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1/25/2016 6:54 PM  #1


Project Deadhorse....

After nearly a seven year wait, I’m finally able to return to working on my coupe.  During that time, I was able to acquire nearly all the parts needed to finish this project and get her back on the road so, now it’s time to get to wrenching.

First up, is completing the body work.  Three major pieces to replace then the coupe with be solid. Those three pieces are both full quarters and the complete cowl assembly.

I’d already taken care of the floor pans and battery tray area with new panels.
Completely stripped the underside to bare metal and painted it.  Installed new brake lines, front Cobra disk brakes, front suspension, rear suspension, freshened up the 8” rear-end.   Glen rebuilt my T-5 and MS took care of the pedal support along with the clutch cable kit......

Today, I hung the passenger door.......third time was a charm I guess.  Went through 3 doors before finally getting one that would align the way I wanted it to.  Tomorrow, it’s time to cut out the passenger quarter panel and, “Get er done”!!

One thing I discovered in prepping for this was the passenger quarter panel was previously replaced.  Not sure when that took place but, they did use an OEM Ford red oxide primer quarter panel.  Shining my light inside the truck, I can read the yellow stenciled part number.  Whomever did the install, utilized some old school brazing to finish the job.  Take a look at the brazing job in the attached pics.  Note also the numerous small holes where the used sheet metal screws to hold the panel in place.......the seams, and the screw holes, where then covered with a thin layer of bondo...

That’s enough typing for now. My plan is to fire up the camera and keep a photo record of my work. I’ll post additional updates here as I go along........

http://i66.tinypic.com/2pzkz9e.jpg
http://i63.tinypic.com/2ln7rwp.jpg
http://i64.tinypic.com/2wgr68n.jpg
fhttp://i68.tinypic.com/25gumbo.jpg
http://i67.tinypic.com/swr85i.jpg
http://i67.tinypic.com/2nso0zs.jpg
http://i66.tinypic.com/imqfpc.jpg



 


.......common sense is a flower that doesn’t grow in everyone’s garden.......
 

1/26/2016 11:37 AM  #2


Re: Project Deadhorse....

Josh, glad to see you are getting to work on the car. Keep the pictures coming.


John  -- 67 Mustang Coupe 390 5 speed
 

1/26/2016 6:28 PM  #3


Re: Project Deadhorse....

Sounds like fun Josh!

 

1/26/2016 10:41 PM  #4


Re: Project Deadhorse....

Sooooooooooo you're gonna be doing the same stuff as Hakan,huh?! Cool...can't wait!!
 maybe Sal and  my "lover" will come and help!  Like ya'll did fer me!!
THAT will be "funner'n crap"!!
6s6


"Get busy liv'in............or get busy die'n!!"
 

1/27/2016 5:23 PM  #5


Re: Project Deadhorse....

Work continued on Tuesday.  Broke out the plethora of HB air tools and dug in.  After drilling out spot welds and running the air grinder, I managed to remove a large portion of the quarter.  I left about a 2 inch strip around the wheel well......the HB metal shears cut through that like butter.  I'll clean up that section tomorrow..One other thing: This is a full quarter replacement so, I fired up the propane torch and melted 50 year old lead from the sail panel seam......may recast that into split shots and fill up my tackle box.  Anyway, took about four hours of careful work and “out with the old” as they say.   Here’s a picture of the carnage and the “naked” quarter section.  http://i66.tinypic.com/2yxenmt.jpg
http://i67.tinypic.com/14wbcz.jpg
http://i66.tinypic.com/iqvd08.jpg

Last edited by josh-kebob (1/27/2016 5:44 PM)


.......common sense is a flower that doesn’t grow in everyone’s garden.......
     Thread Starter
 

1/27/2016 5:41 PM  #6


Re: Project Deadhorse....

