn't have nearly as much low end torque. You might actually prefer the torquiness of the pushrod engine. The 4.6 is a nice smooth and quiet motor though.

How about a blower?

P.S. I missed ya!


Thanks enslow.

A lot more updates to come yet.

A blower? Nah, been there, done that, now too old and fuel too expensive!

Next update then:
Finally managed to make up and spot weld in a joddled patch.







And managed to repair my MIG welder tonight (veteran of years of abuse!!). So its back to welding up the holes tomorrow and then I'm going to cut the hell out of the inner wheelarch!!

Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 03/25/11 09:52 AM

drool
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowrider - 03/25/11 07:36 PM

no the bottom of the page it cant be and i was just starting to feel better about the world.
beer1
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/26/11 03:18 PM

A day off work at last and got the hair dryer and scraper out. Most of the "wood" off the drivers rear quarter now. Just the sticky glue left!!





Before anyone asks, the gas filler cap is also stripped of the wood stuff - although its still brown!!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/28/11 03:54 PM

Trim hole welding up time..........

Here you can see the copper backing plate underneath the hole to absorb a lot of heat and prevent the panel warping.



Now to do something about the gas filler pipe. I want to fabricate and fit a stainless pipe that bends quite sharply around the inner wheelarch, goes through it and exits just behind the rear light unit. Then I can weld up the aperture on the quarter panel.

Here's the first bend in place,...view from the wheelarch



and a view from underneath...



Just remind me to not weld it up with the pipe stuck into the gas tank!! Probably won't be anymore updates if I do rolleyes

Andy.
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowrider - 03/28/11 04:09 PM

Wouldn't the pipe, being so horizontal to the top of the tank, allow for gas to slosh up the neck and not be safe?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/28/11 05:03 PM

Originally Posted By: WSTRLNG
Wouldn't the pipe, being so horizontal to the top of the tank, allow for gas to slosh up the neck and not be safe?


Only if I can afford to put that much gas in!!
I've actually thought about that. If I put the filler neck near the top of the light unit it will actually be higher than the side mount used to be.

Good question though. Thanks.
Andy.
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowrider - 03/28/11 05:46 PM

You should fabricate a hinge with a magnetic latch for the tail light and mount the filler neck behind the light.
Posted by: 81ltdcrownvic

Re: New big ford owner in UK - project resto/lowrider - 03/28/11 07:17 PM

I like that idea WSTRLNG!!!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/29/11 12:58 AM

And thats exactly what I'm going to do!
Great minds think alike. beer1

Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 03/29/11 09:48 AM

Hidden gas filler... cool.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 03/29/11 01:30 PM

Originally Posted By: andyfanshawe
Just a thought...........May, just may, put a quad cam 4.6 engine and box into it along with all the electronics. the one in my Lincoln is gorgeous!


Here's a thought, because you sound like a guy who could pull this off. How about either hybrid technology or turn it into an electric plug-in lowrider? True, it would require one heck of a battery pack, but you're got the space. If you pulled that off I'd almost consider flying over the pond just to see it!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/29/11 04:13 PM

Originally Posted By: enslow
Originally Posted By: andyfanshawe
Just a thought...........May, just may, put a quad cam 4.6 engine and box into it along with all the electronics. the one in my Lincoln is gorgeous!


Here's a thought, because you sound like a guy who could pull this off. How about either hybrid technology or turn it into an electric plug-in lowrider? True, it would require one heck of a battery pack, but you're got the space. If you pulled that off I'd almost consider flying over the pond just to see it!


OMG! That is radical thinking at its best! May put that one off till a later date!!

Back to earth then! I need to remove the inner wheel arch to reshape it like the other side and eliminate that double skinned wheel arch lip rust trap. And of course to eradicate any lurking rust I find. Then, of course, reshape that quarter panel and finish fabricating the new gas filler pipe.

Heres the mark for cutting. You can just see the black line.



First bits removed...







Got a bit late then so the use of a noisy air saw is not really appreciated by the neighbours - so we will continue tomorrow.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/02/11 05:26 PM

Heres the rear quarter lower corner just behind the drivers rear wheel.



looks in good shape, right?

Here it is with the paint ground back



and heres a back view of it



This has been repaired before. Here is the panel cut out





Here is it cut out and a patch panel clamped in ready for spot welding in.





Heres the wheelarch lip marked for reducing in width



.........
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/02/11 05:40 PM

I have to reshape the lower bit to match the other side, so the inner panel has to come out. See the black lines?



Cut out ready for reshaping





Now the inner wheelarch is out and down to a single skin, lets have a look how rusty it is on the inside lip



Absolutely immaculate!! Wish the other side had been like that!!!

Andy.
Posted by: 81ltdcrownvic

Re: New big ford owner in UK - project resto/lowri - 04/02/11 10:46 PM

Nicely done sir!! Looks great!!- Big John
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/03/11 11:50 AM

Thanks big John!

Reshaping quarter panel next.
Here is a cardboard template to fit the passenger side I did last year



And heres the profile of the drivers side after a bit of tweaking



Not too far off!

Look at the rust in the bottom corner here...



Thats now been shotblasted clear.

Heres some temporary supoports welded in place until I can get a panel fabricated



Heres how the back corner matches up after a careful bit of cutting. Managed to get a good butt fit.



Andy,.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/05/11 02:44 PM

Panel made to butt fit where possible.....
Perfect match just above my hand....



Fits perfectly at the back also....

and tacked in



Interesting views from the inside...



Look, no rust!



I'm going to see if I can fabricate the gas filler pipe next.

Andy.
Posted by: gardobus

Re: New big ford owner in UK - project resto/lowri - 04/05/11 03:04 PM

this thing is going to be sweet
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/10/11 04:10 PM

Got to get moving with this car - I need it complete for this summers cruising!
So assuming I am going to use some fuel, I had better finish that filler pipe relocation off.

Here it is clamped in roughly the right place...



The light unit just touches the filler pipe cap with no room for the bulbs and holders. Which is just as well since they are going LED!

Here's a sequence of photos for you

Bracket made and welded to the pipe and discreetly bolted in with speed nuts (captive) and stainless cap head bolts



In roughly the right place..

[So its time to cut a hole. A BIG hole...



And a little more pipe welded on to reach



It was at this point I ran out of pipe, so I made some out of flat steel and clamped it in. I couldn't MIG it at this stage otherwise there would have been a big bang!! So I clamped it up best I can, removed it and welded it a safe distance away.



All in awaiting fully gas welding


That was quite tough to build. I'm going to lose the rear lockable compartment but who cares!

next I'm going to weld up the hole in the quarter where the old filler door used to be. I may use the filler door as part of the patch since it has the shape I want.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/12/11 04:59 PM

Here is the gas door pressing in the quarter cut out.



I decided to not use the door as a patch since I fancied the challenge of fabricating a new patch! After a lot of cutting and measuring, and making a wooden former...and a few swear words...well, actually quite a few damn and blasts...here it is





Welding in next.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/15/11 05:50 PM

Now I don't fancy butt welding this panel in. Too much chance of an irreplaceable panel distortion. So I am going to make a backing plate and spot weld the gas filler panel to it and then spot weld the whole thing to the quarter...









I had to use my spot welder with the long arms to reach into the top right hand corner



Love these photos! Looks like its got spots!



heres a view from the back







Andy.

Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/17/11 03:13 PM

Heres a view of the drivers quarter panel with all holes welded up and all glue residues removed. Took me about 2 hours with a panel wipe solvent and a flat bed sander to get rid of all the stickiness!!



I then started making card templates for the inner arch. Here the first one in place....







Here it is transferred to steel and a 90 degree flange welded on





and here it is clamped for a final trial fit.



Ran out of time then and got too late to do an grinding/welding so decided to strip the tailgate. Here it is with most things stripped off....



Looks a lot better!

I need to remove that lock and handle, so I will have to use a remote to mimick the action of the lock. One button to wind the window down, and a solenoid to pop the tailgate open. I will keep the interior handle so I can still drop the tailgate down.

Now I know this is a silly question and I know what the answer is going to be...whats the chance of getting a new tailgate window seal!!!!!

Andy.
Posted by: 81ltdcrownvic

Re: New big ford owner in UK - project resto/lowri - 04/17/11 08:48 PM

That is so KickA$$ Andy!!! Freakin awesome! - Big John banana
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/20/11 05:28 PM

Right, I've got a week and a bit to do as much of the bodywork as I can. So first job is to fabricate and weld in the inner wheelarch.
First 2 sections tack welded/glued in.







Hopefully complete all the rest tomorrow and final weld in.

Andy.
Posted by: Yoder

Re: New big ford owner in UK - project resto/lowri - 04/20/11 09:46 PM

Have you decided what the final paint scheme and color are going to be ?
Posted by: Yoder

Re: New big ford owner in UK - project resto/lowri - 04/20/11 09:47 PM

BTW, Damn GOOD work.....I'm very envious of your fabricating talents.
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowrider - 04/20/11 10:02 PM

OMFG Andy,

This is so FREAKIN' AWESOME!!


I actually feel like I had a part in this build.
Thanks for considering my idea and implementing it.

...well, after re-reading your response, I see that you already had thought about it. I just forced your cards on the table, so-to-speak.
Anyways, I am very happy to see it coming together.


VERY well done.

You made my day. beer1
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/24/11 05:14 PM

Originally Posted By: Yoder
Have you decided what the final paint scheme and color are going to be ?


Hi Yoder.
Not decided yet!! may do that when its ready to go into the booth for its final paint rolleyes
2 tone certainly. White top half probably, bottom half??????
I need to do some sketches!

I'll keep you informed.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/24/11 05:19 PM

Originally Posted By: WSTRLNG
OMFG Andy,

This is so FREAKIN' AWESOME!!


I actually feel like I had a part in this build.
Thanks for considering my idea and implementing it.

...well, after re-reading your response, I see that you already had thought about it. I just forced your cards on the table, so-to-speak.
Anyways, I am very happy to see it coming together.


VERY well done.

You made my day. beer1


Hi WSTRLNG.
Always open to good ideas and suggestions. Good to hear I cheered you up though! beer1

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/24/11 05:38 PM

Heres a view of the inner arch tack welded in. This is the single skin outer quarter I wanted. No rust for me inbetween the 2 layers!



View from inside the tailgate area



Now onto the tailgate. I want it smooth and clean. Just the license plate and illumination. Which means welding up the hole where the hi level brake light used to be and, of course, welding up the handle and lock holes.
Here you can see the black line where I will cut and weld





Once the outer handle is removed I have no way of opening it until the remote solenoids are installed (which wont be till I order them!!), so I need to rig up another external way of getting in - which will also act as an emergency entrance if the electrics fail. So its upper latch removal time, locking bars/rods/linkages removed (locks? we dont need no stinking locks!! Not without handles anyway). This alternative entrance method will involve a throttle cable routed through the tailgate to behind the same light unit where the gas filler neck is.
Heres a couple of views with the stock latch




And heres what was removed...



And heres it all installed back and a lot less cluttered



Looking forward to removing the handle and rod next.

Heres a view of the quarter with a skim of bondo on ready to be flatted



Andy.


Posted by: pantera77

Re: New big ford owner in UK - project resto/lowrider - 04/24/11 07:11 PM

Incredible work as always!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/25/11 05:30 PM

I must finish the mechanical emergency entry to the tailgate before i can weld up the tailgate handles and locks.

Heres a view of the latch with an extension welded in and a stainless wire attached to it.



Heres the wire going through the tailgate with 2 hooks made from galvanised nails and electrical connectors to attach the wire to the hooks!



It still needs securing properly.

Here it is secured to the loom with bright yellow tie wraps in the opposite corner of the tailgate and going through the conduit into the back of the car



And a view of it coming into the back and bolted through a welded on plate behind the corner of the bumper



And a final view of the cable sticking out of the rear. I know need a lever or handle designing.



And you know what?.............It works! So tomorrow is welding up time.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/26/11 05:34 PM

Inner wheel arch fully welded and sealed. Heres an interesting shot looking up from the drivers rear wheel arch



Thoroughly cleaned inner arch ready for the epoxy paint. Looks in fantastic condition seeing as its now 21 years old!



The gas filler pipe is going in tomorrow for powder coating. Dare I do it the same colour as the frame!!

I was having trouble getting the profile right for the body crease where the gas filler door used to be. So I came up with the idea of cutting a bit out of the old gas door, welding a handle onto it and dragging it across some newly applied bondo on a straight base (part of our dining room door panel!!).



Results were very good! Spot the gas door!!





Onto the rear tailgate. My air saw and carbide burr made short work of the panel.



Welding up tomorrow.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/28/11 05:37 PM

It hasn't actually rained here for weeks! So I've been using it to get a serious amount of bodywork done!

Heres a patch for the tailgate handle tacked in late one night...



Too late too grind so I media blasted the wheel arch lip. Now this is a good sight. A completely rust free lip inside and out! Not bad for a 21 year old in the UK



I was prepping the rear wheel arch for its epoxy silver paint and noticed the rear seat mounting bracket that is spot welded to the inner archwas rusty (I had forgotten about it!). So I couldn't paint until that was repaired.



Here it is with the bracket removed



There was a couple of rust pin holes below the bracket that had gone through, so it has to come out

Heres some new metal ready to be welded in when the rusty bit is cut out



Here the outer black line is a locating mark to make sure I get the bracket back in the right place after the repair, and the inner one is the cut line



Heres a good view of the rust cut out from under the arch. You can just see the back of the front seat



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/28/11 05:47 PM

Patch welded in





Bracket cleaned up and welded back in by plug welding from the back





Looks a damn sight better than before.

I'll have to weld in that tailgate panel handle patch tomorrow!

Andy.
Posted by: gardobus

Re: New big ford owner in UK - project resto/lowrider - 04/29/11 01:20 AM

damn, the before and after shots will be awesome
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 05/02/11 05:08 PM

Great work Andy! Looking forward to see how it turns out.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/05/11 05:14 PM

Heres the handle and lock welded up



Now heres an interesting sight..when trying to drill out the rivets holding the rear window in I saw this



It should look like this



The rivet centre has failed to break off. I am really surprised that it didn't catch on something on the way up! Or perhaps it did!

Heres the wood grain being warmed up and scraped off







Now I dont know if you can see this, but when I was sat on the floor scraping off the wood sticker I saw some writing that isn't visible at all from any other angle. I tried to get a photo of it. Have a close look at the white section just above the wood...



It says "FRED BEANS DOYLESTOWN". Obviously a sticker from a car sales place. After a google search, it is located in PA. Nice to discover another secret from its past.

Finally got the car to fit in the garage ...just!!! can't open my toolbox drawers though until its pushed forwards a bit!



Heres the remnants of the wood from the tailgate!!!



Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 05/06/11 09:13 AM

Nice to see the fake stick on wood go away!
Posted by: lev

Re: New big ford owner in UK - project resto/lowri - 05/11/11 02:04 AM

Way back in April 2010 you said
Originally Posted By: andyfanshawe



The quick ones amongst you may have spotted something strange about the above photos!


I am not one of the quick ones. Can you explain "something strange" to me, please! Nice project
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/11/11 11:06 AM

Hi Lev.
No problems.
The strange aspect was that the sequence of photos started on one arm and finished on the other! Things are on the opposite side!
Only one person spotted it and reported back.

Thanks for the question though.
Andy.
Posted by: gardobus

Re: New big ford owner in UK - project resto/lowri - 05/12/11 05:56 PM

I'm so damn excited to see how this turns out.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 05/12/11 09:37 PM

Originally Posted By: andyfanshawe
Hi Lev.
No problems.
The strange aspect was that the sequence of photos started on one arm and finished on the other! Things are on the opposite side!
Only one person spotted it and reported back.

Thanks for the question though.
Andy.


Hmmm, I noticed that you had switched, but I didn't think of that as being strange. I was tring to find out if a RHS arm had holes drilled as if it were a LHS arm, or something crazy like that. Or perhaps, more technically, an incorrect ball joint installed, which I, personally, wouldn't spot.

I never thought to consider the obvious!
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 05/12/11 09:39 PM

Originally Posted By: gardobus
I'm so damn excited to see how this turns out.


I was going to suggest Andy install automatic hydraulic lift mechanisms for the hatch. Then I thought he has to get this thing finished this summer, so the last thing he needs is one more crzay idea from me!
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowri - 05/22/11 12:39 PM

I noticed this car in a video in another thread and I thought it might be inspirational for future ventures.

Disregard the rest of the video and just go to 0:22 and see the "chopped" Chevy wagon.

http://www.youtube.com/watch?v=S7Ct5UItG90&feature=player_detailpage#t=22s
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/28/11 05:01 PM

Originally Posted By: enslow
Originally Posted By: gardobus
I'm so damn excited to see how this turns out.


I was going to suggest Andy install automatic hydraulic lift mechanisms for the hatch. Then I thought he has to get this thing finished this summer, so the last thing he needs is one more crzay idea from me!


Hi enslow.
Nice one! I will bear that in mind.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/28/11 05:08 PM

Originally Posted By: WSTRLNG
I noticed this car in a video in another thread and I thought it might be inspirational for future ventures.

Disregard the rest of the video and just go to 0:22 and see the "chopped" Chevy wagon.

http://www.youtube.com/watch?v=S7Ct5UItG90&feature=player_detailpage#t=22s


Nice idea, but don't think I'll be doing that........... Not with the UK climate anyway!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/28/11 05:24 PM

Feels like ages that I made some progress on the car. a comnbination of a really busy job getting teenagers ready for their big exams in school, major house mods underway (my Wife's idea), elderly and poor health parents and 2 of my own kids!!

But, here we go.
There is wear in the tailgate hinges, or at least in the bottom one. Not quite so sure about the top one, so out it must come to assess its condition.

The three crossheaded screws are BIG and tight, so I had to use my air gun with a screwdriver attachment to shift them



Here it is removed with the rusty plate from behind it.



Now heres the wear in it. You can just see the worn rusty area where the roller goes in. It has worn slightly out of round, so I will weld it up and file it back into shape.



Heres a view under the tailgate



Rust starting to form in the seams. So after shotblasting........



Heres a quick view of the smooth tailgate



More thoughts to come soon.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 05/28/11 06:13 PM

Now probably just the same as anyone else, I am always thinking of this project, even when I am busy. Probably too much thinking time, because.....

I think its time to perhaps lower this car but without lowering the suspension. This needs to be channelled. leave the chassis where it is and all the suspension but lower the body over it.

Now theres 2 ways to do this,





The first way will ensure the seats still fit but I'll loose interior height and my head may hit the roof (6' 2").

The second way will keep the interior height but may affect the seats.

Hmmm, more thinking needed. What do you guys think?
Andy.
Posted by: gardobus

Re: New big ford owner in UK - project resto/lowri - 06/01/11 12:13 PM

So in the first image, you are raising the entire floor, the second image you are only raising the sections above the frame?

I imagine the first would be less time consuming and would offer a cleaner look inside right? The second method would have odd grooves running along your floors right? Anywhere there is a frame rail or maybe even other parts such as crossmembers and whatnot?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 06/01/11 03:56 PM

Originally Posted By: gardobus
So in the first image, you are raising the entire floor, the second image you are only raising the sections above the frame?

I imagine the first would be less time consuming and would offer a cleaner look inside right? The second method would have odd grooves running along your floors right? Anywhere there is a frame rail or maybe even other parts such as crossmembers and whatnot?


Hi gardobus.
You are quite right. It seems it may be easier. But I will have to section the firewall with this method. ie remove a horizontal section all the way across.

Other spin offs may be that the battery will not fit anymore, nor the washer bottle!! Also the engine plenum may (most likely) hit the underside of the hood. Brake pipes to the master cylinder will be too long (easy fix though), wiper motor may not fit anymore, pedals will be higher up.....and a myriad of other things I haven't thought of yet. But it will look damn good sat on the floor!!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 06/02/11 01:12 AM

Heres the worn guide welded up and filed back



Now its tailgate off time to assess the lower hinge damage



On the floor awaiting dismantling



Have a look at this short vid of the wear. The pin and bushes are okay but the other pivot isnt

youtube

Here it is off to reveal another slight problem





Its actually twisted. Must have been a lot of force to do that.

Rivet welds ground off and took apart then straightened. Didnt realise there was a bronze bush under there. I am going to machine another pin/rivet that is a tight fit in there.



Andy.
Posted by: jwzg

Re: New big ford owner in UK - project resto/lowri - 06/04/11 04:25 PM

In-frickn-sane. Awesome job so far. What do you do for a living?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 06/05/11 08:45 AM

Originally Posted By: jwzg
In-frickn-sane. Awesome job so far. What do you do for a living?


Hi jwzg.
I teach math to 11 to 18 year olds - in the equivalent to your high schools. Although I have been trained at a lot of things!

Andy.
Posted by: 81ltdcrownvic

Re: New big ford owner in UK - project resto/lowri - 06/06/11 10:01 PM

Why is it the teachers that build the coolest car, I teach special ed for 18-22 yr olds for future jobs and independent living wink
Posted by: jwzg

Re: New big ford owner in UK - project resto/lowri - 06/06/11 10:42 PM

I'm a science teacher. Wouldn't you know. Just a suggestion about channeling the body, that seems like more trouble than its worth. Go with air springs. Much less trouble in the engineering, and you can raise it for rough roads. Nothing like a slammed wagon uk
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 06/07/11 10:59 AM

Wow, all the teachers are coming out of the woodwork! I guess that's what happens when you strip the woody.

I teach high school science and chemistry, but I just don't have the tools, skills, time, or money to mod a car. On the other hand, I love my 92 Grand Marquis just like it is.
Posted by: jwzg

Re: New big ford owner in UK - project resto/lowri - 06/07/11 12:38 PM

I just got an early start. Engines got me through geometry and gave me reason to learn.

Back on topic.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 06/20/11 12:38 AM

Hey Andy,

I'm sure you've seen these "shaved door kits" before, but just in case you haven't, here's a linky:

http://www.kmstools.com/shaved-door-kit-7231

I have no idea what the quality is like. I encounter so much aftermarket stuff that is junk.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 06/20/11 12:41 AM

I need to stop looking at the KMS tools site. Seriously.

If I had all the time in the world, all the money, and the most patient wife, ....

How about LED tail lights? For that matter, LED headlamps? Now THAT would cost an arm and a leg.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 06/20/11 04:41 PM

Originally Posted By: jwzg
I'm a science teacher. Wouldn't you know. Just a suggestion about channeling the body, that seems like more trouble than its worth. Go with air springs. Much less trouble in the engineering, and you can raise it for rough roads. Nothing like a slammed wagon uk


Hi jwzg.
All teachers together eh!!

More trouble than its worth? I want the rockers sat on the floor. If I fit air suspension and lower it as far as it will go, it won't do that.
I have designed and fitted air suspension on many vehicles. Yes they look good, but don't go low enough.
I bought this vehicle because it is different and nobody wants to customise one in this country. So its going to be a pretty unique vehicle in the UK.
I want the DUB look with big wheels tucked under and the car flat on the floor. If that takes a lot of work - so be it. Thats what I want and thats what I will get. If it takes all my skill money and time, then it will.

Have a look at this



Thats the look I want. If it was easy, loads would be doing it. This wagon could look absolutely awesome when slammed to the floor.

Andy.
Posted by: gardobus

Re: New big ford owner in UK - project resto/lowri - 06/30/11 06:06 PM

moooreeee
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 07/05/11 01:50 PM

Hi guys.
I'm busy building a kitchen at the moment and designing and building a shed to hold the wagons interior when the time comes for the channeling.
The only thing I have done is to lengthen the garage about 9" (limit of my allowance!) and removed more of the wood stickers on the rear doors.
Saying all this, I must have it primed before the summer ends so I can have a good autumn/winter lowering it. Although I have managed to refit the tailgate with new hinge pin and check strap. Details soon.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 07/17/11 03:08 PM

Hi all.
Sorry for the lack of postings recently! I've not lost interest, just delayed slightly. Very keen to get on with things.
I pack up work on thursday for a 6 week holiday, and the house mods are coming along well, so it shouldn't be long before I am back on it.
I've been spending about 20 mins a day on wood sticker peeling though! Only front doors and fenders to peel now.
Heres a couple of photos when I was modifying the garage a few weeks ago and chucked the car out for a bit.




Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 07/18/11 08:30 PM

Progress is progress. =-)

I don't care for the slope of the driveway the VW is sitting on.

Alex.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 07/18/11 09:50 PM

I'm just impressed that, as a teacher, he's able to do a project like that. I have to wait until my holiday to do anything. I don't get home until a little before dinner. I only have a little time to play with the kids, eat dinner, then get them to bed.

And that slope under the VW, that looks like our slope, but not quite as steep. My biggest pet peeve about it is that I cannot play basket ball there.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowri - 07/19/11 10:45 AM

Originally Posted By: GM_Guy
Progress is progress. =-)

I don't care for the slope of the driveway the VW is sitting on.


When I was a teenager, we had a house with a driveway sloped like that. Your parking brake really had to be in working order to park on it. In the winter, we'd have to park on the street until we shoveled the driveway.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 07/20/11 04:40 PM

Originally Posted By: enslow
I'm just impressed that, as a teacher, he's able to do a project like that. I have to wait until my holiday to do anything. I don't get home until a little before dinner. I only have a little time to play with the kids, eat dinner, then get them to bed.

And that slope under the VW, that looks like our slope, but not quite as steep. My biggest pet peeve about it is that I cannot play basket ball there.


Hi enslow.
My working day starts at 5:30 am. I work/teach all day including breaks and lunchtimes so I can have time in the evening. Any spare time I have at work is spent catching up so I can use my evening time to do something else.

Andy.
Posted by: Black_Sunshine

Re: New big ford owner in UK - project resto/lowri - 07/20/11 05:43 PM

Originally Posted By: Jeff2
Originally Posted By: GM_Guy
Progress is progress. =-)

I don't care for the slope of the driveway the VW is sitting on.


When I was a teenager, we had a house with a driveway sloped like that. Your parking brake really had to be in working order to park on it. In the winter, we'd have to park on the street until we shoveled the driveway.

It looks like you could bump the front of it and cause it to tumble over.
Posted by: interceptor1985

Re: New big ford owner in UK - project resto/lowri - 07/28/11 05:08 AM

Don't forget your bumper mounts! Those still look like they need your tender lovin care, I need to do the same to one of my set's that are starting to look a lil rusty.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 07/28/11 04:02 PM

Hi interceptor1985.
When the car is channeled the bumper mounts will be scrapped anyway! 'Cos they wont fit!

Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 07/30/11 02:34 PM

Originally Posted By: andyfanshawe
Originally Posted By: enslow
I'm just impressed that, as a teacher, he's able to do a project like that. I have to wait until my holiday to do anything. I don't get home until a little before dinner. I only have a little time to play with the kids, eat dinner, then get them to bed.

And that slope under the VW, that looks like our slope, but not quite as steep. My biggest pet peeve about it is that I cannot play basket ball there.


Hi enslow.
My working day starts at 5:30 am. I work/teach all day including breaks and lunchtimes so I can have time in the evening. Any spare time I have at work is spent catching up so I can use my evening time to do something else.

Andy.


I don't have any significant breaks except for a 45 minute lunch. However, my working day starts at 8:00am. By the time I'm done teaching it's 2:20. For me, cleaning and organizing my room takes a couple of hours, then I have marking and planning for the next day. If I did everything perfectly every day, I probably wouldn't get home until 8 or 9pm at night and I can't do that with 2 small kids at home.

I forget for the moment what you teach, but it sounds as if it's project based and most of the evaluation is done during class. That would make for extremely intense class time.

With 2 small kids around, it's taking me 2 weeks to do intake manifold gaskets on my Buick. This job should only take about 2 days! Of course, I'm overly picky about cleanly about gasket surfaces so it usually takes me a day to get them cleaned until I'm satisfied. Most would probably be done in 1/2 hour.

And that doesn't take into account any stupid things I might do, such as overtorque an alternator bolt into the alternator, thus stripping out the alternator casing. Actually, I think it stripped mainly because it got crossthreaded. It's surprisingly easy to do.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 07/30/11 02:37 PM

Are you planning to keep the chrome on the bumper or are you going to paint the body colour? All black? Encorporated into body art?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 07/31/11 02:38 PM

Originally Posted By: enslow
Are you planning to keep the chrome on the bumper or are you going to paint the body colour? All black? Encorporated into body art?


Hi enslow.
Body colour I think. What that colour will be I don't know!-Yet.

Managed to get some time on the car. Next is the rear drivers side door.

If you have a look at this photo you should see the front edge of the door sticking out past the back of the front door, and definitely not in line with the rocker. This is a pet hate of mine. Doors that are not in line at the bottom. I am assuming that over the years when the rear door has been opened against it stops it has bent the B post where the hinges attach and effectively moved the pivot point outwards.



Heres the car with the fake wood off up to the fender.



Correcting this means removing the door which menas removing interior trim and pulling the wiring through. So while I am in there lets lose the door handle and the lock solenoid. Which is a shame really because it works well! Anybody want it for a small fee? Here it is



Another shame is that the waterproof membrane under the inner door trim hasn't been touched in 21 years!!



Once the door is back on and lines up I will weld up where the door handle used to be.

Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 08/02/11 02:31 AM

I always thought that poor door alignment was like that at the factory, for Ford, GM, and Chrysler. I never checked out new cars in the 80's and 90's. Of course, I was still a high school lad in the 80's. In the 90's I had no ability to dream of owning a new car. Today I have no ability to dream of owning a new car.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 08/03/11 06:41 PM

Originally Posted By: enslow
I always thought that poor door alignment was like that at the factory, for Ford, GM, and Chrysler. I never checked out new cars in the 80's and 90's. Of course, I was still a high school lad in the 80's. In the 90's I had no ability to dream of owning a new car. Today I have no ability to dream of owning a new car.


Thats you and me then to have no desire to own a new car!!

You could be right about the door alignment though.
I managed to adjust the door so the front of it is in line with the back of the front door with a consistent gap.



Gap by the rear quarter is also good



Gap by the rocker is also good



BUT, look at the gaps at the top of the door.
This is the top right. The top corner is actually touching the door post but a wide gap at the bottom



Top of the door is really tight.



Top left is too wide



So it looks as if the door frame around the window will be removed and rewelded back into a better position! Bit drastic but the only way.

As a side note, since the door handle will be welded up I have no need for locks, so no need for locking solenoids and locking mechanisms. Only 1 rod is needed to the inner door handle and another link to a door popper solenoid.



Andy.
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowri - 09/18/11 06:21 AM

Keep the updates coming beer1

I hope you have luck getting that rubber door seal.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 09/18/11 09:43 AM

Factory gaps are never perfect. Keep in mind final door alignment is done with a hammer (soft faced) to align the top door frame to the body line. A latch pry bar to lift or lower the door to desired position, or a block of wood to tweak the bottom of the door. That is the method used to this day. I've got a picture here somewhere with a guy taking a hammer to the top of a door frame to get it to blend with the roof line. Only restoration gaps are perfect.

Alex.
Posted by: lev

Re: New big ford owner in UK - project resto/lowri - 09/28/11 11:14 AM

Andy: at some point you were considering galvanizing your frame. You might be interested in this video about exactly that:
http://www.youtube.com/watch?v=8QmcrtClly0&feature=related

Lev
Posted by: GSDNH

Re: New big ford owner in UK - project resto/lowri - 09/28/11 12:14 PM

Wow. This is an awesome project!
Channeling? I haven't heard of people doing that since the 1960s!
Good for you, hope it works out great and can't wait to see it progress!
Posted by: 99_03PantherS

Re: New big ford owner in UK - project resto/lowri - 10/13/11 12:09 PM

Likes this.
Posted by: britishcolumbia

Re: New big ford owner in UK - project resto/lowri - 10/19/11 11:23 PM

I just went through the whole thread, very interesting and great work! Where are you sitting as of now? Havent seen anything posted on here in a while.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/22/11 04:33 AM

Originally Posted By: britishcolumbia
I just went through the whole thread, very interesting and great work! Where are you sitting as of now? Havent seen anything posted on here in a while.


Hi.
Project has been suspended at the moment. My Mum has just had a heart attack at the age of 92, so every evening is spent at the hospital - and most of the weekend, on and off.
My poor Dad has alzheimers as well, so bit of a bad combo! But, I'm going to try for a few hours this weekend on the back drivers door. Welding up the door handle and rust eradicating!

Andy
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 10/22/11 10:48 AM

Best wishes on the family front Andy.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/23/11 04:29 PM

Thanks Alex.

Rightio then....................
Now I've got the chance, its the drivers rear door clean up time

Door handle removed



Cut out


Plate cut out and held in place by a magnet


Welded up


There was a bit of distortion, but nothing that an hour of persuading/panel beating couldn't sort out.

Then its door off and media blast the bottom.



I am going to bend the bottom lip out slightly and pour some dinitrol 3125 rustproofer down and tap it tight again. This will prevent any further rusting inside.

Hers a good sight of the old vinyl wood grain stickers in its rightful place!!



Andy.
Posted by: Yoder

Re: New big ford owner in UK - project resto/lowri - 10/23/11 10:14 PM

Sorry to hear about your Mom. We'll keep her (and family)in our prayers.
Posted by: britishcolumbia

Re: New big ford owner in UK - project resto/lowri - 10/25/11 01:49 PM

Good luck with the family andy. Remember that the car can wait, enjoy the time with your family members while you can. You cant mend them...


The best of luck.
Jack
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/26/11 12:27 PM

Thanks yoder and britishcolumbia. My Mum is now out of hospital and staying with us for a few days. Along with my Dad. Wonder if they'll help me with the wagon!!? rolleyes

Here's the back door with the bottom lip bent out at 90 degrees. Good job as well because there was some corrosion.

Dinitrol 3125 squirted in the door and then heated up with a hot air paint stripper to make it run inside all seams.



Then more squirted on top and the lip bent back and warmed up again to make it flow everywhere.



Then seam sealed.

Here's the door after removing all the adhesive with panel wipe solvent and 120 grit paper, and all holes welded up. Looks smooth.



