Sunday, April 23, 2017

Yes Virginia, there is a Mustang in the shed!

Well, after 3 years of hibernation, I finally cracked the shed today and spent some quality time with SusieQ. It was a glorious Spring day and since I've finally fixed most of the broken stuff around the house after 3 years of zero maintenance, it was time to do some wrenching again.

And though I've not worked on the car during my absence, that hasn't stopped me from thinking about it. One of the things I've decided to change is upgrading to front disc brakes. The car came with drums all way round and I had thought it 'quaint' to leave it that way. But after thinking my wife is probably going to drive this car more than me, I just couldn't send her out with 4-wheel drums. So that's the first thing on my list.

After much research in Australia, the Cobra upgrade seems the most bang for the buck. But unfortunately Vintage Venom is no longer producing their kit (my preference) and neither is Street or Track - so my choice seems limited to Steve's Mustang. I liked the Venom kit as it was a single-piece billet aluminum part while Steve's kit is two-piece steel. Probably could recreate Venom's bracket for myself. Let's face it, it's 6 bolt holes and an odd-ball shaped perimeter. But...all these kits have been road tested, and again, if my wife is driving this car, do I really want to experiment with her life? As an engineer, I fully realize that the devil is in
the details and what seems elementary on the surface, most times is anything but.

Vintage Venom Front Brake Cobra Adapter Bracket

Steve's Mustang Front Brake Cobra Adapter Bracket

So while I percolate this bracket dilemma, I'll start cruising Ebay looking for Cobra/Mach1 calipers. I see they come in both 38 and 40mm piston diameters but unless she plans on racing this thing at Watkins Glen, I don't think she is going to notice +/- 2mm of piston diameter. I plan on powder coating them to match the car so I'm just going to track down some used ones and pull them apart for powder coat then rebuild. So not much progress but at least some - one bite at a time right?

Tuesday, September 1, 2015

Checking In

Hi guys,

Thought you might be interested in what I've been doing with myself with no Mustang to work on for the past year. This sort of fills the gaps while I'm gone. Scratch built by 3 guys in about 6 months. Just getting ready for first field trials in a few weeks. So far so good. Haven't run down over the hill and caught on fire yet - always a good things with robots as they tend to do that a lot. Enjoy!

I've been popping in once in awhile to check all your progress. Seems like we have all been a bit distracted these days. That's the nice thing about not having a deadline. You can work when the time allows it. Take care!


Tuesday, April 1, 2014

Some Sad News

Well gentlemen, I've been putting this off but since time is rapidly running out, I need to come clean. If you remember, last year I spent some time working in Australia on a robot project. Just before this past Christmas, I was contacted by the university we worked with to see if I was interested in continuing on with the project down there with them. Talked it over with wife, daughter, parents, siblings, friends, etc as at our age, one's life is not to do with as one pleases. There are duties and responsibilities to others that must be considered before you can consider your own. But the general consensus was 'Are you crazy - GO!!!!. It's actually a good time - Daughter Julie is out of grad school and working at her first 'real' job. Both sets of parents are in good health and gave us their blessing for taking off. Off we go then - for at least 2 years.

So we've been scrambling to reorganize my own business here since January - and to try and wrap up SusieQ so she was in some movable form. In a Herculean effort last week, we got the front/rear valances installed, the taillights in, the rear bumper on, the front fenders on and the stone guard bolted up. Bought a one-stall garage from a local Amish building company and planted it in the backyard. Last Saturday, we loaded up the car and transported her about 5 miles from the shop to my house.

Right now then, she is sitting about 50 ft from me, snug in her new home and wrapped up for a 2 year hibernation. A shame as it looked like we would have probably gotten her on the road this summer. But she'll be here when we get back and I'll probably get a few weeks worth of work on her when we come back for vacation. Here then is your last look at SusieQ for an extended duration. Of course, I expect you all to continue your own work, and look forward to your postings as I live vicariously through your work while I'm gone. Take of yourselves then and keep those wrenches warm!

