Windows Fitted (at last!)

I don't want to admit how many hours I have spent getting the side windows in and properly gapped.   I actually still have a little work to do on the driver's side door.  In my last post I mentioned that I discovered the window regulator was worn out and I had to get a new one.  I did that, but in the process of removing all the parts to start over, I had to remove the widow "fuzzies".  Those are the fuzzy strips that line the window opening at the top of the door.  They are a one-shot deal.  They can be put in once, but if they are taken out, it ruins them for re-installation.  So I am waiting for Brian to bring down another set. 

Here is a picture of the window parts that go into the passenger side door.  I don't know if I could have ever figured out where they go had I not found a posting on the Vintage Mustang forum where a guy had cut off the OUTSIDE door panel and taken pictures of how everything was attached to the inside and what they looked like at various stages of the window being rolled up and down:

All these parts have to be installed either through the slot in the top of the door, or through a few relatively small holes in the inside panel........and they MUST be installed in the right order!

Then, once they are installed, the fun begins.  The gap between the vent window and the roof (1),  between the top of the door window and the roof (2), between the quarter window and the door window (3), and between the quarter window and the roof (4), must all be adjusted so that it all fits.  A change in one gap usually effects a change somewhere else, too. 

The three windows also must be adjusted so that they fit up against the weather strip along the roof line.  This is made possible by adjustments that tilt the windows inward or outward at the top. 

Here is the passenger side:

Brian is coming down Thursday and Friday and bringing parts he got for Christmas, so we will be doing some work with those.  

Mustang Sally

I haven't had a post for awhile, but that doesn't mean I haven't been working on the car.  We have had grandchildren visiting, which slowed things down a bit, but I still have spent several afternoons working on "Mustang Sally".  Some of the projects are:
1.  Installed lighting harnesses in engine compartment and trunk
2.  Installed  backup lights:

3.  Quarter windows and roof weather strip:

4.  Notice the door handle, lock, and button release above.  This is what it looks like from inside the door:

Most of these jobs have a driver's side and a passenger side.  It often takes me a day to do one side, and then an hour or less to do the other side.  It's a giant learning process.  I start out completely in the dark about how to do a job, and end up an expert in that particular task.  I also do a lot of research being done online, and I also visit my local parts supplier and ask questions.  There is a Vintage Mustang forum with a lot of knowledgeable and active members that has been a great help.  http://forums.vintage-mustang.com/vintage-mustang-forum/

For the past two days I have worked on installing the driver's side door window.  It took me a day to get it in, and then I found out it didn't roll up and down properly.  I finally decided that the window regulator was worn out, and had to remove everything and get ready to start over with some new parts. 

The Error

I guess it wasn't so  obvious after all.  Or maybe nobody cared.  Anyway, here is the error:

The brake bleeding nipple is at the bottom of the caliper, not the top where it has to be to get air bubbles (which rise) out of the system.  This means the calipers have been switched and this one should be on the other wheel.  In my defense, I didn't do it; the paint and body shop put the brakes on, and even though I had to take them off again, I did one wheel at a time so I didn't swap them. 

I guess the reason why this mistake was so obvious to me was that one time when Brian and I did a brake job on one of his vehicles we switched the calipers and didn't catch it.  It was impossible to bleed the brakes even though we tried for hours.  He had to take it to a shop where they pointed out the problem.  I was pretty embarrassed. 

Spot the Error

There is a glaring mistake visible in the photo below.  I discovered it this morning and corrected it.  Kudos to anyone who finds it and tells me. 

Suspension, Steering and Brakes

It's great to have the car looking good, but it has to be a good runner, too.  I've been working on and off this past week on replacing all the components of the front suspension, steering and brakes.  I did one side at a time so I could use the other side for reference in putting things back together. 

The one part of the job that worried me was replacing the coil springs.  Brian had bought new springs, so the old ones had to come out.   In my research of this on the Internet I came on numerous posts warning about what a potentially dangerous job this is, where the spring under tension can get loose and cause damage and injury.  There is a specially made spring compressor for the vintage Mustangs, but it costs a lot of money for a one-time use.  We had asked the paint and body shop to replace the springs, but he declined on the basis of not having the proper tool.  I finally discovered that O'Reilley (Oh, Really?) Auto Parts had a compressor that would work, and they rented it out.  Actually, you pay a deposit and get the whole amount back when you return the tool.  So, after removing the brake, lower control arm, strut, stabilizer bar link and wheel spindle, I got to this point, where the spring compressor is installed and ready to start compressing the spring:

Notice the bump stop is broken.  I had to get another one of those and replace it after I got the spring out. 