Andy.
Posted by: britishcolumbia

Re: New big ford owner in UK - project resto/lowri - 10/26/11 03:49 PM

Sorry if i missed this in a previous post, but where are you relocating the door handles? This is very cool! I love custom handles, they are so underrated.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 10/26/11 04:46 PM

Originally Posted By: britishcolumbia
Sorry if i missed this in a previous post, but where are you relocating the door handles? This is very cool! I love custom handles, they are so underrated.


They are not going to be relocated.
One of my custom touches is shaved door handles, badges, locks and, well,.....everything really. I want SMOOOOOOTH.

They will be opened, as my cars always are, by remote control, off the keyfob. One button for each of the 5 doors, with an emergency release for the tailgate if all electrics fail. Photos somewhere in the many pages gone before!!!

Andy.
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowri - 10/26/11 08:02 PM

this is an awsome thread you are very talented
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 11/06/11 05:14 PM

Originally Posted By: QuicksterP71
this is an awsome thread you are very talented


Thanks QuicksterP71. Just wait for the floorpan to be cut out and the air suspension build and install!! will be loads of fun then.

Anyway, its time to make the rear door on the drivers side to fit properly. For those who remember, the main door is now lined up well with the rear quarter and the rocker, but the window frame touches on the top right....



and is too far from the B post on the left........



So it needs to be moved to the left about 1 cm...ish.

Heres the first cuts with my trusty fav tool - my air saw..



As you can see I am cutting out the frame along with the steel it is attached to and then move it over a bit.

Here it is loose on one side


Other side not photographed but cut the same way.

Heres the door frameless!



Pity I can't get that to work! Looks good. Or could I? No, stop it - lets just get this car painted!!!

Completely cut loose and ready for prepping for welding



Here it is moved to the left a bit and tacked in. You can see how far it has moved over by the gap



Tacked in the other side



Fully welded



Now need to reassemble the door and move the window runners over a bit and also the dew wipe on the weatherstrip trim that goes on top of the door.
Then its on to the drivers door.

Andy.
Posted by: 81ltdcrownvic

Re: New big ford owner in UK - project resto/lowri - 11/06/11 08:52 PM

Nice Andy! Great added touch. So what's the projected finnish line for your girl?

Big John
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 11/06/11 11:20 PM

My Dad's 71 olds had no window frame, just clean glass from the door up. The window track was built into the A, B, and C pillars.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 11/07/11 03:02 PM

Originally Posted By: 81ltdcrownvic
Nice Andy! Great added touch. So what's the projected finnish line for your girl?

Big John


Hi Big John.
Finish time? Planning on having it mobile next summer. Don't know if it'll make it though. Have a 97 Lincoln Mark 8 to perform a rolling resto on!!

But I'll try my best. I won't rest until it is sitting slammed on the floor on airbags and 20 or 22" wheels woot

Managed to get the door back on today and trial fitted the glass. And it all works!!

The gaps look superb...don't know how it comes over in the photos.





I love the smooth look already down the side.



And the glass is not blacked out yet. Looking forward to stripping it back down and prepping the door now for primer.

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 11/07/11 05:04 PM

Quote:

The gaps look superb...don't know how it comes over in the photos.


Great work Andy. And yes, it does come across in photos. We get so used to seeing the slightly off doors that it becomes "normal". Straighten one out and its glaringly obvious.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 11/13/11 04:20 PM

Drivers door stripped down next and after removal of the door trim and glass, time to get rid of the handle and lock..





I'm seriously glad to get rid of those handles. I'll have 5 spare soon if anybody wants any!

The door mirror will be the next to go the way of the trash! When I took it off it fell apart! Have a look at the repair job underneath the mirror



When I looked at the door under the mirror it was obvious that the mirror had been hit and made a good job of bending the door



Here is the first attempt at straightening it out. Thick plates and a bolt between them



An hour or so later... the straight version



Its going to be welded up anyway and another mirror moved to a proper position a bit further forward. In fact I may even use the internals of the old mirror and design and build a new outer shell.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 11/13/11 04:59 PM

Progress is okay at the moment, certainly going to be a few hours spent in there this winter!!

Thinking forward, once every panel is cut, welded, smoothed prepped and primered, they are all going to come off and go into storage (may have to leave front fenders on though).

Car will be put into the centre of the garage with the wheels on a railway sleeper each. The the front and rear springs removed and the wagon lowered down onto its bump stops.

Then bump stops removed and wagon lowered further until the front ball joints go to their limit of side to side movement.

The distance from the bottom of the rocker flange to the floor will then be measured. This is the distance the body will be channeled over the chassis so I can get it on the floor at full drop on the future airsprings.

The car will then be raised back up to its original factory suspension position and soild rods fabricated and put in place of the springs.

Then the fun begins - car stripped to a shell and floor/firewall cutout and everything lowered. And welded up.

One thing I know for certain is that the hood will have to be a cowl induction one to clear the engine, that will have made a break upwards!!

This is going to be one fun winter!!!!!!

Andy.
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowri - 11/19/11 09:58 AM

Wow anybody have a time machine so i can see the end of this project.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 12/05/11 12:27 PM

Not getting much time on this recently, but decided to try a different approach to welding up the door handle gap with MIG. Rather than risk the inevitable distortion I'm going to spot weld this time.

Here's the card template and the exact steel panel spot welded in place.



Zero distortion this time.

Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 12/26/11 02:11 PM

I think Andy is trying to design Ford's answer to the Chevy Nomad Concept:

http://www.stationwagon.com/gallery/1999_Chevy_Nomad.html

'cept Andy's will be better. Way better.

I noted the clean lines, lack of door handles, blacked out windows....
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/05/12 04:35 PM

Thanks enslow-I'll try not to let you down beer1

I'm going to blame my Lincoln Mark 8 for the lack of progress rolleyes I love that car, but have to crack on with this wagon.

I left it welding up the door handle and lock and decided to spot weld it instead to prevent any distortion whatsoever. But I couldn't get to the right hand side of the lock to spotweld, so i was a bit naughty and cut an access hole in the side hairraise



Don't worry I'll weld it up after so no one will know!! Apart from the millions on here that is.

Heres the reason for the hole





I promise to do a lot more updates, honest! Oh, just remembered,....out of the blue (well ebay), I spotted a rare beast, a 1985 country squire that is being broken up for spares! Here in the UK!
So I am taking delivery of the engine and box, all the glass, all the weatherstrips on tops of the doors, all door seals and numerous other bits that would be impossible to find otherwise on this side of the pond!

So, question....are the engine block and the heads and ancillaries the same on the 1985 as in my 1990? And the trans?

I know mine is multipoint fuel injection but this one is not..


1985 engine



Mine (taken when I bought it)


Andy.
Posted by: 81ltdcrownvic

Re: New big ford owner in UK - project resto/lowri - 01/06/12 12:09 PM

Well all I have to say is YAAAAAAAAAAYYYYYYYYY ANDY I WORKING ON HER AGAIN lol, as far as the engine trans deal, it looks like the trans for the 85 has a manual kick down, which you would have to convert over, blocks are the same, over all engine I believe are the same, but not 100% sure, minus you know intake and injection system. Um oh yeah, genius work on the door! I should have done something like that to fix the quarters smile Awesome job, can't wait to see the primer stage, she's going to look out standing! - Big John
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowri - 01/14/12 09:23 AM

GO Andy GO
Posted by: 81ltdcrownvic

Re: New big ford owner in UK - project resto/lowri - 01/17/12 01:41 AM

Andy...........Andy...........come out come out where ever you are!!! LMAO Just wanted to stop in and see the awesome project, hope all is well, I can't wait to see this one rolling this summer wink
Big John
Posted by: Justin McCarter

Re: New big ford owner in UK - project resto/lowri - 01/19/12 02:54 PM

Originally Posted By: andyfanshawe


So, question....are the engine block and the heads and ancillaries the same on the 1985 as in my 1990? And the trans?

I know mine is multipoint fuel injection but this one is not..



Andy.


85 i think wasn't even a roller lifter block, but other than that you shouldn't have trouble shifting your intake and accessories to the 85 long block assembly
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/19/12 04:21 PM

Hi again all!
How busy can life get?!! A Lincoln Mark 8 to restore as well as a country squire, oh and a full time job, a family, 2 parents in their nineties and...........

Anyway, time to get on with the crown vic I think. But I need more space (don't we all).

This has arrived in the shape of a 30 year old wooden 8' by 6' shed! Yes I could build an extension to the garage, but this shed is free woot

It was my Wife's dads shed for 20 years, then he unfortunately died (God rest his soul, poor guy), his Wife then moved into a smaller house and the shed got dismantled and moved to a relatives garden where it stayed for about 3 years laid flat on the garden!
Then it got moved to an allotment where it stayed for about 3 years.
The allotment owner gave it up due to ill health and I took charge of the shed.

Here is the poor thing in the allotment awaiting dismantling and transportation



Here's myself and my lovely Wife enjoying a moment while demolition takes place



and my young 9 year old son looking on



Here it is in our garden awaiting resto...



the shed has now been completely restored by myself and my Wife over the last 2 weeks and hopefully will be assembled this weekend. I'll tell you what, its simpler restoring a shed than a car! For a shed thats as old as this there wasn't much rot really. The roofing felt had been partially replaced by black poly sheeting but the water has taken its toll of the 2 roof panels and the bottom corners of the walls and floor. But its has all been replaced with good stuff and thoroughly waterproofed. Here's to another 30 years!

Here's the door restored and painted in my garage!



The reason for the shed is so I can take a door in one a time and work on it in peace and have a bit more space.

This door for example that is now hanging from the roof of my garage will be the first in!

All welding has been done on the door now so it just needs a bit of panel beating and prepping and priming.







Here's hoping for a good weekend so I can get this shed up and weatherproofed uk

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 01/29/12 05:37 PM

Finally got my shed/workshop up and finished!

Here's as it was a couple of weeks ago..





and here it is now!





Thought this was a nice touch! Although my lovely Wife didn't really agree!



Now I can actually get on with the car!

Andy.
Posted by: 81ltdcrownvic

Re: New big ford owner in UK - project resto/lowri - 01/29/12 06:20 PM

YAY hip hip hoorraayyy, Nice Andy!! Whats next on the list?
Posted by: Packman

Re: New big ford owner in UK - project resto/lowri - 01/31/12 11:07 AM

Nice. I should get a temporary shed for my painting projects. Everything in the garage has a Ford Blue tint/dusting on them LOL



Packman
Posted by: 1990CrownVic

Re: New big ford owner in UK - project resto/lowri - 02/02/12 02:42 PM

This post is simple awesome, amazing!

Congratulations Andy!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/09/12 04:41 PM

Put the drivers door on the hood (on top of foam before anyone moans and groans!)


Bent the bottom lip back to reveal....guess what?.....nothing! almost zero rust.





Then rustproofer sprayed in from inside and outside



and then heated up to make it run into all the crevices



Here it is hung up slightly to get the rustproofer down where it should be



This is never going to rust out!!

Andy.
Posted by: 81ltdcrownvic

Re: New big ford owner in UK - project resto/lowri - 02/09/12 07:24 PM

Good call! Nice to see some more progress! Looking good! -Big John
Posted by: N4RC

Re: New big ford owner in UK - project resto/lowri - 02/09/12 08:50 PM

I just read through this whole thread and I have to say you are a magician! I can't believe how well this is coming along. I can't wait to see the rest.
Posted by: AceVI

Re: New big ford owner in UK - project resto/lowri - 02/12/12 11:57 PM

Hello Andy. Just wanted to say great job! I've completely read your progress so far. Excellent work. You are like the people on tv that make everything look soooo easy. Thank you for taking the time to document your progress so far.

Al
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/13/12 02:27 PM

Originally Posted By: AceVI
Hello Andy. Just wanted to say great job! I've completely read your progress so far. Excellent work. You are like the people on tv that make everything look soooo easy. Thank you for taking the time to document your progress so far.

Al


Hi Al.
Thanks for your comments! It's anything but easy I can tell you. Loads more commentaries coming though.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/13/12 02:46 PM

Got a week off this week so I have every intention of doing quite a few hours on it.

So, started at 7:30 this morning..........

Plan was to finish the drivers door prep. Since I recrimped the base of the door, it wasn't quite straight anymore. A few wobbles so had to be panel beaten flat again and a skim of filler over the top. You can see it here





After using my favourite long flat bed hand sander (no machines for me!) and a coat of hi build primer, here we are



Since its cold in the UK still (is it ever warm?), this is my heat source directly above the door. It's a G clamp on one of the ceiling joists and an old hair dryer hung from it!



Here's a view of the prep where the mirror and the door handle used to be (good riddance)



Then door turned over and the panel I welded in to get access for the spot welder filled level and all seams sealed.



While all that is drying/setting its time to strip the wood grain off the drivers fender and start welding all the trim holes up.

Fender light removed first, but a bit of rust present



so had to grind one bolt off.



This is the last time its going anywhere near the car! I'm going to weld the hole up.



And here's a satisfying view of all the wood grain coming off the fender



And a casual view of my Lincoln Mark 8 patiently waiting for its new fuel level sender!



And here's all the wood grain vinyl on the floor rather than on the fender! Result.



Loads more to come tomorrow.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/13/12 03:21 PM

A few decisions have been made on the car!

Firstly the colour has been chosen. I pulled up at a supermarket the other day and saw a Viper metallic Green VW Scirocco parked in the sun. It looked absolutely stunning.


Going to cause a lot more work, but when its sat on the floor on 20's or 22's with black glass, no handles or locks or badges or fuel filler doors or anything else that could stick out, I think it will look awesome!

The second decision is to go with a custom built 68 charger type front end where the 5th gen camaro headlights are buried behind a black grille, with the headlight doors that open. The bumper will be widened and smoothed and colour coded.

Another leap of faith eh?

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 02/13/12 05:23 PM

If anybody can do it, you will.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/14/12 12:55 PM

Primed reverse side of door this morning





and then stored it in my shed!! I now need the space to perform surgery on the fender.



I love the view of a totally smooth door



Here's the drivers fender stripped of the wood



Now I need access to the back of the fender when welding the holes up, so inner fender needs to come off. Needless to say, I'm sure some fasteners will be seized.

Here it is before



and here it is after







Now its welding holes up time and then fender removal for media blasting

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/14/12 04:23 PM

Out with the welder to fill up the holes in the fender. That rhymes!



Got too late at about 9 pm to grind steel, so removed the hood trim. Looks loads better now.





May be fender removal tomorrow to start prepping it for paint and a spot of media blasting.

Andy.
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowri - 02/18/12 09:25 AM

wow some nice progress
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/27/12 12:56 PM

Nows the time to dismantle the front end so the fender can come off for repairs/mods. And to start to design and build the new headlight and grille arrangement.
Here's a simple sequence of photos. Needless to say the centre grille screws had to be drilled out because they were seized in, but other than that, a simple dismantle.









Time will tell exactly what goes back!!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/29/12 04:21 PM

Finally finished welding up all the trim holes in the front drivers side fender, and there were 22 of the stinkin' things!! Ford could have saved all that money on machines that stamped those holes out!

Time to weld in a patch to replace the light that was at the bottom of the fender, but I saw some rust behind there a while ago, so lets have a look





And here's a view of the lip that has been skimmed over by my grinder. The white stuff is bondo...





So its time for rust repair again! No panels available, so its back to the fabrication again. This car's got more rust than a rusty oil rig....

I'm going to reduce the fender lip by about half and separate the 2 skins, just like I did in the rear. i've got to make sure there is no rust lurking between seams to bubble through the new paint.

Better get my media blaster out then...........

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/03/12 05:18 PM

Okay so its hood removal time so I can get that fender off



Really surprised me how many bolts hold the fender on! 12 in fact!

This is the only one that didn't come out. It loosedend and then kept spinning. No doubt the captive nut holder broke in half



So it was out with my air grinder to grind the head off



Fenedr came off but is that the remains of a bulb at the bottom of it?!! How the hell did that get there?



Doesn't look too bad at the bottom, but here's the other side





Looks a bit sad now!



I try to fire the engine up every so often, and today was it. But it wouldn't play ball-no dash lights or any life at all. Finally spotted this connector that had literally fallen apart! And I had pulled apart a connector where the air compressor used to be. Oops! Started up straight away then.



More to come tomorrow, but the plans for the car are to complete all the exterior bodywork and assemble everything to make sure it all fits, the the fun starts!!!.............

The major lowering will be the cutting of the floorpan and lowering the body over the frame. Airsprings will take place of the coil springs front and rear. Shockwaves at the front.
The car will lay frame when slammed, and I don't care how much work that takes. It's do or die

The frame may need notching at the rear, and the upper and lower control arms at the front may need modifying, and even the frame may need Z'ing.....but I won't know until it all goes back together for a mock up, after the exterior bodywork is done. Even the body to frame mounts may need modifying.
I'll post plenty of pics-don't worry.


