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Old 10-14-2019, 11:31 AM   #1
MrIncredible
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Some old car projects.

By request.

Here we have one basic 1962 Falcon that I picked up back in '08 from a buddy going through a divorce.





It was daily driven for a number of years until kids and life got in the way. It was still driven regularly, but not too terribly much.

I was waffling on selling it but the wife claimed it as her own. She's of rather short height and likes the visibility that comes with all the glass of the mobile fishbowl.

Okay, now it's her car. The seats are too low, she wants to take the kids in it, it's too loud, and she has to sit too close to the wheel. It being a manual steering car, the wheel is huge-the ergonomics suck for the wee folk.
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Old 10-14-2019, 11:33 AM   #2
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That white paint was put on poorly, and was failing. It has to come off.

Removed the windshield, rear glass, and the drivers door glass.

Windshield needed replacing anyway (I have a new one) but what a freaking nightmare.

Rear window-the seal was cracked and leaky, and there was rust starting to form around it which needs to be addressed. More stripping happened:





Quarter panel is rusting out:



Drivers door/front fender gap is....fubar:

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Old 10-14-2019, 11:36 AM   #3
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The fenders were shot on this car as well. They make reproduction everything for a Falcon.

New fenders? $700.

Parts car? $750.

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Old 10-14-2019, 11:38 AM   #4
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Fenders off the parts car!



Fenders off the other car!



Window channel...rusted right the fuck through.

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Old 10-14-2019, 11:39 AM   #5
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Have a beer to steady your hands.

Hog it out:



Have a beer to celebrate.

Patch it



Have another beer, because, reasons.

Weld and grind smooth.



Fall over drunk.
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Old 10-14-2019, 12:08 PM   #6
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Labor of love, and hate... and a test of patience. Good luck!
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Old 10-14-2019, 12:29 PM   #7
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Quote:
Originally Posted by bruceflinch View Post
Labor of love, and hate... and a test of patience. Good luck!
How hard could it be?

Remove the trunk emblems:



Fill 'em



Get rid of the fuel filler hole too





And all those holes that held on the letters? They have to go too.

The rear of the car was too busy-that all has to go.

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Old 10-14-2019, 12:33 PM   #8
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Clean them fenders-stop the rust






Ew.



Less ew. Technical term, that.



Clean clean-oh, the glamour.



Copy, paste,

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Old 10-14-2019, 12:37 PM   #9
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Old 10-14-2019, 12:37 PM   #10
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I like to use POR-15 on my projects. I've had good results for a few decades-a couple things-it stands for Paint Over Rust. They mean that. If you clean the metal first, it won't stick. Don't clean the metal.

Don't get it on you-it doesn't come off.

Don't breathe it-it works on taking all the moisture out of stuff, thus topping the rust. I can only imagine what it'll do to your lungs. Also it has isocyanates in it. Those aren't...good for you in any form. Basically, don't be an idiot.



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Old 10-15-2019, 10:00 AM   #11
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Other quarter.



If you're new to this, it's best to start off with the driver's side, so all your mistakes show better.

It's lighter now





If you're replacing a panel, put the new one over the old (I punch a hole and tack weld it in the middle), then cut through both panels with the thinnest cutoff wheel you can find. When they fall to the floor in a heap, separate 'em and put the new one where the old one was. Now you have a perfect fit with a weldable seam. No, you don't need a plasma cutter. Shut up about them.



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Old 10-15-2019, 10:05 AM   #12
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ZIP WHEELS FOR THE WIN!!!!!!!

You're the man Dave.
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Old 10-15-2019, 10:06 AM   #13
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I miss my old shop.



I learned a lot of this stuff here:



Gene has been in business since 1947. Opened up after WWII. Still working and every winter he teaches a few courses. One in San Jose and one at his place in the Mojave. It (was) $400 for a weekend course. If you have any interest in ever doing metal work, I recommend it. If nothing else, it's not often you can see a true master of a trade in action. I watched the guy make a window frame with a hammer and a piece of oak pallet.

I tried something similar and made scrap metal and firewood.

Gene made the car that Shatner as Captain Kirk or some alien babe drove in one Star Trek episode(along with the shuttle craft), Blade Runner vehicles, and Back to the Future cop cars.







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Old 10-15-2019, 10:09 AM   #14
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Here were the topics:
gas welding - hammer welding - leading
FABRICATION OF
compound curves and complex shapes by using the following equipment
english wheel - sandbag - wood hammer forms - station bucks - sheet metal break - bead roller - stakes - shrinker & stretcher
OTHER TOPICS INCLUDE
basic metalurgy - strategy for metal repair - hammer & dolly theory and technique - shrinking - hole filling - metal finishing

English wheeling-the guy moves too quick and it's impossible to get a good picture:



Leading



Gas welding aluminum



That's me in the green shirt.

I'm still clueless, but now I can get myself into even more trouble.

I took this in November, and it was so helpful, that when another one came up at Gambino Kustom's, I went to that too.

I'm lucky I live close to these things-last couple of classes some guys had come from Arizona, Utah, and Canada.

While at the last class, I saw this up on a shelf and bought it for my daughter:

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Old 10-15-2019, 10:12 AM   #15
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Fuck yeah I would go hang with Gene and let him make me feel inferior for $400!!!
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