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piazzanoob's 1964 Ford Galaxie 500 seeeedaaan


piazzanoob

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  • 2 weeks later...
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this chipping away at this ol girl

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cut out this rusty piece of steel in the R/h front floor pan which had been bogged over.

this piece has most likely rusted out due to a leaking heater. 

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Used this piece of 1.5mm of zintech panelsteel.

spend some time panel bashing it with a wooden panel hammer and sandbag and a steel hammer then tack'd it in with some more hitting with the hammer.

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Then faced my torch underneath to check for any holes 

welded the remaining holes up a few times and now shes air tight.  just like AL's mum puhuhuhu

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will leave the welding on this patch as is for the moment untill she gets the all clear from the repair certifier along with no paint or rust stuff.

also my aliexpress gauges turned up too

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pretty happy with the quality of them.

 

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  • 3 weeks later...

super late reply but never late than never right

so during my Christmas break well only the stat days i had off i made a start on the repair on the rear chassis rail.

so to do this job the body had to be raised of the chassis on the back 

 

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so the dog chilled out with me while pulled it apart on Christmas evening

then with a few hours work and the help of the gantry crane the old girl was free

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we then cut out the previous welded piece out 

As some piss poor american had most likely arc welded it in before 

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which then revealed this 

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which as you can see by the photo that the rail is bent although both of them were.

Now here is the part where you say this is a big NO NO and why the hell am i doing it this way.

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So we gave the chassis rail some heat to move in back into the right shape with the help of a hammer until we got the shape right.

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So the reason we did it this way as if we had used a porta power or chassis machine it would of had to be done with the body still bolted down otherwise nothing would ever line up again.

which also most likely would of bent the chassis even more than it was

but i figure that the metal was formed while glowing hot 

then was rewelded in the past causing it to be glowing hot 

then we played with it causing it to be glowing hot 

So really in my opinion it did not change the metal at all.

And it had a big dent in the centre of the rail which had to have heat to get it out.

Then after we did that we heated up the rail we had cut out and bent that back into the correct shape.

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Then welded it in.

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I then applied some anti rust primer and then followed with some semi gloss back.IMG_2101_Easy-Resize_com.jpg.3960db86e68eee1888edf2cbfacb3913.jpg

so the only reason the top got done is that it cant very well be seen and once the body is back on you wont be able to get any paint on it.

Also note that none of the welding was done by me.

my old man done it as he has done plenty of structural welding in the past on trucks and other equipment.

plus 30+ years doing welding does help.

now go and tell me how ive done it wrong here 

cheers

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  • 2 weeks later...

so with one remaining panel replacement being the trunk floor to be done to have the engineer sign off i may as well plod along getting other bits done.

it never ends with this car 

ordered a fuel sender from northwestern ford from palmy north

pulled tank out again 

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fitted new seal that came with the kit too as had started leaking before.

also made up a new bit of fuel hose from the tank to the hardline

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And also bought a new fuel pump

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has also dulled out abit as i put some degreaser on it.

And this old shitta

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was leaking from around its pressed seal so in the bin it went.

also new one had the added bonus of a built in filter like this puppy

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this is one that came with the car and fits too.

also fitted a new fuel hose from pump to hard line aswell

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thanks work for the hose and clamps

so now the fuel system is leak free and has new hoses and clamps  

 

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  • 2 weeks later...

Another job on the to do list done

starter motor had an issue where it wouldn't engage alot of the time.

so out it came from its hole 

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pulled apart the starter motor and narrowed it down to the clutch not working under load.

so ordered a new one from northwestern ford and received it the next day.

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also gave everything a good clean while it was apart.

then reassembled it with the new clutch  etc

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another job done and dusted 

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  • 4 weeks later...
  • 1 month later...

Another compliance job now to be ticked off the list

with the car having some previous repair damage and a couple rust areas the job needed to be inspected first by a panel beater engineer before any work was carried out.

so i checked with the local panelbeaters who they used and gave that guy a ring 

so organised a day with him and i put it on the hoist at work for him to inspect 

and all that was said is make and weld a new patch in nicely in the front R/f floor 

replace the boot floor (trunk pan) as has many holes 

and cut out and straighten and reweld chassis in R/R 

And job done

so after talking to a few people and taking the car to a few aswell for the rear trunk floor as that was the last on the list to do 

with one guy offering to make one for me but me having to cut the floor out and send it to wellington to get made then sent back then spend heaps of time trying to fit the fucking thing. so figured that was an expensive and fuck around way of doing it 

So the other opinion from who i had seen was to get a good new reproduction trunk floor out of the USA  

so i found a website who did old ford stuff who i had already bought stuff off 

so fired away and bought one off them and sent it to the nz post service depot in oregon why they have it there who would know.