Andy.
Posted by: 81ltdcrownvic

Re: New big ford owner in UK - project resto/lowri - 03/03/12 11:22 PM

Man Andy, isn't cancer rust great!? I have had my fair share thats for sure. It's looking great!! Can't wait to see how you lower the body, that would be neato! banana Anywho, great job!! keep up the spectacular work. - Big John
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/06/12 05:28 PM

Time to remove the inner skin from the fender and see how far the rust goes. I'll also need more space for the wheel to go up into the arch when it lays frame! So here is the cut...



Here's the main section removed



Just leaving this section on the lip. Here's my fav air saw cutting through the top layer - I hope!!



Here's how far the rust goes up the inside of the front of the fender - it reaches up further under the inner skin than I thought.



Here's a few views of the fender lip that is left. I now need to remove the inner lip clean from the outer one by grinding through from the inside and causing little or no damage to the outer





Just before I packed up for the night, I did a surprisingly satisfying job! Removed the chrome trim from the back of the fender near. the screen!



Andy

Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/06/12 05:40 PM

Excuse my ignorance but is this the 3G alternator or is my car going to burn down as soon as I have built it!!?


If it ain't I need an upgrade! May need your guys help for parts!

Andy.
Posted by: PseudoBoat

Re: New big ford owner in UK - project resto/lowri - 03/06/12 09:43 PM

That is not the 3G. That is stock.
Posted by: caltemus

Re: New big ford owner in UK - project resto/lowri - 03/07/12 04:49 AM

I just got through the whole thread, and I must say, you have a tremendous amount of skill in fabrication and restoration. I wish my high school teachers could say the same. I recently recieved a 1989 Lincoln Town Car (my first car), and I might try some of the fixes you have done. I did notice that your driver seat posts had siezed, that happened to mine as well. I can't wait for this to be dropped, good luck with cutting the floorpan!

-Charlie
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/07/12 12:53 PM

Originally Posted By: BigNSlow
Jeez that fender is gone. Is it even worth trying to fix? Maybe try to find one from Southern US somewhere.


Hi BigNSlow.
Definitely worth fixing. This is where the fun is for me. Bringing something back to life that really shouldn't be. And then taking it to a whole new shiney level!!
It really isn't that bad. Once the rust has gone it'll need a few patches welding in, but it'll be worth it. Anyway, whats the cars name?...........................Leap of Faith.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/07/12 12:58 PM

Originally Posted By: caltemus
I just got through the whole thread, and I must say, you have a tremendous amount of skill in fabrication and restoration. I wish my high school teachers could say the same. I recently recieved a 1989 Lincoln Town Car (my first car), and I might try some of the fixes you have done. I did notice that your driver seat posts had siezed, that happened to mine as well. I can't wait for this to be dropped, good luck with cutting the floorpan!

-Charlie


Hi Charlie.
Thank you for your comments beer1
I'll keep you posted on the progress.
Best of luck with your first car (always the best one). Most of all, enjoy working on it. Will you post up a thread on your car?

Andy

PS I have a Lincoln also!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/07/12 03:55 PM

Managed to get an hour on the fender tonight and started to grind back the welds on the inside of the lip and peel back the inner lip. Here's the first bit bent back



And finally we are all clear



Rust has only gone through in 3 places but I will replace all the lip anyway.

I ran the grinder over the rusty steel and it looks far better than before



Rather than media blast the whole thing, I am going to use naval jelly(on liquid form) to eradicate all the rust. I am going to dip the fender into a BIG container and leave it for a day or so till all the rust is gone. then the welding starts.

Heres the back lower portion of the fender bent back to check for any rust under there.



Looks okay under there.

Andy.
Posted by: caltemus

Re: New big ford owner in UK - project resto/lowri - 03/08/12 01:27 AM

Once I get it in good running order, I plan to start the modifications, no use on making a post with pictures of changing a thermostat or cleaning the trunk XD

-Charlie
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 03/18/12 12:18 PM

Here's the bottom of the fender immersed in deox c rust remover



And here it is a few days later



and etch primed


Now on to media blasting the lip and then start to reconstruct.

Andy.
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowri - 03/25/12 03:50 PM

that did a nice job of cleaning it up. To bad you couldn't stick the entire fender in the rust remover.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 04/08/12 05:05 PM

Originally Posted By: QuicksterP71
that did a nice job of cleaning it up. To bad you couldn't stick the entire fender in the rust remover.

My exact thoughts!!

Bit more progress at last! I've actually restored another car in the time I've been away! Not a classic though. A small teeny everyday thing! A 1997 Ford Fiesta 1.4 Ghia





Anyway, back to the country squire. Time to weld up the light in the fender

Here is a patch cut to cover the hole


And the hole cut out very accurately for a butt weld


Tacked in


The welding caused slight distortion so I made a decision to replace the weak lip so I can panel beat it back to shape without losing the shape. So, a piece of wood clamped across to keep it all straight and out comes the first part of the lip









and new lip welded in prior to cutting to width


fully welded in


Now to panel beat it all flat.......................tomorrow

Andy.
Posted by: Black_Sunshine

Re: New big ford owner in UK - project resto/lowri - 04/08/12 07:07 PM

Naval jelly, it's good on toast too.
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowri - 04/08/12 09:26 PM

Outstanding job as always. Can't wait for the finished machine.

as far at the last post... I hope this isn't a "free toast" joke as this thread has NON DEED for this.

...as always, I watch this thread in awe and can only wish I had 1/10th the skills Andy has.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 04/09/12 09:09 AM

Quote:
as far at the last post... I hope this isn't a "free toast" joke


Naval Jelly = phosphoric acid. Naval jelly being the common name you find it on the hardware store shelves (in dry powder, jelly (paste), or liquid form).

Alex.
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowrider - 04/09/12 12:44 PM

^^^ I was referring to...

Naval jelly, it's good on toast too.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/09/12 05:05 PM

Naval jelly aside for a minute (on toast or not!), got to panel beat it back almost flat.



Then stripped all the lip ready for welding repairs in 2 spots.



Also took the paint off the other lower end of the fender to discover some pitting that would have bled through my new paint! Media blaster out next then.



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/29/12 03:40 PM

Media blasted the remaining rusty areas of the fender on the garden!



Here's the pitted area photographed above blasted



And then gone over with a polyester wheel on an electric drill and any deep pits gone over with a die grinder.



Final job to do on it before prepping for paint is to replace a section of the rusty lip and reducing it all in width.

Here's the bad bit cut out



Part of a cornflake packet being used as a template!





To be honest the fender was junk! Its took me weeks to get all the corrosion off, and will take me loads longer to get it flat! But, none available here in the UK so thats that. And I've got to do it all again on the other side!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/05/12 06:19 PM

Lip welded in


Now its time to reduce the width of the lip. Masking tape on and a pencil line to cut down





and cutting



Here's an interesting discovery. Final paint sanding and this line of rust appears through the paint





Same line with rust ground out


That would have caused some paint bubbling a year or so down the line.

Here is the fender all flatted back and ready for a skim of bondo and primer.



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/06/12 03:32 PM

Over to a very suspicious looking A post.



So, what I am going to do is to peel back the layers and try to see what exactly is going on.

First section removed


Second bit peeled up



Third bit peeled back (hinge reinforcement)


and last bit clear so far.

This is some heavy rust. And I know for a fact that the passenger side is far far worse - to a point where someone has welded the hinge to the A post because the bolts dont work anymore!
I still need to find out why its rusted in the first place.

Andy.
Posted by: TheFlyingDingo

Re: New big ford owner in UK - project resto/lowrider - 05/07/12 11:59 PM

This is amazing. Thank you for the super-detailed pictures and whatnot. Keep it up.

Edit-
Went deeper into the thread...

This is the kind of inspiration I need for my Dynasty...
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/10/12 04:58 PM

Originally Posted By: TheFlyingDingo
This is amazing. Thank you for the super-detailed pictures and whatnot. Keep it up.

Edit-
Went deeper into the thread...

This is the kind of inspiration I need for my Dynasty...


Thank you!! Hope you will post up a progress thread on your dynasty.

Anyway, finally finished removing enough steel to know roughly why its rusting.
Take a look here



I think the moisture is coming down the A post here as well as creeping around the hinge.



I'm going to have to cut out here and replace this first



But its dash out first because I ain't setting fire to it when welding it up! And I'm going to need full access to the firewall when moving the floor up.

Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 05/11/12 08:46 AM

I've got the same rust bubbling out around my hinges. You have quite the attention to detail to tear it down that far to fix the rust. I'm impressed.
Posted by: BigMerc96

Re: New big ford owner in UK - project resto/lowrider - 05/12/12 09:26 PM

Thats apparently a spot to check on a box body. I've never seen an Aero or whale with rot there, but several Boxes, one was so bad when you opened the door it'd drop a few inches. Wonder what they did differently in '92?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/14/12 06:08 PM

Now its dash removal time. And if anyone tells you that its easy, well they are a big fat liar nono

The main problem is that there are 2 huge bunches of wires that go through the firewall and into the engine compartment. The one on the drivers side is reasonable,



but on the passenger side the loom goes under the heater box, so that and the passenger inner fender will have to come out to get access. So move the car out of the garage a bit



and out it comes





Thats not going back!

Here's the dash partly removed awaiting loom removal



Took a big decision to remove all the AC and airbag wiring and components. For 2 reasons really. I dont know when the AC worked last and the compressor was seized when I bought it, so it could cost a fortune to put right. And the weather in the UK doesn't really justify the cost.
It will also make the engine bay look a lot cleaner. The airbag is now 22 years old and very unlikely to work efficiently - so out it all comes.

Here's all the AC stuff out so far



Here's a before and after photo of condenser removal





Looks a lot cleaner now (photo taken just before inner fender removal)

Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/15/12 06:16 PM

Finally got the dash clear





Took me 1 hour to try to remove the wiring plug from the fan resistor pack on the firewall behind the plenum. Eventually gave up and had to spend another hour trying to undo the 2 8mm bolts holding it on. Here's the little sucker



Even then it took some pulling and levering to get the plug off. This is why



You can just see the rust on the pins. These are going to need a good clean up.

I said earlier that dash removal on this 1990 cv was a PITA, but I was wrong. PITA is a complete understatement. This could be a new punishment for criminals. Rather than going to jail they have to remove the dashboard on a box panther.
I'm seriously looking forward to putting this back nono
But it wont be going back like this - many mods will be done including removing some of the wires and possible rearrangement. More of that later. Now I can get back to the welding.

Andy.
Posted by: Al Von

Re: New big ford owner in UK - project resto/lowrider - 05/16/12 10:06 AM

Haha! I replaced a heater core on a previous GM. I DREADED it, but took my time, followed the directions posted here. STILL, not in ANY hurry to have to do that again!
Posted by: tikitiki65

Re: New big ford owner in UK - project resto/lowrider - 05/19/12 09:41 AM

I need to do my heater core. Not looking forward to it at all. But this is a great thread. Been following it for awhile. Keep up the great work!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/19/12 05:45 PM

Here's the last state of play with a little flange left over



Out that comes with rust underneath. Here it is cleaned up



Heavy rust to come out next



Oops! Cut through the plate below it, so have to weld it up



New panel fabricated and offered up


and welded in



I'll put the other 2 layers back tomorrow.

While i was removing the air bag safing sensor from the bottom of the A post, I spotted this



and this

Sort that out next.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/20/12 03:19 PM

Ooops! Missed a photo out above! Should have said....

Sort this rust spot out soon


Todays jobs were easy for a change.
Remove all remaining rust..



Fabricate a plate to get the top of the A post back to 3 thicknesses..



Drill some holes in it to be able to spot weld through



Mark where these holes will be on the A post, mask them off and etch prime the post and the back of the plate so it'll never rust again!!



You can just see the small masking tape patches if you look closely!

Weld it in tomorrow and fabricate the final closing off patch.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/21/12 05:27 PM

Here's the plate tack welded on.



and finish welded



I'll try to do the closing up plate tomorrow and its onto the base of the A post.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/24/12 04:12 PM

Not had time to do much since my Wife did this to our Toyota Yaris on a pole





Bit of panel beating later and here we are



No cost so far, but got to fabricate a new rocker section tomorrow, the I can start to match the door to the rocker edge.

Anyway, back to the crown vic.

A cardboard template made to close off the top of the A post



and the exact same made of steel



Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 05/24/12 08:30 PM

Yaris versus Crown Victoria LX Country Squire Wagon.
Weight - Crown Vic Wagon
HP - Crown Vic Wagon
Torque - Crown Vic Wagon
MPG - Yaris

grin
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 05/25/12 12:57 PM

I bet that is stronger than when it was new when you are done with it
Posted by: Leadfoot

Re: New big ford owner in UK - project resto/lowrider - 05/25/12 02:14 PM

amazing skills! love the progress!
Posted by: BigMerc96

Re: New big ford owner in UK - project resto/lowrider - 05/27/12 03:29 PM

That wagon has already come along way from where it started, and you aren't even done yet!! Keep up the amazing work!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/05/12 05:06 PM

Loooong way to go yet though - so better get on with it!

Last 2 sections welded in at the top of the A post awaiting grinding back and prepping for paint



And onto the bottom of the A post that looks bad...





But in fact, once cut back is not bad at all



Heres a view inside the rocker and one looking in just above the rocker





Doesn't look too bad in there.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/11/12 05:14 PM

All cleaned up



Plate fabricated and hole drilled in the centre to get access for rustproofing



Plate and A post painted to prevent further rusting and spots where spot welds would be masked off first





Welded in



Rustproofed and seam sealed





And etch primed...



Not bad for a 21 year old car in rainy UK!

Here's the top of the A post sealed and prepped for etch priming tomorrow.



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/11/12 05:23 PM

better photo


Andy.
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 06/16/12 02:43 PM

Originally Posted By: andyfanshawe
better photo


Andy.


this is amazing well done sir
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/19/12 04:38 PM

Thanks guys!

Don't think i haven't been busy 'cos i've not posted!! This bodywork is taking forever............heres why...........

Now top of A post is repaired, the top hinge is a rusty mess! here it is after it has been dipped in acid



I like the tide mark! I left it in for a week because I forgot about it. Oops!

here it is painted and installed





Which brings me round to the refitting of the doors and the PITA lining up of everything.

Did it all line up? Err.........................no.

I had to cut the frame clear of the rear door again because it was too far in towards the centre of the car when closed and forcing the top of the door out.





Serves me right for welding it up when the car wasnt fully assembled.

After what seemed hours, we have an almost good alignment between the doors and the rear quarter, apart from here....



The bottom of the rear door wants tapping in slightly to line up, A block of wood and a hammer will do here!

Here are the door gaps. I want them nice and tight.





I still like this view of the quarter with no fuel filler door there though! Smoooooth.



I have also spent hours on the drivers fender flatting and spraying - pictures tomorrow.
I really hope it fits against the newly lined up drivers door!

Andy.

PS Anybody want to fly to the UK and help with a bit of paintwork/bondo flatting?!!!!

Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 06/20/12 06:38 PM

i would love to learn from a master but the commute would kill me
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 06/21/12 11:02 AM

Originally Posted By: QuicksterP71
i would love to learn from a master but the commute would kill me

x2 - Me too. I keep thinking I'll eventually retire and maybe I'll have time to learn skills like this.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 06/24/12 12:19 PM

Originally Posted By: andyfanshawe
PS Anybody want to fly to the UK and help with a bit of paintwork/bondo flatting?!!!!



You paying? I'll book the next flight! wink
Posted by: DatRust

Re: New big ford owner in UK - project resto/lowrider - 06/25/12 10:08 AM

I don't think I'm mentally capable of putting this much effort into something. You continue to astound.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/04/12 06:01 PM

Finally got the front fender back on temporarily. All lines up





Looks good being all smooth.

I now need to do the passenger side doors and fender, but need a bit of a bodywork break, so I have started to strip all the airbag wires out of the dash wiring and core support wiring.



Closely followed by all the airbag components also! If anyone needs anything let me know.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/05/12 02:29 PM

Oops! Forgot to post a picture of the inside of the fender painted with 2 part epoxy rust encasulating paint. No way I'm having rust coming back from the inside.



As soon as I have channelled the body and know where the tire will sit, I can redesign the inner structure of the fender.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/08/12 05:42 PM

Moved the car over to the other side of my small garage using 2 trolley jacks!



Then started stripping out the rear doors innards and removing the fake wood trim from the front door





An old hair drier works well



Finally removed it all!


I'd forgotten how awkward it was to remove the rear door glass and quarter light! Finally got it done.

Here's a shot of the glass finally coming out and a reminder of the first move when I'm trying to get it back in!!



Got to get this car moving over the summer. I have 6 weeks off work so should, hopefully, get all the bodywork done and I can then move onto the channeling over the fall and winter time.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/09/12 04:56 PM

Here we go with the rear door....

Back to bare metal round the handle area



My air saw to the rescue to cut it out



Always amazes me that a straight hacksaw blade can cut round corners!!



Patch cut out and stuck in place with duct tape and a magnet and tacked in place





Finished welded over the next hour or two (taking it slow to keep distortion to a minimum



Don't let appearences deceive, there is distortion there that will take a few hours to sort out by tweaking and tapping and levering..etc!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/13/12 02:40 PM

Heres my new temporary worktop in my small garage!



