Front end and Cab Restoration Continued
Jan 10 - end Feb 10. Repairing the inner wings. (Fenders)
After the NEC show we were into December and Christmas and so work started again in January. Parts needed to be
restored and put back onto the front end. The inner wings needed restoring and altering to suit the new
suspension that was to be fitted. The original Mustang 2 suspension had been fitted by the previous owner
and it can be seen in the pictures below that little care (understatement) had been taken in cutting out
the inner wings around the top suspension arm. The new tubular suspension arms would be even more compact and
so very time consuming fabrication work was need to both repair and remodel the inner wings. There
were also many holes left in these wings, some GM and some from past projects. They were all filled with
new metal. The strength of the inner wing was re-instated by folding the new metal along the bottom edge,
following the shape of the suspension turret joining up to the original GM folds. A small gap was left
between the inner wing and the chassis as these structures are not meant to be connected. It is planned
to add a rubber skirt along the bottom of the inner wing to stop any splash water from getting through
from the wheels to the engine bay.
After alteration and test fitting, the inner wings were media blasted and painted.
March 10 - April 10. Repairing the "A" pillars.
The bottom of the A pillars looked OK at first but after further inspection it was clear another "can of worms"
had been found (hopefully the last can!) New metal was needed for the bottom sections of the A pillar and more
new metal where they attached to the floor. As usual, 2-pack acid-etch primer was used, then primer and top coats.
Pictures are shown below of this work. Pictures are shown below of this work.
June - July 10. Front end preparation and re-assembly.
The A pillars were sprayed with Shultz to protect them in the water splash areas. All wiring was renewed
and routed through the chassis keeping the inner wings clean from wiring. The new tubular suspension was fitted.
This suspension did not have any provision for the anti sway bars. This did not make any sense. Why produce a
better suspension system and not include a method of fitting the front anti sway bar? We have always suspected that
some companies or enthusiasts are more interested in appearance than
performance and this would tend to support that
view. A re-design was needed. The tubular arms were modified and additional parts were fitted so that the front
anti sway bar could be bolted on. This involved using some anti sway parts from a modern GM car and making
anchorages for them on the lower suspension arms. These new parts transferred the sway forces
from the suspension arms to and through the anti sway bar. See pictures below.
The painted inner wings were fitted. They were bolted on through Evo Mastic. The side of the inner
wings in the splash area (near the wheels) was sprayed with many layers of Shultz. The lower front panel
(with horns shown bolted to it) was media blasted and painted. A new heavy duty low noise electric fan was fitted.
This involved modifications to the radiator so that it would bolt on. The wiring to the alternator was improved.
The wiring from the fusebox in the cab now emerges just forward of the A pillar then runs downwards then in and
across to the chassis. A new accelerator was manufactured including the bearing that bolts to the firewall. The
top of the radiator was restored, and modified to improve appearance, then painted. Stainless steel bolts, both
hex and buttons, were used throughout the re-assembly. The outer wings, front sections and hood were bolted back on.
The outer wings and hood etc. were not to be restored and painted at this stage. They needed to be removed later
so that the new air conditioning pipes can be fitted and rerouted through areas that again will keep the inner
wings (fenders) and firewall free from clutter inside the engine bay. The (new) transmission oil cooler was
relocated behind the front bumper bar just forward of the cross member facing forwards in the air
flow. The horns were re-positioned below the oil cooler
An improved (Lokar) accellerator pedal was fitted in 2015.
11th July. Americana 2010.
The front end of the truck was re-assembled in time for the Americana show on the 11th July 2010
This did not include the re-assembly of the air conditioning pipes. New pipes had been purchased
and the plan was to re-route them through the right hand wing to keep the engine bay
as uncluttered as possible. Apart from that, the truck performed well on the motorway
with the modified tubular suspension. See below the picture from this show.
July - November 2010. Cab restoration 2.
Considerable work had already taken place previously in the cab. The reinforced flat floor, the 10 way powered
seats and the sound deadening. "Dynamat extreme" had been applied on the underneath of the floor, the rear of
the cab behind the seats and on the floor up to the end of the seats. Now for the second stage - The front
windscreen was removed. The gauges, the heater, air con. box, the glove box etc were all stripped out of the
cab. The dash and the firewall were stripped to the metal and re-painted. The bare metal was acid etch primed,
primed and painted. Dynamat extreme was applied to the floor forward of the seats and right to the top of the
firewall, even including applying it upside down to areas at the top of the firewall. The sides around the
A pillars was also covered. Indeed almost all of the cab from rear window to dash was now covered, sound
insulated and sound deadened. It was decided not to re-fit the inside metal trim around the windows. Instead
demisting vents were manufactured into the curved dash. This resulted in an improved uncluttered dash.
Everything was re-assembled and finished just in time for the NEC show on the 12th November 2010 The pictures
below show the state of the truck 10 days before the show with the final top coat of paint going on 5 days
before the show. Once again it was down to the wire!
13th November 2010. British Classic Car Show. NEC 2010.
sponsored our stand.
Here you can see the dash was all put back together in time for the show.
Most pictures are taken before the public enter the halls but the picture below shows how busy it becomes.
Even in this picture it was a matter of waiting until the public are not in front of the truck.
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