Today, I managed to remove the remaining old wheel opening sheet metal......wasn’t terribly difficult.  No pics but, I used a twisted wire wheel brush on my grinder and cleaned all the surface rust on all the weldable seems and tabs then decided that “while I was at it” I cleaned virtually all the newly exposed structure.  Kinda held my breath with respect to the wheel house area. Fortunately, I only have about a 3 inch section on the outer rear wheel house bottom corner to deal with.  I’m  planning to sacrifice a dynacorn panel and section in what I need.  
After everything was wire brushed I ground down any spot weld humps or other slag until all surfaces were smooth.  At that point, I decided to hang the new quarter and I’ve included a pic of what it look likes.  This quarter, is a Ford panel and I was very please with not only how it fit but, how everything lined up. The picture shows it only “snapped” in place......no clamps or tack welds used.  

http://i66.tinypic.com/xc3z4p.jpg
Cleaned up the shop and called it a day.....other items on the honey do list were calling my name.
Tomorrow, I plan to prep the inner metal and rehab the quarter window mechanism so everything will operate smoothly.  Then I’ll start prepping panel for welding....
Needless to say, I’m having fun as I make progress on this much awaited project.   In the near future, I’ll probably post the history of this coupe and how the evil, evil, Mrs JKB got involved with it........

 

Last edited by josh-kebob (1/28/2016 4:48 PM)


.......common sense is a flower that doesn’t grow in everyone’s garden.......
     Thread Starter
 

1/29/2016 6:14 PM  #7


Re: Project Deadhorse....

Thanks to an ungrateful new quarter panel, had to take the day off.  Sliced the fire out of my finger, right in the  bend of the first joint.  Couldn’t get it to stop bleeding for most of the day...

I’ll tell you this much, if you spouse seems eager to treat a cut with “new skin”, my advice is you run away like you’ve never run before.  That crap burns like fire.................and my spouse laughed like crazy....

Hopefully more progress tomorrow...
 


.......common sense is a flower that doesn’t grow in everyone’s garden.......
     Thread Starter
 

2/01/2016 3:43 PM  #8


Re: Project Deadhorse....

Your marriage will last longer when you keep the wife laughing.

Josh you should let that quarter panel know who's boss and beat it with your favorite hammer.


John  -- 67 Mustang Coupe 390 5 speed
 

2/09/2016 1:48 PM  #9


Re: Project Deadhorse....

Super glue works well also but "Stings" a little. http://cdn.boardhost.com/emoticons/happy.png
  Looking good on the project.

 

2/09/2016 10:22 PM  #10


Re: Project Deadhorse....

Progress update on Project Deadhorse.  
I’ve found what works best is to set a daily goal, meet the goal, and call it a day.  So, since I last posted I have managed to weld in the passenger side quarter panel.  Had to wait on a dynocrap outer wheel house so I could cut out the lower rear corner and splice it in.  Before I actually fired up the buzz saw, I decided to compare the re-pop wheel house to the Ford Quarter.  
I layed the quarter face down then layed the wheel house inside.  Bottomline: the arch on the re-pop wheel house is 1 1/8 inch wider than the Ford quarter.  I would assume to use this wheel house I would have had to do a little slicing and dicing to make it fit...........guess the stamp die is “plumb worn out”.  I did take pics with my Sony camera but, the camera gave up the ghost so, I’m without pictures to post for this parts comparison.

Anyway, I prepped all the weld surfaces and shot some weld thru primer.  Fitted the panel and clamped everything down.......didn’t realize I owned so many clamps!  On the B-panel, I used self tapping sheet metal screws to hold that seam tight.  Got everything welded in and called it a day.  The next day, I ground the welds and cleaned the shop.
Then, the coupe did the hokey pokey and got turned around so I could start on the driver side quarter.
Yesterday, I cut most of the quarter out and retired for the day.  
As for today, I removed the quarter panel remnants and test fit the new quarter.  Tomorrow, I’ll prep everything and fire up the Lincoln MIg........
I have to say, I certainly appreciate this former Arkansas mustang.......the driver side wheel house does not have rust issues!...........solid!!  