Skim of filler on the welded up door and off we go to the worktop





Base of door paint stripped off to check for any corossion (none)



Then door turned over and bottom lip bent open to find any rust beneath. There was minor stuff but not too bad (forgot to take a photo but I will soon). I made up a container to fill with phosphoric acid out of an old gutter and submersed the bottom of the door in it for a day or two.





I fancy laying the windscreen back a few degrees to make it look more streamlined, so will have to do a few drawings to see what it looks like. I'll have to do that after the chanelling though.

Andy.
Posted by: ChromeDaddyO

Re: New big ford owner in UK - project resto/lowrider - 07/17/12 04:17 PM

This is absolutely amazing. I have been following this post for a long time. I cant wait til you begin the air bag suspension and chaneling, I recently started the air ride suspension on my 1999 Mercury Grand Marquis. Good choice going with Shockwaves that would definitely have been easier on my project, I relocated my shocks and now have to figure out my sway bar as the shocks are occupying space where the sway bar used to reside. Unfortunately Shockwaves are not in my budget. Any way keep up the amazing work you are certainly very skilled.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/17/12 05:09 PM

Thanks ChromeDaddyO.
Very kind words. Good luck with your marquis. Have you any photos of the suspension build? Progress thread?

Back to the plot..
Here's the front passenger door lock and handle cut out


and joddled patches spot welded in



Heres the bottom of the pass rear door that was in the acid guttering bath





Looks good and rust free.

Onto the dashboard wiring tidy up. Removing all the airbag wiring. Once the defroster/heater ducts are removed theres plenty of room and plenty of wires came out









More tomorrow, but never imagined how events would unfold over the last few days.............

My poor Dad at 88 years of age had a stroke last wednesday night, which is bad enough, but then fell down the stairs he was just at the top of. Unfortunately he has now lost the use of his right leg and right arm, broke his sternum and one rib and now doesn't recognise anybody or knows what he is doing or saying. My Mum, who is 92 is shattered. None of her friends are alive anymore so she has no-one to talk to of her own age. Living to an old age doesn't seem so attractive anymore.

In a way this project of mine is really keeping me sane. Certainly takes my mind off things temporarily. Heres hoping for some peace for my Dad, whatever that turns out to be.

Andy.
Posted by: ChromeDaddyO

Re: New big ford owner in UK - project resto/lowrider - 07/17/12 05:19 PM

Andy,

Actually posting the build thread in suspension and brakes forum.
https://www.crownvic.net/ubbthreads/ubbthreads.php?ubb=showflat&Number=2556932#Post2556932

Sincerest best wishes on the family front i'm very sorry to hear.
Posted by: Yoder

Re: New big ford owner in UK - project resto/lowrider - 07/17/12 11:16 PM

Andy, Tell your family that your friends across the Pond are praying for Peace and Recovery. Keep up the Good Work!!!!
Posted by: Packman

Re: New big ford owner in UK - project resto/lowrider - 07/18/12 09:40 AM

I wish your father a speedy recovery. Hopefully you (or whoever found him) were able to get him to the hospital quickly. Most of the time, the doctors have to wait for the stroke to end (from what I was told) before they can do anything, but it's the time between the end of a stroke and treatment which is crucial. What kind of stroke did your father have?

Kinda in the same situation here. My father had a hemorraghic stroke (15% of stroke patients get these) two years ago. He recovered frm the stroke, but is still adjusting to all of the medications. This is why I haven't done anything but maintenance with my mom's CV. Hopefully at some point I can resume work and semi-finish that car.



Packman
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/21/12 06:04 PM

Thanks guys.

Originally Posted By: Packman
I wish your father a speedy recovery. Hopefully you (or whoever found him) were able to get him to the hospital quickly. Most of the time, the doctors have to wait for the stroke to end (from what I was told) before they can do anything, but it's the time between the end of a stroke and treatment which is crucial. What kind of stroke did your father have?

Packman


They are now saying he may not have had a stroke but they can't really explain his trouble speaking and paralysis down his right side.

Anyway, thanks for the good wishes guys. No improvement yet but we have hopes.

Okay, moving on with the wagon

Heres the extension to the window channel inside the rear passenger door



This has now gone into my acid bath at the top of the garden!

That red thing on top is a sledge for anyone that doesn't know about snow!! I know the summers in the UK are bad but its only there to stop the acid bath being rained in!

Here's the rear pass door skimmed with filler and awaiting primer


And the back of it already primed





Moving onto the fender and off it comes


This is a familiar view of rust carnage..



I'm going to cut the hell out of it tomorrow with my air saw!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/22/12 05:13 PM

inner fender cut out exactly as the other side and the lower front sat in my acid bath









That will be in there for a day or two so its onto the front door. Onto my worktop it goes and the base stripped of paint just in case there is any rust underneath



Which is a good job because if you look closely in the next picture you will just be able to see some rust marks that would have bubbled the new paint up.



I knew of the underside rust but hadn't seen it for a bit, so door turned round and here is my next job!



Should be simple enough to sort out....lip bent back, rust cut out, a spell immersed in acid and weld in new steel.

Andy.
Posted by: ChromeDaddyO

Re: New big ford owner in UK - project resto/lowrider - 07/22/12 06:43 PM

As always A+ Andy!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/23/12 05:26 PM

Originally Posted By: ChromeDaddyO
As always A+ Andy!


You're not doing so bad yourself!

Remember this window channel?




Here it is out of the acid




Its now etch primed.

Remember this one rusty spot under the passenger front door?


here it is now




Even though the lip of the skin is rusted the actual skin is not perforated, so its into the bath of acid to see what comes out.

Fender out of the acid bath and onto my worktop!


I've strapped it up to hold it at an angle so I can de double skin the lip.

Here it is all gone.









Apart from that one spot near the G clamp, it actually looks in good condition- a bit rusty but not thin. Far far better than the other side. Spot of media blasting coming up!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/27/12 05:04 PM

Remember the rust at the base of the passenger front door?



Which turned into this




and finally into this





That has now been seam sealed, so back onto the fender. A puddle of acid to get rid of some more rust



Leave that do do its work and onto the hinges on the passenger A post.
The top one had been welded for some reason. You can just about see where the weld has pulled a lump out of the corner of the A post



and the corresponding hinge



pity you cant see the lump of weld on the hinge face in the photo very well.

I'm moving on a bit so I can get this car channeled within the next 4 weeks or so!

Andy.
Posted by: ChromeDaddyO

Re: New big ford owner in UK - project resto/lowrider - 07/27/12 09:27 PM

Channeled! Yippee, I'm so excited.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 07/28/12 03:59 AM

Hi ChromeDaddyO.
your car looks awesome low down. Good job on the air suspension install.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 08/02/12 11:52 AM

Been on holiday for a few days so managed to find a few minutes to do a quick sketch of the finished project!



Not to Chip Foose standard but we can't all be geniuses!

Andy.
Posted by: ChromeDaddyO

Re: New big ford owner in UK - project resto/lowrider - 08/07/12 09:08 PM

Nice rendering Andy. Was that a motivational tool? How's the progress?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 08/13/12 01:50 AM

Originally Posted By: ChromeDaddyO
Nice rendering Andy. Was that a motivational tool? How's the progress?


Yes! Heres a progress update.

Onto the passenger A post top. Heres a sequence of photos as it is cut away











Going to have to go down one more layer. Certainly far worse than the other side. Shouldnt take long to do though.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 08/13/12 04:58 PM

Metal cleaned up as far as I want to go



Worried about how deep the rust goes on that corner, so out it comes as one unit



Heres the top of the panel removed



and the other side



Really surprising that it has only gone through in that one area.

New steel going in tomorrow.

This was an interesting sight. Loads of media from the blasting I did over a year ago.



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 08/15/12 06:20 PM

First plate fabricated and clamped in place





Next plate fabbed and drilled for spot welding and etch primed underneath



Dont know whether you can see the tiny pieces of masking tape in this picture where the spot welds will be




Weld it in tomorrow and close it all up.

Andy.
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 08/16/12 04:33 PM

Have you ever used that weld through primer they sell now

Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 08/16/12 05:52 PM

Originally Posted By: QuicksterP71
Have you ever used that weld through primer they sell now



Hi QuicksterP71.
I have used it but my MIG and spot welder doesn't like it at all. Spatters all over the place. Careful use of etch primer and rust proofer and a hot air gun is far more effective.

More progress time;
Plate welded in



and welds ground down



Final plate made and holes drilled for spot welding. Notice the painted panel under it with masked off areas where it will be welded through



Welded in



have a look at this for welding penetration! Gone through 2 thicknesses!



Heres where I think some water gets in to the A post. Here I am levering up the panel at the bottom of the windscreen revealing a gap where the sealant has gone.



Onto the bottom of the A post. On the other side it was rotted out, so I thought I would cut this side out to check



Looks good this time but the inner rocker has some corossion on that may need doing.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 08/23/12 03:21 AM

Loads of bodywork done over last few days.
Top of A post finished and sealed



Bottom of A post welded up with an access hole for rustproofing



Bit of a warning here. Found this at the bottom of the A post stuffed in a corner


no not drugs, but sound proofing.

Quite a few of these in that area and I thought I had got them all out. You can see the weld burns in it. Could have set the damn car on fire.

Just the fender to do now so heres a couple of views of where we are at.









Then we are bracing up and engine removal for the floorpan to be cut out!

Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 08/23/12 10:31 AM

Looking good!
Posted by: ChromeDaddyO

Re: New big ford owner in UK - project resto/lowrider - 08/23/12 04:06 PM

Sweet. Can hardly wait to see!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 08/26/12 02:16 PM

Here's what it will hopefully look like!!



Front bumper may be a bit too ostentatious!

Andy.
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 08/26/12 03:42 PM

i like the hood
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 08/27/12 02:29 AM

You have to forgive my Star Trek leanings, and this would be to corny anyway, but I just had to add it.

Swirling lights behind the grill to emulate a fake warp drive.
Posted by: grandmacar

Re: New big ford owner in UK - project resto/lowrider - 08/27/12 11:59 PM

stumbled across this post and just spent three nights going through this post.....holy awesome work, love the work you are doing, too bad there has been so much rust. or is it too bad rust you have met your match
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 08/29/12 07:14 AM

it does kinda look like a shuttle craft fon star trek lol
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 08/30/12 05:36 PM

Dont want you all to think I've been slacking! Bodywork is taking ages.......

Heres the fender in the middle of fettling.



Patch made and joddled and spot welded in place of the lower light



and sealed off



Heres a rusty lip!



and repaired



And heres how much I've reduced the fender lip by. A good 12mm cut off!



Andy.
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 08/31/12 10:08 AM

Just keep doing the quality work you have been doing. It would be a shame to start taking short cuts now. Plus it seems that you are running out of stuff to fix.
Posted by: N4RC

Re: New big ford owner in UK - project resto/lowrider - 09/04/12 12:53 AM

Wow, that has come so far. It looks great. Keep up the awesome work!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/17/12 04:35 PM

Is it really halfway through september already? Wow, time flies.

But, I'm on schedule because the bodywork so far is finished. All filling and etch priming done









Now its time to get ready for the big floorpan cut!
Engine out next, all doors removed, car up in the air, interior stripped out totally, firewall stripped back to bare bones, metal supports welded in, springs removed, 6 jacks in place and we are cutting!!

Watch this space.........................

Andy.
Posted by: ChromeDaddyO

Re: New big ford owner in UK - project resto/lowrider - 09/17/12 05:02 PM

The anticipation is killing me. I can't wait to see the body drop!
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 09/20/12 02:09 AM

you might be waiting awhile he started this build almost three years ago
Posted by: ChromeDaddyO

Re: New big ford owner in UK - project resto/lowrider - 09/20/12 07:22 AM

I know, that's why I'm excited, it's been great, to get caught up (when I became a member) , then follow along. The scale of what Andy has taken on here is huge. I think he's making amazing progress, most people would have lost interest long ago.

Great job Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 09/20/12 10:28 AM

Originally Posted By: QuicksterP71
you might be waiting awhile he started this build almost three years ago


I, for one, am amazed at the progress thus far in the last 3 years. Andy is a teacher, has his own family, has been dealing with ailing parents. I admire the patience of his wife too! I'm also a teacher and I can say that even if I had Andy's skills, I wouldn't have gotten nearly this far in 3 years.

Yes, Quickser, we may be waiting awhile. (At the same time, the suspense is killing me!)
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 09/20/12 10:32 AM

This whole thread is full of win. I love the step by step nature with pics!
Posted by: Packman

Re: New big ford owner in UK - project resto/lowrider - 09/20/12 10:40 AM

I just love the attention to detail. Makes me realize why a good auto body shop charges good $$$ for the work that they do.



Packman
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 09/21/12 12:44 AM

Originally Posted By: Packman
I just love the attention to detail. Makes me realize why a good auto body shop charges good $$$ for the work that they do.



Packman


I know of only one, and it's in England. Seriously, no shop, unless they're doing custom work for you and you are paying tons.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/23/12 05:16 PM

Thanks for all the replies guys! I'll do my best to keep you all entertained over the next few weeks.

The plan is to get everything stripped out and get the car in the air, reove the engine and brace for cutting - all within the next 2 weeks.





Interior totally stripped out..



Engine out next weekend.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/25/12 03:46 PM

Got the front stripped down ready for motor removal





Not much space down each side of my garage but its possible.



Heres my shed packed to the roof of country squire parts!!





Here's a view of the underside that will change soon..



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/28/12 06:52 PM

Engines out and going off to be rebuilt tomorrow morning







All springs out next.

Andy.
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 09/28/12 10:49 PM

some good progress
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 09/30/12 04:22 PM

Right, got to get on with this.

All springs out



and car lowered to its bump stops





Nylon rope stretched across the bottom of the tyres to see how far the floorpan has to go up into the car



Looks like its 10 cm then!



Which takes the floor up to the 10 cm mark here.


I'll level the car up next, then brace it and its floor cutting time!

Andy.
Posted by: Packman

Re: New big ford owner in UK - project resto/lowrider - 10/01/12 09:42 AM

Out of curiosity, when you had that wagon jacked up outside, did you find water inside of the car after rain or snow? I have had my Crown Vic in the air, supported by jacks up front for a week and yesterday I started to smell mildew. I'm assuming my driveway is nowhere near level and that may be bending the car a little or enough to misalign the weatherstripping around the doors and windows. Do you think that is the cause of the problem? I had this happen to my Chevelle when I changed the crank gear and seal (was up in the air for a couple weeks). Sorry to threadjack like this, but I figured that you would be the person who would know.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/01/12 11:33 AM

Hi Packman.
Was the car at such an angle that the water running down off the windscreen remains on the metal panel below it?

There are areas at each end of this panel (under the fender) that seperate and leak water. There is also a drain under the fan on the firewall that gets blocked. I bet if you removed the glovebox door and looked at the vacuum operated door behind it, it will be wet at the bottom. Water could be dripping into the car inside under this door, rather than running out down the firewall in the engine bay due to the angle the car is at.

I'll try to find some photos for you.
Andy.
Posted by: Packman

Re: New big ford owner in UK - project resto/lowrider - 10/01/12 02:10 PM

Thanks Andy smile I know at some point, I will be doing a heater core, so I will most likely get behind there to check that out. There is an abyss on the cowl that I can't get to with the hood installed. I know this is filled with crud. When I swap engines and remove the hood, I will get the wet vac and suck up whatever is in that hole.



Packman
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/02/12 01:56 PM

Just to let you all know that my lovely Dad passed away this morning in hospital. Age 88. May he rest in peace and he will always be in my thoughts.

I am going to dedicate this car and its build to my wonderful Dad.

Andy.
Posted by: Yoder

Re: New big ford owner in UK - project resto/lowrider - 10/02/12 07:07 PM

I'm so sorry for your loss. You and your family will be in my prayers. R.I.P. Good Sir, GOD SPEED.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 10/02/12 08:24 PM

RIP. Condolences Andy.

Alex.
Posted by: WSTRLNG

Re: New big ford owner in UK - project resto/lowrider - 10/02/12 08:30 PM

I am so sorry Andy. Even though you have never met most of us, you have our support.

I know that this build will be your best ever just for him.

R.I.P.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 10/03/12 06:41 AM

I'm sorry for your loss.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/06/12 05:34 PM

Thanks for all the good words guys. He's certainly in a better place now.
But the build goes on............

20mm angle iron bought and welded in position across the A, B and C posts and connected to the D posts








Sure looks naked now...


Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/07/12 04:23 PM

Since I haven't got a fancy 2 post lift, I'm going to have to use 6 scissor jacks to lower the body down over the floor.





I've even managed to persuade my lovely Wife to let me leave the dashboard in the hallway!!

Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/10/12 03:02 PM

Body is now supported on 6 modified scissor jacks!





I have had to get all the jacks at the same extended length since they are not linear. In other words, one turn of the handle doesn't move the same distance throughout the travel of the jack. That will cause an alignment isssue as it goes down.. Shouldn't be too much but really dont want anything at all.

This has got to be removed next



Then this


Then this area needs welding up because the floor will need to be welded across there



Oh and the chassis at the rear will need shortening about 6cm so it clears the back as it is lowered. Photos from that next.