SusieQ heading towards hibernation - March 29, 2014

Sunday, March 23, 2014

Tail Light Recovery

Finally got back around to those tail lights buckets that I managed to mangle last month in a fit of impatience. I'm blaming it on cabin-fever and the need to see sunshine again :/ Anyway, during the cooling off period, I went ahead and purchased a set of the satin-finished tail light bezels from Scott Drake.I would have rather de-chromed the originals and powder coated a matte-silver - but de-chroming stuff is such an environmental disaster if you do it at home - and expensive if you send it out. The Drake option seemed the best choice as I was looking for a little less chrome to start with. 

Once the bezels arrived, I used them as the color template for picking a powder that would match them. The intent being to strip the chrome trim that attaches to the rear 1/4 caps and deck lid and powder coat in a color to match the bezels. I've read that these pieces are stainless but I'm pretty sure they are just anodized aluminum. Being such, I decided to try the oven-cleaner trick to remove the anodizing prior to powder coating. Surprisingly, it worked fairly efficiently. I placed them in a shallow tray and just kept them 'wet' with the cleaner for approximately an evening of shop time. You could literally see the anodizing sloughing off the pieces. Once I got the anodizing off, I took them to the weld table and VERY carefully tapped  a few nicks/bumps out of them using a small hammer and various small round pieces of scrap metal. A quick trip to the blast cabinet and they were ready for powder coating. I ended up sending to Prismatic Powders for 5 different color samples, and the one that seemed the closest was Silver Satin. So I ordered a pound of that and a pound of Casper Clear (Sven recommended) to topcoat with.

While waiting for the powder to arrive, I sucked it up and went after the buckets. First step was chemically stripping as much of the damaged powder coat off as I could. Took three applications to finally get to a point where I could finish them in the blast cabinet. Even then, it was a long hour for each one. That powder coat is TOUGH stuff!!! I took my time this go-around - did the proper surface prep - set the oven for 400 deg and let 'er rip. Happily there were no surprises when I popped the oven door this time. Beautiful, mirrored surface like I was looking for the first time. Lesson learned...

Tail Light Bucket - Satin Silver Powder Coat

Tail Light Assembly

Monday, March 3, 2014

Front Fenders and a Quiz

Got a rare window of above 40 deg temps on Saturday in this 'Winter That Will Never Quit'. Took advantage of the 'warm' sunshine and dragged the front fenders outside for final prep of the inner surfaces. Another glamourless job that no one will ever appreciate save for the few of us crazy enough to do it. Used my standard protocol for jobs like this:

1. Scrape old undercoating off with putty knife

2. Remove residue with solvent

3. Scour with SOS pads. (I like using them for this as you get the combination of soap and steel wool. Leaves a nice clean, smooth surface.)

4. Treat with TSP, rinse with water, let air dry in warm sunshine

5. Coat with Rustoleum's trusty, rusty metal primer

6. Top coat with Rustoleum's Truck Bed Liner

Got the second fender top coated just as the sun ducked behind the hilltops and the temps dropped 10 deg. Nice to get that job done outside as the bed liner contains Xylene which is some really nasty stuff for working with indoors. 

Once I get the inner splash shields in place, I should be ready to mount the fenders. At that point she should start looking like a car again rather than a 20 year long high school science project.

 So for the quiz. Anyone wants to guess why there isn't an antenna hole in the top of the passenger fender? You'll be surprised by the answer. And no, I didn't weld it shut.

Mystery Fender

Saturday, February 15, 2014

Yeah...those things no one likes...

Well I finished installing 'the things no one likes' this afternoon. This will FINALLY allow those pesky quarter windows that have been out of the car for 15 years to make their appearance. I had to open up the trim holes from .201" to .25" before installing. Put a dab of silicone behind each washer to make sure I had a good seal with the body. I'm still happy with them despite the reception. A cool industrial look. 

Before I got too carried away, I decided to buff/polish the areas where they installed so that I didn't have to work around them when buffing the entire car. Which obviously should be done before any hardware is attached but due to some upcoming events, I'm in accelerated-mode to get as much of the car reassembled before the end of March.

