Sunday, November 29, 2009

Frame rail, we don't need no stinking frame rail!



Yes, that is my frame rail.

After a frustrating day last Friday, today I made a lot of progress on the car. First I was able to remove the lower control arm bolts that were seized. Heated them up for about 45 second each and they came right out with the impact.

The spring was a little more difficult because the sway bar and slapper bars are still on the control arm and rear end respectively (seized, for now ;-). I eventually removed the shocks and the rear end settled down enough that I could pull the spring out. Five minutes later, the rear end was on the ground.






I then moved to the rusted frame rail. I was able to cut through a bunch more spot welds until finally I broke out the sawzall and cut through the mounts at the radiator support. They were so rusted I wasn't able to find where the original welds were.

As you can see, there was no chance to 'patch' this rail. It is rusted through in several spots.







Here is a shot of the rail over the k member. I don't know for sure if I need to replace the whole rail or just cut out this inner piece and weld some new steel to it. Advice?









It is also obvious I need to replace part of the radiator support.






Next steps are to get the rear end cleaned up, painted and new brakes put on. Then start on so getting it rolling is probably a good next step.

Friday, November 27, 2009

Thanksgiving update

The fall was mostly taken up with torrential rains, floods, Softball and Color Guard, so I didn't get to do anything until this weekend.

Last time I worked on the car I dropped the driver's side rear lower control arm and spring to begin cleaning up that part of the car. I then had the good idea to remove the axles to make is easier to remove the brake backing plate to clean and paint it. Well, two different days, lots of different techniques (including a torch!) I gave up. I guess I'll work around the axles.

I also figured it would be easier if I dropped the rear end completely, moved it out from underneath the car and then work on the underside of the car and the rear end with much more room. Except the passenger's side lower control arm bolts won't move. Lots of PB Blaster, impact wrench, breaker bar with a 4 ft pipe. Nothing worked.

So, I gave up on the rear end of now.

Instead I removed the steering wheel and dash. Two reasons. First to make sure there was no 'rot' under the cowl (a very common problem on Fox bodies) second to get access to the Heat/AC box. I am going to change the heater core and A/C condenser before I put everything back together. Both are of questionable quality after sitting for so long, so I'd rather replace them than take the chance. I haven't replaced them yet.

Next I started removing the front brake lines since I need to rebuild the front suspension before the car can be moved. Most everything here is rusted together. I couldn't get the brake bleeders free nor remove the brake lines from the calipers. So no progress here.

I did however begin removing the rusted frame rail. I bought a spot weld cutter a couple of weeks ago and today started removing the welds. I was able to do about a dozen before I ran out of time. More tomorrow!

Sorry there are no pictures, but as you read, I haven't actually finished anything lately.