Exciting times.....

Andy.

PS Is this thread really approaching 1 million views?!!!!!!!!! Is this a record?
Posted by: ChromeDaddyO

Re: New big ford owner in UK - project resto/lowrider - 10/10/12 03:14 PM

WOW, its really happening. I'm excited! It must be a record for views, I think people (myself included) are generally amazed at what your accomplishing in that modest single car garage, shed, and front entrance way (dashboard)! LOL, Keep it coming.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/13/12 05:54 PM

Originally Posted By: BigNSlow
Originally Posted By: andyfanshawe

PS Is this thread really approaching 1 million views?!!!!!!!!! Is this a record?


Nah. What did you do to your Panther thread is over 7 million.


Aspirations then!

Welded in 4 3mm thick plates at the bottom of each A and B post so the new floor can be welded to it.









Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/14/12 05:23 PM

Removed both rear tailgate area sections today to clear the decks for the up and coming cut.

Before




After








More cutting tomorrow.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/20/12 05:20 PM

To get the chassis rails higher up into the body, I need to shorten it and consequently move the rear body mount forward out of the way.

Heres the start of the access



I need access to the top of the rail, so out comes the section above it



Chassis marked for cutting



And cut out





Heres the old mount position compared to the new position



More cutting tomorrow.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/28/12 04:44 PM

Rear floor cut right across the back so it can go up when the body is dropped around it.





I now need to remove the top of each rear wheel arch to enable the wheel/tyre combo to go further up







Heres the level marks to determine when the floor is at the new desired level. Lowest mark is at 6cm, then 8cm, then 10 com.





Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/29/12 05:58 AM

Here is the intended firewall cut - red line you can just about see.





I will cut out the steering column hole (red line) (can you cut out a hole?!!) and weld it back in later.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 10/31/12 01:40 PM

Final bit of cutting done before we get to the firewall and the big cut!!











Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 10/31/12 08:24 PM

Wow.

=-)

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/08/12 04:24 PM

Here's a chunk of the firewall missing to enable the floor to move up 10cm.





And here's the floor finally moved up 10 cm all round..













Here's a view of the rear tyre/wheel looking good tucked up underneath!





View from underneath later

Andy.
Posted by: ChromeDaddyO

Re: New big ford owner in UK - project resto/lowrider - 11/08/12 06:59 PM

This thread is like my cocaine... I can hardly wait to get the email that there was a reply on the topic and then I go crazy until I can view it on my laptop. I refuse to view it on my phone because I feel like I can't take it all in on the small screen. Seeing that wheel tucked up in the wheel well makes me want my Merc lower! Keep up the amazing work Andy cool .
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 11/08/12 08:00 PM

Originally Posted By: ChromeDaddyO
This thread is like my cocaine... I can hardly wait to get the email that there was a reply on the topic and then I go crazy until I can view it on my laptop. I refuse to view it on my phone because I feel like I can't take it all in on the small screen. Seeing that wheel tucked up in the wheel well makes me want my Merc lower! Keep up the amazing work Andy cool .


Andy's the only I got a Samsung Tab2 7".
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 11/09/12 08:46 AM

drool
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/10/12 06:41 AM

Heres a view of the rear of the frame legs before and after the body drop





This is how far the frame sat below the rocker panels before the body drop



This is where the frame is now





I suppose this is why a box cannot sit on the floor because the frame and exhaust sit below the bottom of the rockers, no matter how far its lowered on the springs.



A lot of work though just to be fashionable and radical!!

Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 11/10/12 04:21 PM

I'm thinking under body cover for aerodynamics, even if its an oxymoron for a box body. might get too much heat build-up from the exhaust. I am curious about Andy's ideas about the rocker panels though.
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 11/11/12 02:01 AM

wow i was wondering how this was going to be done good work
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/19/12 05:30 PM

Right, need to weld the floor back in its new place.

Starting at the back (because this is the hardest part!). Heres a view of the back left frame rail



And here's a new mount tack welded in in a new place



And a view from underneath



The plan is to take most of the winter welding the floor back in and then roll out the chassis from underneath and finish weld the body underneath. Then prep and paint.

Chassis back under and start to fit everything back (but of course most things wont fit anymore!!). Engine might be rebuilt by then also.

Phew, this could take some time!!

Andy.
Posted by: AOD

Re: New big ford owner in UK - project resto/lowrider - 11/20/12 11:10 AM

Awesome action shots! smile
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/21/12 02:56 PM



Another layer fabricated to go here



and holes punched in it to spot weld through



Masking tape put on where welds are going to be and etch primed on both plates and welded in





Captive bolt frame modified to fit. Look at the before and after....



and welded in



Sorry about the poor picture.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/22/12 01:40 AM

No, not at all redundant.
2 reasons for all this, seemingly, random nonsense!

Firstly, when I bought the car, a straightforward rebuild/modifications including airbagging was planned. During the process I had to pull the engine but cash was short (2 kids etc) so I took a gamble at a partial engine rebuild and hoped for the best. This gamble didn't pay off when the engine had low oil pressure. fair enough, I took a chance and it didn't pay off.
Also the car had been taxed for a year (allowed to use it on the road for 12 months, but only 7 months remained on it. So I had to complete the repairs in that time since I was working on the car outside on the (very quiet)street. If the tax would have run out, the car would have been clamped and towed away/scrapped. So it was imperative that the car was back roadworthy asap. To chop the floor out at that stage would have been far too lengthy a job. I wanted a trustworthy, non rusty rebuild in less than 7 months. But then i went to a local car show......................which brings me to the second reason....

There was a squire there that was very low, but not on the floor. Obviously on its bump stops on air. There was a rod at the side of it that was lower but again, not on the floor. This really was the inspiration I needed for the next evolution (shall I call it?) - get it on the floor no matter what. And since I had sold my previous show car, I had a garage available so could take my time and not be worried about being clamped.

So there you have it. Good question you posed and I can assure you that my Wife asks me what the hell I am doing loads of times. There are resons for everything, they are sometimes not clear (try working with teenagers everyday for the last 30 years to understand that one!!)

And I'll tell you what, I really enjoy doing it! Actually more than driving them at the end. Its the climb.

Theres a possibilty that the design may change again before it is finished. It could take years to build and I may be an old man when it is done (if ever!) but I really enjoy doing it even if it hurts sometimes.

So, redundant? No. Enjoyable? yes. Fun? Damn yes!

And a possible third reason? Why do I do it? Because I choose to!!!!!!!!! wink


Wishing you good luck in your life's projects. Thanks for the question.

Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 11/22/12 02:13 AM

Originally Posted By: andyfanshawe
(try working with teenagers everyday for the last 30 years to understand that one!!)


THIS I understand. Coming from a highschool chemistry teacher. I'm determined to figure these kids out. And the game changes every year. Frustrating, yeah. It's also part of the fun!

In this way I can relate to what you are doing. I can also understand the need for an outlet.

Andy, do you share your stories and challenges of modding with your students?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/22/12 11:10 AM

Originally Posted By: enslow
Originally Posted By: andyfanshawe
(try working with teenagers everyday for the last 30 years to understand that one!!)


THIS I understand. Coming from a highschool chemistry teacher. I'm determined to figure these kids out. And the game changes every year. Frustrating, yeah. It's also part of the fun!

In this way I can relate to what you are doing. I can also understand the need for an outlet.

Andy, do you share your stories and challenges of modding with your students?


Hi enslow.
I do indeed share my stories with the students, and for the least intelligent ones, its a life saver! For me and them.

I also take the cars in sometimes also! My car looks like a dinosaur in a field of sheep in the car park?

Do your students share your passion?

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 11/27/12 03:23 PM

Spent last few days trying to not sell my Mark 8!! wink Don't tell my Wife!

Anyway, I'm working from the back to the front welding the floor back in and the various associated panels.

Here's where the rear floor ended up when it went further up into the body (red arrow)



Here's the section I cut out (photographed it out of order!! Sorry.



This is so I could weld it back further down





Corner gaps welded up with filler strips





Here's a card template made of the new side panel being made to tie the rear of the car (D post) to the inner wheel arch.



Make it out of steel tomorrow.

Andy.
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 11/28/12 07:51 PM

you have gotten a lot done
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 12/01/12 01:06 AM

Originally Posted By: andyfanshawe
Hi enslow.
I do indeed share my stories with the students, and for the least intelligent ones, its a life saver! For me and them.

I also take the cars in sometimes also! My car looks like a dinosaur in a field of sheep in the car park?

Do your students share your passion?

Andy.


I will borrow examples of car maintenance to illustrate problem solving skills learned in science. I also relate stories from my kids, heck I'll even talk about fashion, if it captures interest. Whatever I can do to develop a relationship with the kids.

I'm not about to hotrod my 92 grand Marquis!

Come to think about it now that you're lowering it, have you ever thought of chopping?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/01/12 01:13 PM

Originally Posted By: enslow
Originally Posted By: andyfanshawe
Hi enslow.
I do indeed share my stories with the students, and for the least intelligent ones, its a life saver! For me and them.

I also take the cars in sometimes also! My car looks like a dinosaur in a field of sheep in the car park?

Do your students share your passion?

Andy.



Come to think about it now that you're lowering it, have you ever thought of chopping?


Oh yes! Many times. Even had it drawn out! But I'm 6 feet 3" and it will be tight for headroom now!! But, once I have got it back on its feet I will pop a seat back in and see if I can take out an inch or two!

I'm sure your students would appreciate it if you did hotrod your grand marquis! Think how much of an hero you would be!!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/02/12 05:29 PM

Trial fitted the side panel and a right angled strip



Strip spot welded in on top of rust proofing fluid that has now flowed all over because of the welding heat



Vertical panel etch primed on the planned tough to reach areas and spot welded in







Next I will produce a second vertical wall running alongside this one and close it all off to mimick the factory setup.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/04/12 05:43 PM

Starting to close off the side section with the boxing in of the frame captive nut





Top section made and clamped in place. This will be spot welded and plug welded in- but not before sealing it all inside with rustproofer.





Andy.

Gonna be a looong cold winter in the garage.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/06/12 05:00 PM

Trying to close off the back left corner now.

Quick reminder of state of play



Here's the closing off side section and the top being spotwelded together



And the finished product


Here it is in place as a quick check for fit



Tomorrow it will be removed and seam sealed inside and etch primed, then fully rustproofed before finally welding in.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/08/12 05:05 PM

Rectangular body mount access hole cut out and edges flared to retain some rigidity.





3 more access holes created by my sheet metal punch





Welded joints seam sealed and inside of panels etch primed and painted white for rust protection once it is all welded in and inaccessible





All welded in...





Tomorrow I'm going to etch prime, prime and paint that area green - just to see what it may look like when the cars painted!! Bit of motivation............!

Andy.
Posted by: Packman

Re: New big ford owner in UK - project resto/lowrider - 12/11/12 01:19 PM

Out of curiosity, did you widen the wheel arches? Or can you fit wider than stock wheels as is?


Packman
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/11/12 01:51 PM

Originally Posted By: Packman
Out of curiosity, did you widen the wheel arches? Or can you fit wider than stock wheels as is?


Packman

Hi Packman.
Thanks for the question. No, I haven't widened the wheel arches. The limiting factor inboard is the chassis rail. This may be moved later, but not in the plans at the moment.
The constraint outboard is the shape of the quarter panel above the wheelarch. As the body sinks over the tyres the quarter gets closer to the sidewall.

Saying all that, I can go about 1" wider in towards the rail as long as the outer rim stays where it is.

I'll try and get a photo for you later.

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 12/11/12 09:46 PM

As always, nice work Andy. Still boggles my mind you'd rip your car apart on the street, work in a space that makes most of our available work areas look like the royal palace courtyard size wise, and yet we complain about no where to work. Good inspiration.

Alex.
Posted by: Packman

Re: New big ford owner in UK - project resto/lowrider - 12/12/12 03:56 PM

Originally Posted By: andyfanshawe
Hi Packman.
Thanks for the question. No, I haven't widened the wheel arches. The limiting factor inboard is the chassis rail. This may be moved later, but not in the plans at the moment.
The constraint outboard is the shape of the quarter panel above the wheelarch. As the body sinks over the tyres the quarter gets closer to the sidewall.

Saying all that, I can go about 1" wider in towards the rail as long as the outer rim stays where it is.

I'll try and get a photo for you later.

Andy.


I was just curious; no need to go through the trouble of getting pictures. I have to read through this thread to see what wheels and tires you plan on running.


Packman
Posted by: RESlagle

Re: New big ford owner in UK - project resto/lowrider - 12/13/12 04:59 PM

wow I like where this is going. I can't believe I have been a member here for about a year and managed to miss this thread.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/16/12 11:13 AM

onto the other side.
In this shot you can see the edge of the floor and where it has been cut from the rest of the body



Heres a view from above that shows how much of a gap I have got to fill! Its taken from the top downwards if you are trying to figure it out



Heres the first side panel made up to fill that gap and a right angled section spotwelded on for the floor to be welded to





Welded in and thoroughly rustproofed before anything else





Cardboard template made up for next section



Transferred to steel and here is how I put the right angled bends in





Card template made of side section



More soon...........

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/16/12 11:23 AM



New steel cut and shaped and offered for trial fit. Not bad!





Now needs the body mount access hole and rustproofer access holes. Here is the way I get the flares on the corners...with a 3/8" extension bar and a hammer! And some mole wrenches to start the bends off.


Before it gets welded in the whole interior section gets further rustproofing and the new steel gets seam sealed, etch primed and painted white (spare colour left from previous touch ups when the car used to be white!!





Now I've got to wait for the paint and rustproofer to set/go off before welding otherwise it all goes up in flames. Still produces loads of smoke though!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/16/12 11:29 AM

2 random sexy pics of my Lincoln Mark 8 awaiting springtime again! One photo taken at my Mum's house and the other taken at a local supermarket





Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/18/12 03:34 PM

Finally finished welding it in! And loads of rustproofing injected inside.



And onto the front. The firewall to be specific.

Ran a few short welds so far on the passenger side.



Have to be careful here because I am welding galvanised steel and it gives off small quantities of cyanide gas! I'm trying to grind the coating off where I can before welding.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/23/12 12:38 PM

I like this shot. Shows how far the front tyre/wheel goes up on full drop



Another general shot


Heres a view of how far the servo has gone down. It is very close to the brake pipes, but still fits.


The steering column intermediate shaft goes through the firewall 10 cm further down that it used to do and I will have to make it JUST clear the servo and modify the shaft to work.



Andy.
Posted by: pantera77

Re: New big ford owner in UK - project resto/lowrider - 12/23/12 01:02 PM

You can use a 92-02 brake booster if you need the extra room. They are significantly smaller then the 79-91 and are a direct bolt in. Of course I'm not sure how easy it would be for you to get one...

Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/23/12 02:57 PM

Originally Posted By: BigNSlow
I will have to check my parts boxes but I think I have a 92' booster. You can have it for the cost of shipping if interested.


Hi BigNSlow.
That would be fantastic. Can you get me a shipping price?
I'll PM you my address.

Thanks.
Andy.
Posted by: pantera77

Re: New big ford owner in UK - project resto/lowrider - 12/23/12 04:15 PM

My only concern would be if it will hit that upper control arm. I wouldn't think so, but it's hard to tell from the pics.

Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/24/12 07:51 AM

May be a good thing then, because it looks as if BigNSlow can't find it.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/24/12 04:01 PM

New extended "step" made up out of 3mm steel sheet and welded in place.





I will weld the floor back to this.

The weatherstrip will go along there so will have to be shortened. The bottom inside face of the door will have to be reshaped and the door card shortened.

More to come.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/26/12 03:28 PM

Started to close the gap between the rockers and the floorpan on the drivers side.
Hope you all can understand this but here is the gap





Here's a patch welded up to go in that gap













Bending that wavy section took some considerable time!!

I intend to spot weld it to the floor pan and spot weld to the verticals then seam weld across the floor to stiffen it up.

Interestingly, in a few weeks I have to get the body up high off the chassis, wheel the chassis out and work underneath for hours then wheel the chassis back in overnight.
No 2 post ramps here. At the moment I have 3 block and tackle systems ready to go to raise it up but may incorporate other ideas yet.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/26/12 04:41 PM

Firewall tacked together and gaps filled in at the side and just under the servo lower holes. Excuse the rusty appearance, I've not cleaned it up yet!!







Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/27/12 05:11 PM

Only had an hour or so on it today, so decided to have a break from the painful fabrication and welding and do something simple!
Shorten and rebend/reflare the brake pipes at the master cylinder.

Here's an indication of how far the master cylinder has moved down


Completed it an hour later and its back to the fabrication tomorrow.

Andy.
Posted by: Suze91CVLXwag

Re: New big ford owner in UK - project resto/lowrider - 12/29/12 05:42 PM

Hi Andy,

Great work! I am restoring a similar car, a '91 CV LX LTD wagon titanium. 5.0. In 30 years living in California, I've not seen one like mine. I did see a couple of mid 80's CV wagons, but they weren't LXs, and one I know has been junked since then. My beloved wagon was my Dad's. He bought it in New Hampshire in '91, drove it to Seattle. Then I got it in 2000. Just put a new engine in it. And new tranni 5 years ago. Want to drive it forever!