Sven recommended going with a 3 step process called Perfect-It from 3M. I bought 3 bottles of the stuff from the inner-web and did a trial run on the rear valance. Stage 1 is rubbing compound, Stage 2 coarse polish and Stage 3 fine polish. Pretty much idiot proof. Squeeze the stuff onto the matching foam pad and have at it with your D/A. I was very happy with the results. I had a slight tinge of red to the rubbing compound pad which confirmed I was skimming a bit of color off the top - then diminishing color residue in Stages 2 and 3. If the rest of the car comes out as well as the valance, I'll be a happy camper. For a daily driver shot in single stage Dupont Centuri acrylic enamel, I can't ask for too much more.

Once I got the valance buffed/polished, I flipped it over and shot some truck bed liner on it just to protect the inner surface. Got the back-up lights out of  storage and dropped them in just for looks. Ended up media blasting the back surfaces and clear coating before installing. I'll get the gaskets installed then mount permanently next time I'm in the shop. Once that's done, the rear valance should be ready to mount. Will be nice to see some sheet metal going on the car rather than coming off of it for a change!!!

There's a quarter window track hiding inside that quarter panel !

Rear valance moving towards completion

Saturday, February 8, 2014

Bad Day at Black Rock Canyon

Why, oh why, oh why did I hurry today ?!!!!!! Powder's easy...but it is still a form of painting and as such requires proper prep and execution. I choose to do neither today and have paid the piper for it. Arghhhh....

Decided to head to the shop after getting some early morning skiing in. Have been working the rear of the car lately, trying to get the valence, taillights and trim installed. Today I wanted to get the rear taillight buckets media blasted and prepped for installation. I hadn't decided if I was going to powder coat, re-zinc plate or just leave them natural.

I first wanted to see what was under all that dirt and grime - then make the decision afterwards. So swapped out the blast garnet for walnut shells as I didn't want to abrasive-blast the zinc-plated surface if there was a chance I could save it. The first bucket came out great. I couldn't believe how nice it was. I thought, if the other one looks this good, I'll just hit them with some satin-gloss clear powder coat and be assembling them in front the TV  tonight while watching the Olympics. 

But as all things in car restoration, nothing goes as planned. The second was dreadful. Under all that dirt, were a bunch of oxidation patches, deep scratches and discolorations. Always the story with zinc-plated parts. Here you have 2 buckets that have lived their entire lives, just 3 feet away from one another. One is pristine, the other a disaster. What to do? Decided, since the second was unsalvageable surface-wise, there was no reason to not powder coat it argent silver. Not my favorite option but for a part typically hidden from view, I just decided for the sake of efficiency and getting the car done before my wife is 80,  to press forward with that. So back to the blast cabinet - swap in the garnet and go after all the oxidation patches. An hour later, the zinc-plating now obliterated, it didn't look too bad. Cleaned it with solvent, pre-heated it to eliminate any outgassing from the oxidation areas and coated it with argent silver powder. And this is where the train came off the tracks. I typically like to preheat a part to at least 400 deg or a bit higher to get rid of any potential outgassing but the part looked so clean, I only preheated to 150. After a 20 min cure, I pulled it from the oven and was already patting myself on the back for a flawless surface....and then I turned it over. Noooooooo!!!!!!! Blisters all over the backside of the part. Then, like Dennis and his deck lid, God and I had a short, but intense discussion regarding my powder coating technique. Oh fudddggggeeeeee.....

argent silver

blister city

Disgusted but undeterred, I swapped out the silver powder in the gun for satin clear, figuring I might as well  finish the other bucket while the oven was hot. In then end, it was the direction I wanted to go anyway. Long story short, another disappointment. The gloss was uneven and there was a slight yellowish hue to the clear. So 4 hrs in the shop - score 0-2. I cleaned myself up and went home with my tail between my legs. I now have 2 fubar'ed parts coated in impregnable powder coat - totally unusable for the moment.

satin-clear with just a hint of warm yellow :(

I have 2 more spares in the basement, so I might try and media blast them and see where they stand - then pay attention to my prep and execution and get my head out of my butt and focus on what I'm doing. Double fudge....