Here’s a few pics that provides the progress thus far...........
http://i66.tinypic.com/34edudu.jpg
http://i65.tinypic.com/2i0f69t.jpg
http://i64.tinypic.com/2uyqdms.jpg
http://i67.tinypic.com/5oikag.jpg
http://i64.tinypic.com/f3hy14.jpg
http://i64.tinypic.com/dzxmxl.jpg
http://i65.tinypic.com/14nmq8o.jpg
http://i65.tinypic.com/2ps1vn6.jpg

Last edited by josh-kebob (2/12/2016 10:33 PM)


.......common sense is a flower that doesn’t grow in everyone’s garden.......
     Thread Starter
 

2/10/2016 5:27 PM  #11


Re: Project Deadhorse....

Today proved to be a little longer than I had planned however, the quarter is now welded in......
Have to say I’m beat but, having installed two full quarter panels in two weeks has me jazzed to keep on going to the dreaded full cowl replacement......I plan to read and study the write up on this topic provided by Professor Ramses so I get it right.....

Here’s a couple of pics from today........tomorrow I’ll dress the welds and focus on the cowl.......

http://i66.tinypic.com/30jjnsy.jpg
http://i65.tinypic.com/2lvef0o.jpg

Last edited by josh-kebob (2/12/2016 10:33 PM)


.......common sense is a flower that doesn’t grow in everyone’s garden.......
     Thread Starter
 

2/11/2016 3:12 AM  #12


Re: Project Deadhorse....

How did the drivers quarter fit length wise?  Mine is about 1/4" too long.  Everything from the sail panel forward lines right up, it's the quarter extension end that needs a nip and tuck....


65 mustang coupe, 351W, C6-  2800 stall, B&M blower, 9inch- trac-loc 3.70 gears
 

2/11/2016 8:01 AM  #13


Re: Project Deadhorse....

The d-side quarter fit fine.........these are Ford quarters, not re-pops so that’s likely the difference.


.......common sense is a flower that doesn’t grow in everyone’s garden.......
     Thread Starter
 

2/11/2016 1:01 PM  #14


Re: Project Deadhorse....

Okay--- I'll have to go to Autozone and get a quarter shrinking tool!


65 mustang coupe, 351W, C6-  2800 stall, B&M blower, 9inch- trac-loc 3.70 gears
 

2/12/2016 10:38 PM  #15


Re: Project Deadhorse....

Update: Project Deadhorse was on hold today because I had my electrician replacing the breaker panel in the house today.
In the morning the plan is to remove the windshield, hood, engine and trans and start assassinating 150 spot welds......

Couple pics of the “last” piece(s) of new sheet metal for this for this project plus, a pic of my “helper”.....

http://i63.tinypic.com/21jx341.jpg
http://i64.tinypic.com/rs7tbb.jpg


 


.......common sense is a flower that doesn’t grow in everyone’s garden.......
     Thread Starter
 

2/15/2016 8:36 PM  #16


Re: Project Deadhorse....

Deadhorse Update:

Today, I was able to successfully perform a “Cowl-N-ectomy” on the coupe.   I used a 4” wire wheel on my grinder and cleaned all the “seams” so I could clearly see all the spot welds.  I must say, the dude running the spot welder “way back when” must have thought, “if ten spot welds are good then,  100 must be better”.  

Previously I was using an automatic center punch but as time went on, I found it to be rather useless.  I’ve got bigger dimples on my..........chin, then this thing can make.  So, I found the good old craftsman punch and center punched all 147 spot welds!

I opted to use a quality spot weld cutter, thanks Glen B for the great recommendation.  You have to be careful when using these so you don’t drill through all three layers of metal; they’re super sharp and hungry.  I found that if I went slow I had the best results.

http://i64.tinypic.com/30vhqus.jpg



 


.......common sense is a flower that doesn’t grow in everyone’s garden.......
     Thread Starter
 

2/24/2016 9:06 PM  #17


Re: Project Deadhorse....

Thanks T!  Not sure what that could be but, I’ll look into it and see.........


.......common sense is a flower that doesn’t grow in everyone’s garden.......
     Thread Starter
 

3/16/2016 11:45 AM  #18


Re: Project Deadhorse....

It's been awhile since my last update due to my inability to upload pic's.  The cowl replacement is finished.............thanks Ramses for the outstanding write up on this topic.  Anyway, here's what it looked like as I worked my way through the replacement.  Only 147 spot welds.......really no big deal.  The replacement cowl fit nearly perfect and lined up nicely with the fenders.  Took all of two days and it was done.  Now, the coupe is rust free and ready for the next phase.   I'm finishing a budget rebuild of a 5.0 roller engine and may post a little info on that as well.  With cowl removed, you can get a decent look at the famous Mustangsteve clutch cable set up too!!

http://i63.tinypic.com/4l4wep.jpg
http://i65.tinypic.com/282ophj.jpg
http://i67.tinypic.com/5psvs.jpg
http://i63.tinypic.com/4l4wep.jpg


.......common sense is a flower that doesn’t grow in everyone’s garden.......
     Thread Starter
 

3/16/2016 11:46 AM  #19


Re: Project Deadhorse....

Now that I've successfully posted pics, I'll take one of the finished product and upload later..............


.......common sense is a flower that doesn’t grow in everyone’s garden.......
     Thread Starter
 

4/28/2016 10:01 AM  #20


Re: Project Deadhorse....

When you had the cowl off, did you follow Bullet Bob's advise and paint the under dash/under cowl white for future visibility?

 

7/11/2016 9:38 PM  #21


Re: Project Deadhorse....

Josh,

I have really enjoyed reading your work narrative and looking at the pics.  Looks to me like you are doing a first rate job.


Made it to Fort Walton- Visit was too short
 

7/12/2016 7:27 PM  #22


Re: Project Deadhorse....

Looking good Josh! I too love my Blair spot weld cutter.

 

9/13/2016 8:39 PM  #23


Re: Project Deadhorse....

Looking good Josh!  Keep it coming.

 

11/30/2016 5:56 PM  #24


Re: Project Deadhorse....

Project Deadhorse is out of hibernation and the work continues.
Most recently and in no particular order, I've installed the rebuilt 92 5.0 roller engine, a clutch kit, and the T-5.
Welded up the subframe connectors, seam sealed what needed sealing on the underside and painted it.
I'm running the stock PS set up that Stanger59 rebuilt for me several years ago but, with the Fox PS pump, the pressure hose needed a mod. Thanks to my friend at O'reillys, a new hose with correct fittings was made.
Cooling: years ago when MS sold alum rad's, I purchased one for a 65/66 and one for a 67/68.  Now, I'm using the 67/68 with this setup.  That posed a slight problem with upper and lower rad hoses.  A little research yielded part numbers that worked great.  So, as an FYI, the upper hose is part# 21736; the lower is 20609.  That upper hose is actually the lower hose for a Bronco II with a 2.9L engine. The lower hose is from a SB Maverick.  With a small amount of trimming, the upper fix great and clears the alt along with the belt tensioner.  To complete the cooling set up, I was able to find/utilize a fan with fan clutch from a '85 full size Bronco with a 351W.  Gives me good clearance, fits the rad, and is the correct rotation for this application.
I just rebuilt the emerg brake set up and will finish install this week.  I also stripped, primed, and painted the truck and set the new gas tank in place.  New fuel line from tank to pump should be here in a couple days.

So what's next, besides everything!!?

-Install the dual exhaust system
-Have a new drive shaft made
-The heater box will be rebuilt and ready for install after I spray the floors, etc with lizard skin.
-Then the AC, wiring, instrument cluster, yada, yada, yada.............

Finally, prep the beast for paint........

Will it make it to FWB for the bash???   Doubtful but, I'm eating this elephant one bite at a time so at least I'm headed in the right direction.
If I take some worthy pictures, I'll post them later on the continued progress......

Thanks............JKB

Last edited by josh-kebob (11/30/2016 6:34 PM)


.......common sense is a flower that doesn’t grow in everyone’s garden.......
     Thread Starter
 

11/30/2016 6:28 PM  #25


Re: Project Deadhorse....

Saweet!   Good job man. Kinda motivates me to go put the brakes on mine!


65 mustang coupe, 351W, C6-  2800 stall, B&M blower, 9inch- trac-loc 3.70 gears
 

Board footera


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