Do you know how to fix the rt front passenger door? It won't open at all. The key turns but nothing happens. The child proof lock is disengaged (broken).

Thanks,

Suzanne,
teacher in San Jose, CA
Posted by: PseudoBoat

Re: New big ford owner in UK - project resto/lowrider - 12/29/12 08:19 PM

Will the door open if you open it from the inside? If not, you are going to have to take off the interior door panel and reach in and figure out which rod to pull to open it.

If you can get the door open, you can pull the entire lock assembly out and fix whatever. Gotta get it open first though.

If it won't open, start disassembling the arm rest, and then stick your fingers underneath the door panel and just pull it off.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/30/12 10:42 AM

Originally Posted By: Suze91CVLXwag
Hi Andy,

Great work! I am restoring a similar car, a '91 CV LX LTD wagon titanium. 5.0. In 30 years living in California, I've not seen one like mine. I did see a couple of mid 80's CV wagons, but they weren't LXs, and one I know has been junked since then. My beloved wagon was my Dad's. He bought it in New Hampshire in '91, drove it to Seattle. Then I got it in 2000. Just put a new engine in it. And new tranni 5 years ago. Want to drive it forever!

Do you know how to fix the rt front passenger door? It won't open at all. The key turns but nothing happens. The child proof lock is disengaged (broken).

Thanks,

Suzanne,
teacher in San Jose, CA


Hi Suzanne.
Got any photos of your car?

Heres a photo of the rods inside



If you can get the door panel off as pseudoboat says or can get a thin metal rod down the glass it may give you a clue where to pull/push/lever.

Good luck with this.
Andy.

PS A teacher as well as me eh?!! Nice one.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 12/31/12 02:33 PM

Heres the 3 mm thick steel plate cut out



to fit here



No plasma cutters or any other fancy profile machine! Just an angle grinder, air saw and die grinder! Took about 2 hours!

Heres a shot of the floor finally welded back to the floorpan.





Wishing all of you who are following this a very happy and prosperous new year..........hoping in 12 months time this project will be somewhere near finished!!

Andy.

PS I'll be back on it on new years day!!
Posted by: Packman

Re: New big ford owner in UK - project resto/lowrider - 12/31/12 03:53 PM

No rest for the wicked I guess laugh


Packman
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/03/13 04:39 PM

While I am welding on the passenger side I spotted the fuel filter bracket bolted to the frame. It was the only bit I didn't have blasted and powdercoated. So off it comes and here it is





Just a little bit rusty then! So it goes into my acid tank for a few days and I will then weld it up

New rocker extension welded in where the rear door is



Now I will have to fill in this gap





Heres the next gap to fill in



Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 01/04/13 03:12 AM

I was wondering how the door frame bottoms were going to work out. Now I see. Are you planning to eliminate the door seals along the bottom or reconfigure them? I wonder if you can find a plastic vinyl fabricator to make a cover trim for the rocker extensions? Or would that just cover your beautiful metal workmanship?
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 01/04/13 03:12 AM

I was wondering how the door frame bottoms were going to work out. Now I see. Are you planning to eliminate the door seals along the bottom or reconfigure them? I wonder if you can find a plastic vinyl fabricator to make a cover trim for the rocker extensions? Or would that just cover your beautiful metal workmanship?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/04/13 05:38 PM

Originally Posted By: enslow
I was wondering how the door frame bottoms were going to work out. Now I see. Are you planning to eliminate the door seals along the bottom or reconfigure them? I wonder if you can find a plastic vinyl fabricator to make a cover trim for the rocker extensions? Or would that just cover your beautiful metal workmanship?


Hi enslow.
I am keeping the weatherstripping at the bottom of the door, but I will have to reshape the door slightly to seal against the new higher position of the seal.

Don't know yet how the step will be covered. Depends how close to the door bottom it is. Cant check the clearance yet because the doors are buried deep in my shed!! I'd like it painted the same colur of the car, but time will tell.

To be honest, I'm almost making the build up as I go along! Not sure how things will fit until I've tried them.

I'll post up all details as they emerge and evolve.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/06/13 03:57 PM

Decided to fillet weld the floor back to the rockers this time.







Right at the front is a bit awkward.



So I made this panel



to go here.



then welded up and panel adhesive where I cant get to weld



Onto rear wheel arches next! Oh and my engine is ready to pick up! Fully rebuilt.

Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 01/07/13 11:15 AM

Originally Posted By: andyfanshawe
Oh and my engine is ready to pick up! Fully rebuilt.


Nice.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/08/13 04:43 PM

My garage is quite small and I have absolutely no space left to put my new engine on a stand let alone paint it! This is the space at the back



and the front rails of the car is up against the roller door at the front!

So where the heck do I put the engine so I can paint it?

Then I had an idea! Put the engines stand in the engine bay. Will it fit? Have a look





I know it will be a PITA to get round it but it is possible. After painting it I will hoist it off the stand and bolt it back into place and assemble the engine in situ (the block already has the bottom end in, its just minus the heads and everything else!)

This may work!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/12/13 05:09 PM

Engine pickup day! And cylinder head drop off at the same time.

Here's the plastic wrapped thing in the back of our Chrysler Grand Voyager



and the crane ready to pick it out



Here's sneaky peek at the top of one of the pistons





and onto the engine stand!



I've had a standard rebuild but with the exception of higher compression pistons to make it slightly more "peppy!" but without causing any pinging with our fuel.

Painting it next and then assemble time, once the heads have had their 3 angle valve job etc. Nothing fancy but more modern!! My performance engines disappeared with my youth! Now its slow and low.

Andy.
Posted by: Monster_Addict

Re: New big ford owner in UK - project resto/lowrider - 01/13/13 04:33 AM

Hello mr Andy, i found this thread today and im amazed in your motivation and energy that goes in to your wagon, i can imagine ur finished wagon with the help of your sketch and it belongs in car shows everywhere, i would like to suggest some projectors for your wagon i have some and they are good but i think it would be nice to install HID's(assuming that is legal to have HID's in UK)i have a pair in my 83 ltd.

Greetings from Houston TX
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 01/13/13 01:44 PM

Some people leave the plastic on new car seats. Andy leaves plastic on new engines! (Sorry, couldn't resist)

Are all your UK fuels ethanol laced like ours in Canada? I've discovered the 76 in the USA has ethanol free regular.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/13/13 02:38 PM

Originally Posted By: enslow
Some people leave the plastic on new car seats. Andy leaves plastic on new engines! (Sorry, couldn't resist)

Are all your UK fuels ethanol laced like ours in Canada? I've discovered the 76 in the USA has ethanol free regular.


Hi enslow.
As far as I am aware, we have 5%, but apparently our government wants to go to 10% eventually.

Don't know the consequences though!

Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 01/13/13 09:28 PM

Worse fuel mileage in carbureted vehicles.
And fuel separation for things that sit long periods of time.

Enslow, Shell premium fuel does not have ethanol in it here in Ontario.

Back on topic: She is coming along nicely Andy. But I have a bad feeling about the engine stand in the engine bay...

Alex.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 01/14/13 09:58 AM

GM Guy is right that many premium fuels have no ethanol. I just don't want to run premium. Because of the added oxygen, ethanol will cause engines to run leaner, thus less efficient but cleaner. It seems you're going to run a higher compression, so you may want to run premium.

Is that panel adhesive a good option for those who can't weld? I don't think I'd want to use it alone for anything structural. You've got at least some of it welded, and it looks like it was a piece to fill a gap.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/14/13 04:11 PM

Originally Posted By: GM_Guy
Back on topic: She is coming along nicely Andy. But I have a bad feeling about the engine stand in the engine bay...

Alex.


Only going to paint the block, paint the oil pan, install timing chain cover, install both and lower into its home! So wont be there for long.
And....nowhere else to put it!
Agree its not ideal, but needs must!

Andy.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/14/13 04:19 PM

Originally Posted By: enslow

Is that panel adhesive a good option for those who can't weld? I don't think I'd want to use it alone for anything structural. You've got at least some of it welded, and it looks like it was a piece to fill a gap.


I only use it on non stressed items, but it is damn good! I don't know about "some of it being welded"! All I seem to be doing is welding the damn thing up!!
MIG welding isn't that difficult enslow. Would only take you a short time to get the hang of it.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/21/13 04:34 PM

Had a bit of a break from the continuous welding and fabrication!......

But, back we are!

Here's the back passenger side rear wheel inner arch tacked back in 10 cm higher and slightly recurved tighter




This means that the back seat upper cushion will probably not clip into the catch, so that will need repositioning slightly.

Because its double curved, I filled up the hole with a few panels, not just one



We had a bit of snow today, enough to close most schools so I had a day off!







Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 01/21/13 05:26 PM

You seem to have had more snow than us so far this year!

Alex.
Posted by: Monster_Addict

Re: New big ford owner in UK - project resto/lowrider - 01/21/13 11:35 PM

I wish more teachers were like u andy
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 01/22/13 08:39 AM

Looking good.
Posted by: 81ltdcrownvic

Re: New big ford owner in UK - project resto/lowrider - 01/23/13 11:02 PM

Originally Posted By: Monster_Addict
I wish more teachers were like u andy


There are shortbus Special ed teacher as a matter of fact.

Andy, from one teach to another, outstanding job sir!!! I've been popping in from time to time checking on the progress. Love how your "raising the floor" to accommodate for lowering. I'm looking forward to her done. I wish I could come over there and give you a hand. Some day I'll have to come to the other side of the pond to take a look at everything you've done. -Big John
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/26/13 08:56 AM

Originally Posted By: 81ltdcrownvic
Originally Posted By: Monster_Addict
I wish more teachers were like u andy


There are shortbus Special ed teacher as a matter of fact.

Andy, from one teach to another, outstanding job sir!!! I've been popping in from time to time checking on the progress. Love how your "raising the floor" to accommodate for lowering. I'm looking forward to her done. I wish I could come over there and give you a hand. Some day I'll have to come to the other side of the pond to take a look at everything you've done. -Big John


You would be made very welcome!!
Thanks for looking in!

Andy
PS Who will get the millionth view?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/26/13 03:00 PM

Forgot about my fuel filter bracket in my acid bath!

This is what it looked like before



And this is how it came out





I'll weld that up the next few days, while the "welding the floor back to the bodyshell" continues into, what seems like its millionth hour...................

Andy.
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 01/27/13 12:07 AM

i am always amazed how well that rust remover works
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/27/13 03:25 PM

Over to rear drivers side wheelarch. Here we are tacking it all back together







Andy.
Posted by: Monster_Addict

Re: New big ford owner in UK - project resto/lowrider - 01/29/13 02:19 AM

wow u hit 1,000,000 views
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 01/29/13 04:08 PM

Originally Posted By: Monster_Addict
wow u hit 1,000,000 views


Wow! Have people got nothing better to do than watch me work wink

Hope I can take the pressure! Hope you all keep watching...............

Closed off part of the inner wheelarch.





Getting close to body off time. Just some finish welding to do. And engine block to paint and install and we are up and away.

Andy.
Posted by: Monster_Addict

Re: New big ford owner in UK - project resto/lowrider - 01/30/13 01:27 AM

I guess you are doing something some people cant do or would like to do in the future
Posted by: Bondfreak13

Re: New big ford owner in UK - project resto/lowrider - 01/30/13 11:52 AM

Originally Posted By: Monster_Addict
I guess you are doing something some people cant do or would like to do in the future


I just love the fact that a Brit is taking a an american land yacht and making it a custom low rider to cruise around the streets of the UK with. And best part about it is he can take 6 of his friends with him.
Posted by: Monster_Addict

Re: New big ford owner in UK - project resto/lowrider - 01/30/13 03:32 PM

Originally Posted By: Bondfreak13
Originally Posted By: Monster_Addict
I guess you are doing something some people cant do or would like to do in the future


I just love the fact that a Brit is taking a an american land yacht and making it a custom low rider to cruise around the streets of the UK with. And best part about it is he can take 6 of his friends with him.


And then some in the back lol
Posted by: SHOdude

Re: New big ford owner in UK - project resto/lowrider - 01/31/13 03:21 PM

I just spent the past few hours reading this entire thread, and the only thing I have to say is bravo. To me, this is the car related version of the Chroinicles of Bruiser. We laughed, we cried, we cringed, we raised eyebrows in disbelief, and we are utterly entranced. God Bless You for bringing this little slice of joy.into our lives, even if from afar.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/01/13 11:42 AM

Originally Posted By: SHOdude
I just spent the past few hours reading this entire thread, and the only thing I have to say is bravo. To me, this is the car related version of the Chroinicles of Bruiser. We laughed, we cried, we cringed, we raised eyebrows in disbelief, and we are utterly entranced. God Bless You for bringing this little slice of joy.into our lives, even if from afar.


Hi SHOdude.
Thank you for your comments.
Makes it very worthwhile for me.
Certainly a roller coaster of emotions on this end!!
There's still a small chance I will hit major problems and sell it as an abandoned project!! But, loads more fun to come as I weld up underneath (minor stuff) with the body off the chassis and try and get things to fit. Important things like pedals, and throttle linkages and interior trim, and cutting another hole in the floor so I can get my feet lower! Silly little things like that............

Stay tuned and looking forward to seeing some colour on it this summer.

Andy.
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 02/01/13 09:42 PM

i have been watching this for about a year now and you have come such a long ways it would be a shame if you would quit now. This car is amazing keep up the good work
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowri - 02/02/13 12:25 PM

Originally Posted By: andyfanshawe

Wow! Have people got nothing better to do than watch me work wink



Considering you are the only one who is actually working on a cvgm, yes. =-)

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/05/13 03:57 PM

No quitting here I can tell ya!

Heads rebuilt - phosphor bronze valve guides, 3 angle valve seats..



Taperd plug fitted to seal off unwanted passages



Etch primer



and bright red!



Onto the engine-bored 40 thou over







Oil pan and timing chain cover next.

Andy.
Posted by: ChromeDaddyO

Re: New big ford owner in UK - project resto/lowri - 02/05/13 04:23 PM

Andy, as always you continue to inspire me to go out in the cold garage and build stuff! Thank you! grin
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/08/13 04:20 PM

Originally Posted By: ChromeDaddyO
Andy, as always you continue to inspire me to go out in the cold garage and build stuff! Thank you! grin


My pleasure! Plenty more cold garage visits to go.........

Spent too many hours prepping and painting engine parts..

Oil pan...



Timing chain cover



Water pump etch primed



and painted red



This weekend its back to the welding!! I'll see if the back seat will fit and if my head catches the roof! As if I'll be sitting there anyway.....

I know for certain the back seat rear squab wont latch because they are in the wrong place!

Oh, and the throttle pedal welded back in its new place would be a good idea...

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/10/13 11:09 AM

Finish welded the rear wheel arches and trial fitted the seats



The stop on the drivers side was slightly out so just needed pushing over slightly (you may be able to tell)



Slightly out of line on the passenger side



So off it comes





And in its new position

Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/13/13 04:31 PM

Ok. Confession time!
Tried to fit brake pedal box but it wouldn't fit. I welded the firewall up without bolting it up to check! Yeah, I know.........should have known better.

So, had to cut across my welds and pull the firewall out at the bottom a bit




Then making sure the pedal box is in, cut out the plates I so lovingly welded in before (serves me right).



Pedal box in as first plate is welded in





Oh dear!!! Soon be back though!

I've also just got my block and tackle pulleys to hoist the body off the frame very very soon!!



Andy.
Posted by: Monster_Addict

Re: New big ford owner in UK - project resto/lowri - 02/13/13 05:21 PM

Keep up the good work!
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/15/13 04:29 PM

Swore at the car a lot today............
Posted by: enslow

Re: New big ford owner in UK - project resto/lowri - 02/16/13 12:23 AM

Originally Posted By: andyfanshawe
Swore at the car a lot today............


Glad I'm not the only one....
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/17/13 02:41 PM

Fitted timing chain cover, water pump, oil pan and crank pulley and harmonic balancer.
Why has the water pump got to be such a PITA thing to fit?
Small block chevys are a damn site easier!!





Fitted my block and tackle in the roof and took the strain!



Intentions are to pull the engine off the stand, fit the flex plate and install the engine. Then hoist the body off the frame, wheel out the chassis and finish weld underneath. Then paint entire underside and bolt back permanently to the frame.

Then its painting green time!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/18/13 03:19 PM

Isn't it just typical...... when you want some help to do a quick car job, everybody disappears. Especially when it involves a bit of work-like helping to put an engine in.

So on my own it is.........

After a short time it was in. No swearing, cussing or anything like that. Just a smug smugness!!





Tomorrow its starting to hook things up like trans shifter cable, heater, vacuum lines etc. But I can't hook the throttle up until the heads and plenum are on and I haven't got the head bolts till about Wednesday.

In the meantime, 2 more block and tackle pulleys to go up in prep for lifting the body off the chassis.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/21/13 01:52 PM

Time to fabricate all the simple things on the firewall now. Starting with the hole for the Trans shifter cable and ECU slot.





After hours of messing about, this is what we have ended up with





Now at least I can refit the ECU bracket and shifter cable.

Now onto the parking brake. The hole where the cable goes through has moved up 10 cm so will no longer be any good - although I could cut up the bracket and relocate the cable.





and relocated about here



I'll post a photo of the finished product later on.

In the meantime, the pedal is too long!

Needs this much cutting off



And rejoined but had to be flared to match the contours



The almost finished product



Heater box next.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowri - 02/21/13 02:12 PM

Just spotted that I have lost my hood release cable hole! Here it is/was from an old photo



Put it on my list! I've got a big list.

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/25/13 04:13 PM

Remember this rusty thing?


That was acid dipped to look like this?


Well I welded it up and painted it. Now it looks like this




Funny how the simple little things like this are really pleasing!

Onto my hood release cable. Not to make it too simple, I drilled the right size hole through, then enlarged the sheet steel on the outside of the firewall to smoothly join with the emergency brake cable slotted hole!



From the inside



Heater box next!
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 02/28/13 03:29 PM

Had an optimistic completely mad thought that the heater box would just about fit! Never know, just MIGHT......

Well, did it fit? Err,......no. Not a piggin' chance. Why did I even think it might?

More photos to come-as if anyone else will do something as stupid as this! rant

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/04/13 04:10 PM

Bolted the heads down on the block so I can start to see where various things need to go! Photos soon.

Meanwhile for a break from the metal fabrication, its seeing if I can get the heater to fit time!

First the "air inlet assembly ducting" as its called in the shop manual.
This thing


Here's a temporary fit and you can see where the bottom of it is touching the firewall before it sits flush



So I need to cut the bottom off so it has a chance of sitting flush.

Here's the cut line planned to completely flatten the bottom





Here's my airsaw in action


Here's the bottom cut off flat



And a side view looking across the bottom showing the flat profile



I'll make a new base and bond it in, then produce a water drain hole.
Then its onto the other heater boxes...
Andy.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 03/04/13 09:17 PM

I'd completely forgot about the heater box.

You might want to think about how you might/could make the heater core accessable when you have the car complete without having to remove the entire dash to get to it. (a stock vehicle has barely enough room to "roll" the plenum out from under the (loosened) dash.

Alex.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/09/13 04:53 PM

Hi Alex.
I'll bear that in mind and see what I can do.

Been assembling the engine so I can trial fit the throttle linkage etc.





Back onto the heater box. Fabbed a closing off plate for the base and a water drain hole. Now its completely flat on the bottom and actually fits the firewall now!







and a view to the inside



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/09/13 05:19 PM

Onto the A/C fan heater box that goes on the firewall under the hood.

I don't need the AC matrix now so I split the box open to remove it





The other side of the matrix (fan side) was filthy and partially blocked with debris



And here's some more debris in the case



What I intend do here is cut the box diagonally with a saw to remove the bulk and close it off with a steel plate and incorporate an oil pressure gauge in it perhaps! To show everyone what I mean, this is the exact thing I did when I built my 77 Trans Am back in the early 90's



Here's my saw in action







A trial fit and the base is touching the frame (just) so tomorrow I'll remove the bottom "bulge".



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/11/13 05:09 PM

Had to shorten the height of the box and then plastic weld a bit of it back together. Hopefully the pics will tell the story.





Steel closing off plate bonded in to the base and left to set.



Still got a flange to weld on and a corner to cut, but not far off finishing this bit now.

The main heater box that contains the heater core nearly fits!!! But it may as well be miles off.

Finally got the inlet manifold on and the fan and alternator, but it looks too tall to me! I will relocate the alternator down low on the other side and most likely use an electric fan.





Has anyone got one of PCM's these lying around? Need a spare just in case!



Andy.
Posted by: Monster_Addict

Re: New big ford owner in UK - project resto/lowrider - 03/11/13 07:56 PM

I have that PCM laying around but sadly its for CFI not SEFI(MPI).
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 03/14/13 11:12 PM

I hadn't thought about hood clearance. Will you have to notch the hood?
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/15/13 01:05 PM

Originally Posted By: enslow
I hadn't thought about hood clearance. Will you have to notch the hood?


Hi enslow.
Homemade cowl induction hood.
This will answer your question better!


Andy.
Posted by: Packman

Re: New big ford owner in UK - project resto/lowrider - 03/15/13 02:02 PM

Hopefully you start this before I begin my hood scoop project. I will be completely on my own when I do this in a couple months. I figure that I will be using a lot of epoxy.


Packman
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/15/13 06:37 PM

Originally Posted By: Packman
Hopefully you start this before I begin my hood scoop project. I will be completely on my own when I do this in a couple months. I figure that I will be using a lot of epoxy.


Packman


Hi packman.
Why a lot of epoxy? What are your plans?

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/17/13 06:27 PM

Onto the inside heater box where the core is located. As you might expect. it doesn't fit, but its not far off.
But this time I can't shave the box down because the flaps are too close to the outside of the casing, so there's no choice but to modify the firewall and trans tunnel.

Got to be careful I don't get too close to the top of the transmission if I ever have to pull the engine again!

Here's the largish hole!



I'll weld it up when I hoist the body off the chassis in a few weeks.

Here's a fabbed bracket bonded to the underside of the air recirculation box to secure the heater boxes together through the firewall (just to the left of the drain hole).



Fitted the plenum to the motor today, but the throttle cable was slightly too tight, so I spaced the bracket off the plenum about 10 mm.



I'll see how that works out with the engine flexing about.

Andy.
Posted by: Packman

Re: New big ford owner in UK - project resto/lowrider - 03/18/13 09:23 AM

Originally Posted By: andyfanshawe
Hi packman.
Why a lot of epoxy? What are your plans?

Andy.



I am planning on a 351W build with aftermarket EFI (Trick Flow) intake. Since these cars didn't come with EFI on a 351W (all carb'd) I would imagine that I will need a hood scoop. I bought a fiberglass Thunderbolt scoop, but it doesn't have any mounting flanges that point inward. So, my only guess is that I will be using quite a bit of Epoxy to get that thing stuck to the hood.


Packman
Posted by: KEEPINITOLDSKOOL

Re: New big ford owner in UK - project resto/lowrider - 03/22/13 09:58 AM

oh no! I've reached the end! What will I do with myself now?

You have an impressive build going on!
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 03/26/13 02:34 PM

Originally Posted By: KEEPINITOLDSKOOL
oh no! I've reached the end! What will I do with myself now?


Check for updates every day like I do? grin
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/26/13 02:51 PM

Sorry guys!
More coming soon.
Trapped a nerve in my back (old age and crap posture!) but still mobile and got a week off next week, so more to come.
Just shortening pedals now and body should be off chassis for final welding underneath and prepping for paint.

Photos shortly.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 03/28/13 05:52 PM

Right its shortening pedals time.

Here's the full length gas pedal



and here's the pedal shortened awaiting finishing and final welding



And bolted back into its new welded in mounting place



Now the brake pedal wants shortening

Here's a section cutout awaiting welding back together



and fully welded with the missing bit looking on!



Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/08/13 02:37 PM

Don't know whats more painful, having a nerve trapped in your back with the inevitable red hot daggers down my right leg all day, or trying to get this damn car to work again!

Anyway, back to the heater. Last job to do is the shrinking down of the lower centre air vent that directs air over the trans tunnel and down to the footwells.

This is how big it was in height



and this is the new lower profile design







Now thats finally done, its refitting dash (joy) and steering column and see if I can get the column to connect up to the steering box!



And servo removed to get access for cutting and welding.
Here's the firewall cut out a bit more and ready to tack in position. The UJ misses the bottom of the servo by about 10mm! But it works and it steers!



Finish weld that up, strip it all out again and its hoisting up off the chassis for its final welding and painting underneath.

May even get this to the paint shop this year!!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/12/13 05:57 PM

Last few jobs before body is hoisted off the chassis (again!)

Final welded up the steering column mount through the firewall



Had a trial fit of the wiper motor but it doesn't fit!! Touches the rocker cover and throttle cable and TV cable are in the sweep



So I will fit a kit car type one in this space



All welding completed on the firewall inside



Now its welding up a framework to support the rear of the car when I use 2 hoists





More tomorrow.
Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/14/13 09:46 PM

2 brackets welded up to help lift the rear of the car







Andy.
Posted by: Monster_Addict

Re: New big ford owner in UK - project resto/lowrider - 04/14/13 10:49 PM

nice u have my SUPPORT
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 04/24/13 12:38 PM

Not been on for a bit. Can't believe how painful a nreve trapped in the back is! But it doesn't hurt there, oh no, just down my right leg.
Anyway, doesn't appear to be getting any better so while I wait for an mri scan on monday (cant wait) I'm going to get on with it.

Bet you can't tell what I've done here!










Andy.
Posted by: enslow

Re: New big ford owner in UK - project resto/lowrider - 04/27/13 03:12 PM

It may be a good idea to consider installing an oil separator between the PCV and intake. If your PCV is at the back of the engine like it was on my Dad's 87 it will be much easier to do this before the body is dropped onto the frame.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/06/13 01:40 AM

Got to apologise to you guys - been diagnosed with a herniated disc in my back, so I have had to take it slow and steady, but I'm still going!

Working underneath the body for a few weeks now, so I have designed and built a custom car creeper to get me higher up. Photos tomorrow.

Got to start blocking holes up and reinforce areas under the floor where it has moved up 10cm.

First one here






and another one







Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/06/13 02:04 AM

I bought a 1991 camaro in 2001 for about $400 that was wrecked and had a lot of fun ressurecting it but sold it in 2005 for the wrong reasons, (Nearly got involved in a major highway crash that I thought I caused (turned out I didn't) that put me off and scared me to death).
Anyway it went to its caring new owner and I've got the chance to buy it back







Click here for the story

http://andyfanshawe.freewebspace.com/rscamaro.html

May cause a divorce and the slowing down of this project, but its loads of fun!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 05/14/13 07:04 AM

Hi all.
Just to keep you informed that progress is nil due to my prolapsed disc not really improving and waiting for physio to start to give me a chance.
I've been signed off work for 2 weeks but can't do much obviously.

My only chnace of completing the underside work on this car is to design and make a rotisserie that is attached to the ceiling joists and not the floor. In fact, there is so much to do under there, I don't think I would be happy doing it even in my 20's or 30's anyway!!

So, design is under way and I will post up pictures as it progresses. Be warned though, this will be sloooow 'cos my back and leg hurts! I've not actually sat down for 8 weeks now - cos I can't! Driving is darn near impossible.

Keep you all informed.
Andy.
Posted by: ChromeDaddyO

Re: New big ford owner in UK - project resto/lowrider - 05/14/13 07:22 AM

Get well soon Andy. I've been lucky, but I have some friends with recurring back problems and it seems terrible, in particular if you like wrenching or DIY. Make sure you let it get better! We all need to see this car get finished.
Posted by: GM_Guy

Re: New big ford owner in UK - project resto/lowrider - 05/14/13 08:57 PM

Hope you get to feeling better soon.

Alex.
Posted by: Monster_Addict

Re: New big ford owner in UK - project resto/lowrider - 05/16/13 04:04 PM

YOU sir need a helper while you rest.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/08/13 03:48 PM

Okay, I'm back. Well sort of!
My prolapsed disc is improving but I am still having to take it steady. Lost confidence I think they call it.

Anyway, onwards with the engine fire up wiring and plumbing etc.

Bought a new coil and redesigned the mount and placed it here





Front rad panel replaced temporarily



Oh, forgot. Stripped and repainted the valve covers, even going to the extent of cutting out and rewelding in the internal baffle to make sure all the old oily residue/carbon is removed







I am going to temporarily fit these horrible things





and try to fit the fuel tank on the frame to enable the fire up.

I'll struggle along the best I can but without compromising my improving back.
Keep you all informed guys.
Andy.
Posted by: LysanderMB

Re: New big ford owner in UK - project resto/lowrider - 06/09/13 08:41 AM

So glad to see you back! I've been following this thread since it started and continue to be amazed at the quality of your work. However long you take I'll keep checking in until you finish the car....
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/13/13 12:17 PM

Originally Posted By: LysanderMB
So glad to see you back! I've been following this thread since it started and continue to be amazed at the quality of your work. However long you take I'll keep checking in until you finish the car....


Thanks for your kind words! Much appreciated and very encouraging.


[yt]http://www.youtube.com/edit?video_id=fETZ_OqDXWM&video_referrer=watch&ns=1[/yt]

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/13/13 04:29 PM

Oops! May be a bad link!

Try this
http://youtu.be/fETZ_OqDXWM

Andy.
Posted by: Monster_Addict

Re: New big ford owner in UK - project resto/lowrider - 06/13/13 05:15 PM

NICE!
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 06/14/13 06:07 PM

lol
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/24/13 02:50 PM

I'm Back!!
Didn't think i would recover from that back injury. Took 3 months but I'm 90% there. So, its back to work on the lowrider wagon.

Here's the back of the dash stripped of wiring because its not going back in, and I want to wire the engine to start for the very first time after an extensive rebuild!





Here's the engine all wired up with the harness going into the car through the heavily modified firewall



Here's my instrument panel



and my ignition switch!



So, tonight after more than 2 years and a full engine rebuild, blood, sweat and tears, I went for the start........And it fired first time!!! Sounds fantastic. Forgot how that V8 burbled away to itself. I know its only a 302, but its MY 302 and it works!

Timing adjusted and its as smooth as a babies bum!

Now, inbetween waiting for my back to recover, and needing a fix (and a possible profit) I bought these 2 foird fiesta zetec s cars





The first is heavily modified and may sell on for a small profit. The second is a reshelled write off that I will use as my everyday car.

Yeah, I know, the first one is a bit fast and furious for a 52 year old but I don't care!!

Andy.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/24/13 11:56 PM


Anyway, more interesting news. I have decided that after 30 years of teaching teenagers, enough is enough. So I'm going to open up my own shop where I can build my wagon in peace (with 2 post ramps etc) and do custom work for anyone interested. So, exciting times. May take a year or so to get up and running but I can keep teaching during that time.

Andy.
Posted by: Jeff2

Re: New big ford owner in UK - project resto/lowrider - 06/25/13 08:41 AM

Glad to year you're doing better!
Posted by: Packman

Re: New big ford owner in UK - project resto/lowrider - 06/25/13 10:14 AM

Good to hear you're back in the game. Also, congrats to a shift in career. I would imagine that the wagon and Camaro (perhaps if you Fast&Furious your daily driver Ford) should attract some business; especially if you show potential customers how much work went into them. I will wish you good luck, but I don't think you need it.


Packman
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 06/25/13 03:09 PM

Thanks guys! Really excited to do this. But 1 step at a time.

Now the 302 is running, its time to scope some components as an intervention method to reduce the chance of a breakdown in future.

Here's the fuel pump waveform when running



And, I don't like this at all.
Current is only about 3 amps or less, but the overall shape is good, with no commutator segment drop-outs. If I'm not mistaken, it should be between 6 and 8 amps, but I will have to confirm.
But, I have no record of it ever been changed, and the wagon has done about 241 000 miles,so it damn well deserves a new one!

Here's the voltage waveform for injector number 5



Shows a good injector turn on and I can plainly see the injector pintle closing (the hump on the downward slope). So the driver in the ECU looks good and the injector itself also. Peak voltage is about 35V which is perfect. Then it ran out of fuel! Better get used to that.

So, next job is to disconnect the wires again in to the shell and build the rotisserie so I can tip it on its side and finish the welding underneath. Then its a good coat of paint on the underside and back on the frame it goes. And its then going back together!!
Luckily my new shop is right next door to the chap who is going to paint it for me!!

More exciting times!

Andy.
Posted by: AceVI

Re: New big ford owner in UK - project resto/lowrider - 07/28/13 01:17 AM

More exciting times indeed Andy!

As you stated might as well do some replacing right now that the hard to reach stuff is easily accessible.
Posted by: Yoder

Re: New big ford owner in UK - project resto/lowrider - 07/28/13 11:36 PM

Glad to hear about your decision to open your own shop. I think you'll be overrun with work,especially with your quality. I just wish you were considering a move to the southern part of the U.S.A as well.
Posted by: FiberGlass Master

Re: New big ford owner in UK - project resto/lowrider - 08/19/13 02:47 AM

Holy Crap....this is a great thread. So much detail.

I will feel sad when it's finished.
Posted by: andyfanshawe

Re: New big ford owner in UK - project resto/lowrider - 08/24/13 04:20 PM

Not been here for a long time! Been building 2 other cars in the meantime, while the wagon waits!..

Now they are just about done, I have spent a few hours in the garage welding up a rotisserie that is suspended from the roof.

And here it is




and a view of the scaffolding pole that goes through the car!



I have a week and a half before I am back at work to roll the chassis out, pivot the car at 90 degrees, Finish weld the underside and paint it green. Then its back on the chassis and off it goes down to my new workshop onto my 2 post ramp (posh eh?).
Then perhaps it will get finished for next summer.

Andy.
Posted by: QuicksterP71

Re: New big ford owner in UK - project resto/lowrider - 08/25/13 05:09 PM

AMAZING !!!!!!
Posted by: