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71 Mach1 rebuild
#1
Right to begin with a little history of the car.

 I have hade this car for about 16 years and until about 9 years ago it was used regularly, up until on the way home from a owners club show it decided to eat its gearbox, as the car was a bit of an oil burner anyway I decided to take the engine and gearbox out to do a bit of restoration work to them, but with the engine and gearbox out I decided to start prodding around the bodywork ( fatal mistake ) next thing I know was that the rear light cluster fell out. with this in mind I decided to pull the car apart and do a total rebuild.

A photo of the car as I bought it.

[Image: 36299051433_a08da76e39_b.jpg]002a by karl stroud, on Flickr

The first thing tackled was the gearbox rebuild, this also involved in fitting a shift kit.

[Image: 36970332451_9fd85b6692_b.jpg]DSC00100a by karl stroud, on Flickr

The next job tackled was the replacement of the back end..

[Image: 36923282106_d890e8cfe0_b.jpg]DSC00107a by karl stroud, on Flickr
[Image: 36276441734_ccc45f78cd_b.jpg]DSC00118a by karl stroud, on Flickr
[Image: 36923284316_65459f2f54_b.jpg]DSC00119a by karl stroud, on Flickr
[Image: 36299079323_061ef02236_b.jpg]DSC00352a by karl stroud, on Flickr
[Image: 36970341161_1bd6abd6d2_b.jpg]DSC00353a by karl stroud, on Flickr
[Image: 36923289596_6d421026fe_b.jpg]DSC00354a by karl stroud, on Flickr
[Image: 36276452244_5f3da8f321_b.jpg]DSC00357a by karl stroud, on Flickr

Also done at this time but not photo's were taken, was both rear torque boxes repaired and the front passenger torque box also repaired, and also the aftermarket sunroof was removed and the roof repaired and re strengthened, I also fitted chassis connection bars.
 Next up was the scuttle and heater intake repair.

 [Image: 36276456994_8a42154f97_b.jpg]DSC00364a by karl stroud, on Flickr
[Image: 36299087383_8c813e6b47_b.jpg]DSC00368a by karl stroud, on Flickr
[Image: 36276457024_37fb38953a_b.jpg]DSC00373a by karl stroud, on Flickr

Next up it was the turn of the chassis rails, shock towers and inner fenders.

[Image: 37111738665_db9ba7a962_b.jpg]DSC00375a by karl stroud, on Flickr
[Image: 36923297706_7385d2ddc4_b.jpg]DSC00377a by karl stroud, on Flickr
[Image: 36715275040_bcafe0f353_b.jpg]DSC00382a by karl stroud, on Flickr
[Image: 36923300476_80418c4221_b.jpg]DSC00383a by karl stroud, on Flickr
[Image: 36923302056_fdf0e12dec_b.jpg]DSC00384a by karl stroud, on Flickr

After this was done the main shell was painted with primer then after this was flatted off then painted with topcoat.

[Image: 36941557132_60a37b74cf_b.jpg]P1000875a by karl stroud, on Flickr
[Image: 36923307696_eb59c7a794_b.jpg]P1000876a by karl stroud, on Flickr
[Image: 36941564962_1cb9f79f0b_b.jpg]P1000880a by karl stroud, on Flickr
[Image: 36941562322_a773a0beb0_b.jpg]P1000881a by karl stroud, on Flickr

The doors, front fenders, hood and trunk lid were all stripped and filled where needed then primed and painted..

[Image: 36715277380_89e50b0244_b.jpg]DSC00398a by karl stroud, on Flickr
[Image: 37111746015_08bfe4c2c2_b.jpg]DSC00406a by karl stroud, on Flickr
[Image: 36941563682_31d4275c4c_b.jpg]P1000900a by karl stroud, on Flickr
[Image: 36941566912_61b8bd5cfc_b.jpg]P1000924a by karl stroud, on Flickr
[Image: 36970380231_8b05457ded_b.jpg]P1000964a by karl stroud, on Flickr

The fuel tank was reconditioned and modified for fuel injection and fitted to the car as well as new fuel lines being run.

[Image: 36941564092_92c4873420_b.jpg]P1000902a by karl stroud, on Flickr

The next job to be tackled was the suspension, first was the rear this just required fitting new springs shocks and poly bushes, and at this time custom made traction bars were fitted, a rear sway may be fitted at a later date as I fitted the correct fixings in the chassis for a factory sway bar, then it was the fronts turn this involved re-enforcing the front upper and lower arms and making custom stay bars as well as fitting new springs, shocks and poly bushes and fitting an uprated sway bar.

[Image: 36715295150_8b7994e1ef_b.jpg]P1000946a by karl stroud, on Flickr

The front upper and lower arms were boxed in and seam welded.

[Image: 36970375211_76db730714_b.jpg]P1000959a by karl stroud, on Flickr
[Image: 36970371071_55bc9e4a34_b.jpg]P1000960a by karl stroud, on Flickr
[Image: 36715293330_feeb2cf75c_b.jpg]P1000962a by karl stroud, on Flickr
[Image: 36715309070_518bb4a1e4_b.jpg]P1000970a by karl stroud, on Flickr
[Image: 36970389151_7b263c2e60_b.jpg]P1000972a by karl stroud, on Flickr
[Image: 36715335010_cfbf3d4205_b.jpg]P1000995a by karl stroud, on Flickr
[Image: 36715335620_b1469bc243_b.jpg]P1000996a by karl stroud, on Flickr
[Image: 36715340270_cec70fc7ca_b.jpg]P1000999a by karl stroud, on Flickr
[Image: 36715342850_6644b02b46_b.jpg]P1010001a by karl stroud, on Flickr
[Image: 36299187043_00f63a8efa_b.jpg]P1010009a by karl stroud, on Flickr
[Image: 37111792485_2fcb509cdf_b.jpg]P1010010a by karl stroud, on Flickr

I also started sound proofing the inside.

[Image: 36970394601_2fa93ac8f7_b.jpg]P1000982a by karl stroud, on Flickr
[Image: 37111771845_4fedaf5d0a_b.jpg]P1000983a by karl stroud, on Flickr
[Image: 36923343706_84797664bb_b.jpg]P1000988a by karl stroud, on Flickr
[Image: 36970406291_7474c6f12e_b.jpg]P1000991a by karl stroud, on Flickr

The rear lights where also reconditioned.

[Image: 36715341430_739da35449_b.jpg]P1010003a by karl stroud, on Flickr
[Image: 36299183103_48a5bd0a3b_b.jpg]P1010004a by karl stroud, on Flickr
[Image: 36970420761_92d3210733_b.jpg]P1010005a by karl stroud, on Flickr

Also done was the repair and repainting of the steering assembly.

 [Image: 36715364670_5c923644cc_b.jpg]P1010019a by karl stroud, on Flickr
[Image: 36276542994_23e4a4493e_b.jpg]P1010020a by karl stroud, on Flickr
[Image: 37111805725_70434216ca_b.jpg]P1010024a by karl stroud, on Flickr
[Image: 36715375770_62646eaf76_b.jpg]P1010026a by karl stroud, on Flickr
[Image: 36299047153_e5bcc2a3b2_b.jpg]P1010031a by karl stroud, on Flickr
[Image: 37111717965_6702bd1aa3_b.jpg]P1010032a by karl stroud, on Flickr

Next was the repair of a very broken front grill.

[Image: 37004506786_ce3d6964da_b.jpg]P1010035a by karl stroud, on Flickr
[Image: 37194417265_528e7189a0_b.jpg]P1010038a by karl stroud, on Flickr
[Image: 36357749274_e3b218ab2c_b.jpg]P1010039a by karl stroud, on Flickr
[Image: 37052528111_4c997e52e8_b.jpg]P1010090a by karl stroud, on Flickr

I also started to fit the roof sound proofing and head lining.

[Image: 37111796785_b2e2e7cd3a_b.jpg]P1010013a by karl stroud, on Flickr
[Image: 37111797455_7c6ee0535f_b.jpg]P1010014a by karl stroud, on Flickr
[Image: 37194422845_e89f47e88d_b.jpg]P1010047a by karl stroud, on Flickr
[Image: 37194418095_b8823aaa7d_b.jpg]P1010048a by karl stroud, on Flickr

At this time I decided to get the exhaust system out of the way and made some adjustable brackets for it as the engine is not in yet I could not finalise the position.

[Image: 36797067750_aa24031b4f_b.jpg]P1010059a by karl stroud, on Flickr
[Image: 36357748384_36d5c77bb6_b.jpg]P1010060a by karl stroud, on Flickr
[Image: 37052517541_ac668e7e44_b.jpg]P1010061a by karl stroud, on Flickr

The trunk has also been soundproofed.

[Image: 37004515566_f99323614d_b.jpg]P1010076a by karl stroud, on Flickr
[Image: 36380553823_8d714a9932_b.jpg]P1010078a by karl stroud, on Flickr

Then the swirl pot and fuel pumps have been fitted.

[Image: 37004524816_7421c0f1d2_b.jpg]P1010093a by karl stroud, on Flickr
[Image: 37004502696_b79c652c66_b.jpg]P1010095a by karl stroud, on Flickr

And the custom made brake pipes.

[Image: 36357732454_575f8be22e_b.jpg]P1010096a by karl stroud, on Flickr
[Image: 37004503696_c7884b7ffe_b.jpg]P1010097a by karl stroud, on Flickr

The next job done was to media blast the wheels and repaint them..

[Image: 36648840553_c63dd3a12b_b.jpg]P1010102a by karl stroud, on Flickr
[Image: 37062384680_671f8f7ba0_b.jpg]P1010105a by karl stroud, on Flickr
[Image: 36648842373_2bf6cd7123_b.jpg]P1010107a by karl stroud, on Flickr
[Image: 37062388200_fe560cae6d_b.jpg]P1010108a by karl stroud, on Flickr
[Image: 37062389090_82187d7e8f_b.jpg]P1010110a by karl stroud, on Flickr
[Image: 37288909862_6716579c2c_b.jpg]P1010114a by karl stroud, on Flickr
[Image: 36609010834_833bc6f897_b.jpg]P1010116a by karl stroud, on Flickr
[Image: 36609013064_0f2509c931_b.jpg]P1010120a by karl stroud, on Flickr

The next job I decided to do was to repair and modify the front side/indicator light assembly so it will be legal for use in the uk.

[Image: 26132912809_22b4aac7d4_b.jpg]P1010133a by karl stroud, on Flickr
[Image: 37908942221_f75ffe20a7_b.jpg]P1010136a by karl stroud, on Flickr
[Image: 37860580116_0b7ce4615c_b.jpg]P1000463a by karl stroud, on Flickr
[Image: 37199464844_91335db690_b.jpg]P1000464a by karl stroud, on Flickr
[Image: 37199465824_6d0ba3f6e9_b.jpg]P1000466a by karl stroud, on Flickr
[Image: 37199470534_6ec97441f7_b.jpg]P1000468a by karl stroud, on Flickr
[Image: 37199468294_531b785b72_b.jpg]P1000469a by karl stroud, on Flickr
[Image: 37908943111_a99a8d251c_b.jpg]P1000470a by karl stroud, on Flickr
[Image: 26132930119_58b6e016f1_b.jpg]P1000473a by karl stroud, on Flickr
[Image: 37908948221_96498d7441_b.jpg]P1000476a by karl stroud, on Flickr
[Image: 37860588196_a11164db2d_b.jpg]P1000478a by karl stroud, on Flickr
[Image: 24057247498_7afa33e892_b.jpg]P1000482a by karl stroud, on Flickr

Now it was the turn of the interior trim starting with the cracked and damaged dash top.

[Image: 24215967417_49daae88ab_b.jpg]P1010150a by karl stroud, on Flickr
[Image: 27299432199_9f30f4dac8_b.jpg]P1010152a by karl stroud, on Flickr
[Image: 39077047591_72b6986d13_b.jpg]P1010153a by karl stroud, on Flickr
[Image: 24215970867_517676cf8a_b.jpg]P1010154a by karl stroud, on Flickr
[Image: 39077049761_19ea122e66_b.jpg]P1010155a by karl stroud, on Flickr
[Image: 39046482672_35806491b5_b.jpg]P1010158a by karl stroud, on Flickr
[Image: 40805882462_88a2945d3e_b.jpg]P1000540a by karl stroud, on Flickr

Then the door cards.

[Image: 38195662075_aff1073016_b.jpg]P1010161a by karl stroud, on Flickr
[Image: 25743610168_2d0a111d3c_b.jpg]P1010167a by karl stroud, on Flickr
[Image: 38906597694_30fc56bf41_b.jpg]P1010168a by karl stroud, on Flickr
[Image: 39953250645_aaacf08088_b.jpg]P1000530a by karl stroud, on Flickr
[Image: 40138916584_c10087ee05_b.jpg]P1000532a by karl stroud, on Flickr
[Image: 39953250385_a160f06bb0_b.jpg]P1000533a by karl stroud, on Flickr
[Image: 40805879122_fd0853da06_b.jpg]P1000539a by karl stroud, on Flickr

Also at the same time a lot of other interior trim parts where also repaired and repainted.

[Image: 25975857247_6e47909787_b.jpg]P1000535a by karl stroud, on Flickr

After doing all of this work to the main part of the car I thought it was time to start doing some work on the engine. With this in mind I started collecting parts for its rebuild first up was a cheap pair of alloy heads for me to experiment on ( the original 2v heads require to much work ).

[Image: 39077043951_22f171f746_b.jpg]P1010165a by karl stroud, on Flickr

Next up was the rebore, this was a complete nightmare as one of the cylinders had over 25 thou of wear on the thrust face so the block required a rebore of 60 thou, the engine was sonic measured and was found to have plenty of meat on the walls.

[Image: 40342875672_a4fa23605e_b.jpg]P1000506a by karl stroud, on Flickr

New pistons and rods where then ordered..

[Image: 41852545242_af2a03041e_b.jpg]P1000562a by karl stroud, on Flickr

The block was then smoothed inside and out and then painted.

 [Image: 26977590588_eb7b70d786_b.jpg]P1000542a by karl stroud, on Flickr

Next I started collecting parts again and I also modified an old accel distributor to act as a cam position sensor for the EFI I will be fitting at a later date.

 [Image: 41703813462_73a705149d_b.jpg]P1000546a by karl stroud, on Flickr
[Image: 40845459205_759bc409f6_b.jpg]P1000547a by karl stroud, on Flickr
[Image: 26876500987_3f079ca497_b.jpg]P1000548a by karl stroud, on Flickr
[Image: 40845459895_7026a033b3_b.jpg]P1000550a by karl stroud, on Flickr
[Image: 40845462035_a7aced21b2_b.jpg]P1000551a by karl stroud, on Flickr
[Image: 39953248095_2162409a09_b.jpg]P1000543a by karl stroud, on Flickr

This where I have got to as of may this year, almost no work has been done since then as my mum passed away in may and I have been helping my dad out, in fact I have only started doing a few bits to the car in the past week or so, and that was only sorting a couple of paint reactions and a couple of small cracks which had developed on the roof.
 I will update this thread when I get around to doing some more work to the car, plus I have got to get some advice on the final spec of the engine.

Karl.
[+] 1 user Likes kusanagi's post
  Reply
#2
First off...very sorry for your loss! 

Wow you've done a lot of work and it looks great!  goodpost I like the fact that you were able to restore all of the interior pieces rather than buying new parts.  I have a very long road ahead of me with my 72 Mach 1 and all I've been doing is looking at new parts.  I'd love to know what you used to fill the cracks in your dash pad, steering wheel and other interior parts and what other products you used to finish them.  They all look great!  Maybe you'd like to come to Florida to help with my project.
  Haha
  Reply
#3
Very impressive and well done!
Especially when I see the living room, garden becoming the garage extensions, the work done outside...
I know the lack of space adds so much extra work. This makes what you did even more impressive!

I wish I had a neighbour like you! Smile

73 modified Grandé 351C. Almost done. 
71 429CJ. In progress
  Reply
#4
On the repair on the dash crash pad and the doors, First I opened up the cracked or damaged area's with a die grinder, then I then melted some polyurethane tubing ( this was the closest I could get in likeness to the original sponge ) into the ground out sponge area's with a gas powered plastic soldering gun. This was then sanded down to just below the surface level then filled with flexible filler ( the type used on bumper repair's ) this was then sanded flat then skimmed with a thin layer of Stopper ( a self quick setting soft filler ) then sanded again. In doing all this sanding I lost the grain on the panels so to get some type of grain back I sprayed the panels with plastic primer then primer then a final coat of texture paint ( satin black ).

I also repaired the rear plastic trims using a similar technique as they had damage and had lost all of there colour and texture due to sun bleaching.

For the steering wheel to repair this I opened the cracks up with a small grinder then filled the cracks with a dry 2 part epoxy resin, this was then left to dry then sanded, this was then filled with stopper, sanded again then primed with plastic primer then a grey primer which was sanded smooth then sprayed with a gloss black paint, also repaired at this time was the horn push which did not work due to damage and corrosion.

The other thing I did to my door cards was to bond on some thin aluminium sheet with holes cut in them ( for the fixings ) as the cards had some damage and were also warped due to dampness, this will give them a bit more strength and rigidity.

P.S. most of the shots in the living room were done when my parents were away visiting my sister.

And thanks for the condolences.

Karl.
  Reply
#5
Excellent work, can’t wait to see your car finished!

run_horse Run Horse Run!
John 72 Q Code
  Reply
#6
You have some good skills. Cant wait to see it finished. The power is a world away from that 71 Spitfire you have

Steve
1971 Grandé
  Reply
#7
WOW, I cannot believe all the effort you have put into that car. I have scraped many with less rust and issues than yours. Looks like you are doing a great job. I guess we are spoiled here in U.S. when we can get parts much easier than you can.
Keep the pics coming as you progress. On your engine build. Be sure you retain the baffle under the thermostat and that you get the proper thermostat to prevent any over heating issues. Be sure you get the head gaskets turned the right way will have Front marked on the gasket.
Cheers,
[Image: 100_3511.jpg]

[Image: 100_3513.jpg]

William Warner poems


When a man is in the woods and talks and no women are there is he still wrong??
Tongue
David
  Reply
#8
The baffle is still there ( thanks for the pointer anyway ) and will be getting the correct thermostat for the engine, I will be getting a pair of cometic head gaskets to get the correct compression ratio, and will have to triple check to make sure that they are fitted correctly.

That spitfire of mine ( which I have owned for 25 years ) currently has a multi-point sequential injected 3.5 litre v8 in it with a 5 speed box behind it and Granada diff and custom rear suspension fitted, so it is no slouch Big Grin .

[Image: 36923046716_97853aff12_b.jpg]DSC00386a by karl stroud, on Flickr
  Reply
#9
Excellent restoration work. I am amazed of all the work done restoring the interior. Looks awesome! Keep at it. You are almost there. Like i say to myself, closer than when I started.....

Sent from my SAMSUNG-SM-G930A using Tapatalk

        [Image: 20160929_171923_edit2_small.jpg]

1971 M-Code Mach 1 w/Ram Air, 408 stroker, 285/291 0.558" roller cam, Blue Thunder intake, TKO600, Hooker headers with electric cut-offs, FiTech EFI w/ RobBMC PowerSurge pump
4-wheel disc brakes
  Reply
#10
runninpony 
You DO have great craftsmanship!

Old Mustangs never die, they just go faster!
  Reply
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