Then got an email a couple days later stating that the item had arrived but was considered oversize wait what!

so gave you shop a call but had to call them here as they don't have a number for the US service 

20 minutes on hold and my lunch break is over

so called again same thing on hold for 20 minutes so they say they will send an inquiry out for them to check why it is oversize etc 

so i rang them the next week to get an update as had not heard anything for over 4 days 

waste more time on hold with the same shitty music 

then to be told the combined size is too big 

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  so my item only being 1350mm or so i figured i was way under so figured it would be fine but no.

perhaps they could of worded it abit easier for people to understand the combined size etc? or make people more aware of this?

so i was then told i have to email the oversize freight team to get a quote to have it sent here.

so did that and had to wait a couple of days for the quote be emailed to me 

then paid the money as figured it was way less hassle to be Air freighted through them then sending elsewhere and at this point my engineers deadline was coming up.

so the item arrived a week later into nz and was waiting customs check for a duty bill etc

3 bloody weeks went by and i had been TRYING to get hold of them but 20 minute holds and by then i just hang up 

I eventually talk to someone to say an invoice had been sent to me but they sent it to the wrong email address 

but the thing is i had already been talking to the person who was going to be sending the invoice via email so why didn't he just reply to our current conversation and he did state he would email me the invoice.

so i pay the invoice and get told i will get the item on Friday via courier as they don't accept pickups but end up getting the item on MONDAY...

so now im a week away from my deadline and there is no chance i can get the trunk pan in because of work.

so i open my box to look at nice new trunk floor only too..........

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what on earth is this piece of crap

where is my swages 

there is no straight edge on this panel too 

And they also have the cheek to put a sticker stating its made in the USA  m8 could've made a better panel myself with a grinder

 

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so this is what the panel should look like.

And at this point the panel owes me 835.64 dollars and its scrap 

so tip one - don't use quality USA replacement panels 

tip two - don't ring nz post unless you want to waste your life away on hold

tip three -  nz customs hold times are great also

tip four - don't be as gullible as me and assume it would be easier to get one from the states and it would look like the original. like other panel beaters told me.

 

 

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Another job on the to do list done but again took way too long.

One of the jobs that needed to be completed for the engineer's sign off was a wheel alignment. Not that is any what related to the chassis repair but i guess is a standard on any repair.

seen as i work in a shop and have to do wheel alignments on a daily basis why not do it myself right.

well we don't have the spec's for any car of that era.

so i gave the guy at northwestern ford a call to see if he had any spec's to which he found some and sent them via email which was choice.

so spent way too long trying to convert the measurements over to millimeters from inches then into our alignment computer. only to make 3 different ones with different spec's on each one to making one for better drive ability.

then thinking some more and changing it again.

so then on one of my days off i took it in to do the alignment.

well it started off with not being able to put the rear sensors on the car due to the rear wheel arches. That's cool seen as there is no rear adjustment anyway.

then set the computer up for front alignment only... but ive only done one other car that way so had to figure all that out again.

then computer had a spaz and wouldn't do the full procedure so try again and again then decides to play ball.

so then get to do the alignment only to find its miles out and requires shim's in the front for both camber and caster.

so jack it up slightly to release the suspension load then loosen the nuts and remove and insert shims until within spec.

so that was about 2 hours work to finish that alignment. woohoo.

only to find the computer would not communicate with the printer. so just figured i would sort it the next day as it gets kept on the database.

so check on the database only to find that the spec part of the alignment is blank. great.

we had then got the IT guy in to check the printing issue only to find that it had a issue with the ip address being a wireless printer but all of this was caused by the Auckland storm causing the power cut.

so when the printer was working i figured i would just chuck the car on the alignment hoist run it through the procedure then not have to adjust anything due to doing it the week before. but nah off again and where i would have to shim it again...

so off it went and brought it back in to work another day to do it.

then edited the spec's again but really made a new lot of spec's altogether    

then spent a few more hours getting it to the new spec 

And then printed 2 copies of the new spec's and is still on the database which is good. And now noticeably drives and steers better than the last alignment. 

but i also tried to correct the steering wheel location as it is far off from straight. but couldn't pull the wheel off even left some puller tension on it overnight with no luck so have put that in the too hard basket for now.

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oh and one i was doing on @chris r van a few months back for engineer's sign off 

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was also shim's and a long alignment job.

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Another no so important job on the list done.

pulled out this piece of sheetmetal 

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Spent a whole bunch of time cutting bending and welding some nuts in to make this

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then applied some rattle can black to it

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so i guess now your wondering what its for but have some sort of idea in your head.

And your right! its a radio mounting bracket

decided i was sick of driving it with no radio and had planned on making one so put one in.

As the original radio was still in its factory hole but didn't work and i wasn't keen on chopping up the dash to make a modern unit fit. or spending mega bucks having a reproduction one in its place.

was also keen on tucking the radio away from being well seen also so this works

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And you can see the factory one in the top R/H corner.

Also just used this radio as had got it years ago from a car that was being wrecked. might chuck a nice modern bluetooth item in if i feel like spending money later on down the track.

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shes pretty level mate.

so yeah now i have a radio but no speakers.

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So with having a radio in the hole and no speakers that was the next job on the list.

so i figured this system would end up with 2 rear 6x9's and one front 6x9 in the dashtop.

so started with the rear by pulling the parcel tray off to mark some holes out to place the speakers

and thats when i came to know really how shit the rear parcel tray was

the material on it is sun fucked and i knew that but figured it would just need a recover

but it had been patched up in the past and done quite poorly plus it was the wrong shape

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so i got a piece of plywood and started to make a new one 

this required many hours of cutting and sanding to get the shape right. With also needing to taper the edge due to the chrome trim.

and some weight to get the bow out of the ply too

 

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And i guess now your wondering why those speaker holes are small.

well unfortunately there is not enough space without chopping the metal frame below to make two 6x9's fit and to look right too 

As im also not keen on cutting this car up too.

but there is a spot in the centre for one 6x9 on the parcel tray but figured two speakers would be enough.

so i then got to work on how to hold the parcel tray to the metal frame so for when the speakers are working they are not causing rattling issues.

IMG_1984_Easy-Resize_com.jpg.c31604e8fcf44358ca6c685a628573e3.jpg 

so i then routed out these bits in the top of the parcel tray for my mounting plates to be secured in.

oh and the holes are offset because that's where the holes in the metal tray below were.

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used some 1.3mm panelsteel and welded a nut to it.

i think these plates were 50 x 50 

sprayed them black and screwed them into place.

i then got some vinyl material from @64vauxhall 

and placed it over the ply using staples and ADOS in a can 

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i then bolted it into the car and fitted some soundstream speakers i had.

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so all in all i think it came out pretty good considering im not a interior guy or a wood butcher.

but now after ive finshed it and made it would've i been any better off using mdf? 

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  • 4 weeks later...

next job on the list was some wiring work.

The old fuse box in this car was dangling under the dash and missing its cover plus with it having the glass type fuses its well overdue for replacement.

so did some shopping on ali and bought this 

 

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for the price the Quality is good 

then the next part of the job was to get @chris r to rewire this new fuse box in 

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with chris doing that i made a bracket to hold the fuse box in place.

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did some cutting and bending and made this 

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And there it is bolted in place tidy under the dash

And placed the cover in upside down for bonus points.

so with that now in and that side of the electrical working 

i just need to order a big fuse and holder and then i can remove the old fuse box from dangling there 

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so seen as all the work that was required on the engineers cert check sheet was done.

I arranged a time with him to come view it on one of the hoists at work 

so he comes 

inspects the work and is quite impressed with the chassis repair and replacement floors bits put in.

so figured sweet it will get signed off...

well he wanted where the chassis repair was done painted right up until the wheel arch meets along the back rail and the other side to suit. well FFS i left the underside unpainted so you could see the repair.

then wants the leftover bog taken off the bottom of the sills as when it was painted in the states the sills were bogged and left the bottom side untouched as you cant see it right.

and he also wanted the floor inside the car cleaned up and painted in a couple of areas due to him stating its surface rust. that i was fine with

then he starts going on about the very very light underbody surface rust. to which i said i would get it done after its legal and stated that it would be getting lightly sand blasted then painted.

to which hes reply is

oh just put some rust converter on it then a top coat. cheers m8 

so now im left with more stuff to do and all this stuff being not on the list he wrote. this made my blood boil due to him already inspecting the car and not saying the first time round which fucks me around as i could of already had that stuff done.

so now i have 0 faith in these repair cert cunts doesn't know shit from chewed up dates. 

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