Next step is to ratchet the spring compressor nut, which draws the fingers holding the coils upwards:

 After the spring is lifted off the lower spring perch far enough, the upper control arm can be removed, and then the spring compressor relaxed and the spring removed:

There were a bunch of wheel alignment shims behind the upper control arm and they all fell out.  That's probably OK, though, because the wheel alignment is certainly going to be changed with all the new parts and will have to be done over. 

Here is the new spring ready to be compressed.  It takes a lot of turns on the compressor screw to get enough clearance to put the new upper control arm with the spring perch back in.  I finally got smart and used my air wrench to turn the nut. 

In taking all the old parts off, I discovered that every bushing was completely worn out, and sometimes even missing.  The car must have been a real evil handling devil towards the end of it's last life. 

Here is a pic I took after I got it all back together.  I'm also practicing labeling parts of a photo, so click on the picture to see this clearly.  These are just some of the parts replaced.  All the steering linkage was also made new.  The shocks go down through the middle of the spring and attach to the spring perch at the bottom, but we don't have new shocks yet. 

Here is a picture Carolyn took with her camera last weekend, just to document that I was there too.

Next, I'm thinking of taking on the side window and door window and latch installation.  This is scary. 

Mike's New Bike

Big Mike has a new Dual Sport bike:

No, it's not an XR 80, Mike just makes it look like one.  It's an 86 Honda XR600.....a big motorcycle.

Yesterday we did a little test ride to see how it worked.  Since it was sold as a pure dirt bike, Mike will have to modify it to make it street legal, so yesterday we had to stay on state forest roads which do not require street legal motorcycles.  We rode in the local dirt bike riding area of Jones Creek, where I spent many hours riding and working on trails.  I'm amazed at how much the area has changed due to the extensive logging going on.  Here are some examples:

After we rode about 35 miles and pretty much exhausted all the roads he could legally ride on, Mike decided to call it a day.  It was a really nice day, though, so on my way home I did a little exploring of some of the forest roads I hadn't been on yet.  Having my Garmin Zumo on the bike really helps when doing this because you can always find your way back out of an area by following your track back.  Without the Zumo and with my fading short term memory, I have a tendency to forget which way to turn at intersections I come to.  I ended the day with almost exactly 100 miles. 

I took the obligatory mountain view pics on the way:

Mt St. Helens

I think this will be my winter schedule:   If it's a nice day, get out and ride.  If it's raining, work on the Mustang.  God, I love retirement. 





Great Progress

Brian came down Friday around noon and we had almost two full days of working on the Mustang.  We first concentrated on the back and installed the quarter panel extensions and the valance (piece under the bumper location).

A lot of effort was spent in the two days in getting body parts to fit as good as possible.  Gaps like the one you see here between the quarter panel and quarter panel extension were adjusted to be even and minimal......sometimes requiring shims.  We had been warned that reproduction parts often did not fit well due to the stamping or casting dies getting worn out over the years. 

Then the bumper, the trunk latch and lock, the taillight bezels and one of the taillight lenses (the other lens was cracked and broke when I was cleaning it).

The order in which things were put together is sequential in this blog, but was not always that way when we were working.  Sometimes I would be working on one end of the car while Brian was working on the other.  Also, we made a trip to a local parts supplier looking for some missing parts, and this turned out to be a goldmine of things we needed.  So we could continue on working in places that we had been stopped. 

Moving to the front, we installed the headlight buckets, front valance, stone deflector, and grill

You can see that the bumper guards are installed in this picture, but they had to be removed because it turned out the bumper had to go on before the guards.  This happened fairly often, as we had no instructions for assembly sequence and sometimes guessed wrong.  Same kind of thing happened with the rear bumper.  At first we installed the bumper brackets to the frame, and then found out we needed to first install the brackets to the bumper, and then the brackets to the frame.....just part of the fun. 

Then the bumper itself:

Then the interior grill parts including the Mustang in it's "corral", and the new rallypac fog lights:

The final steps for this weekend were installation of the remainder of the grill and one of the headlight bulb buckets and the headlight itself. 

Brian found the horns in the bin of parts that had not been cleaned and painted, so he got to use the bead blaster to clean them up. For some reason he really likes that bead blaster.

The car is starting to look real good: