| We have had an overwhelming response from our fellow SEMA/ARMO members and other business people. We will update the list as contributions come in. Our many humble thanks to everyone who helps out on this project! | Concours Parts www.concoursparts.com Moser Engineering www.moserengineering.com Master Power Brakes www.mpbrakes.com |
Painless Performance Wiring www.painlesswiring.com Edelbrock Corporation www.edelbrock.com | Keystone Automotive www.keystone-auto.com RPM Performance Engines www.rpmperformanceengines.com |
Coker Tire www.cokertire.com Auto Custom Carpets www.accmats.com | Sunpro gauges www.sunpro.com Mr. Joe Potter and family of San Mateo, CA |
Lizard Skin Ceramic Insulation www.lizardskin.com | Hot Rod Air www.hotrodair.com |
March Pulleys www.marchperf.com | Milodon www.milodon.com |
| | |
| | |
 | We feel this Police Officer is a hero and feel honored to be able to participate in this project. Our President, Melvin Benzaquen, felt compelled to donate his time and resources to this project and has called upon the industry to donate parts for this project. We will be listing the contributors as the project progresses. The car will be on display at the Concours Parts display next to the Overhaulin tent at the 2007 SEMA show in Las Vegas. Watch the movie "World Trade Center" starring Nicolas Cage and directed by Oliver Stone to see what this hero went through for our country! This car looks pretty good, right? Scroll down for the real dangers that we have found. |
 | Here is the left rear frame rail that has had a metal patch just welded over the rust hole and cracked frame. This is not going to stop the rust, in fact, it will probably accelerate it. |
 | Rear axle brake line junction block. If you look closely on the other side, you can see a steel line coming out of it. It is supposed to be rubber. A better shot is coming. |
 | Left rear quarter trunk extension panel is not even welded together |
 | frame patch and cracks |
 | Here is the front shot of the steel brake line coming from the brake junction block. This is supposed to be rubber so when the rear axle goes up and down, the rubber line flexes with it. This steel line will eventually break form flexing. On these pre 1968 cars, there is only a single master cylinder chamber. That means when one line breaks, you lose total braking. |
 | Fuel line is routed outside of frame and in between the rear leaf spring. This could potentially crush the line and have fuel spill everywhere. |
 | This is a body mount that is not connected to the chassis as it is supposed to be. Doesn't do much for structural integrity in an accident if your body is not mounted to the frame |
 | If you do happen to not have your brakes fail, your fuel get pumped everywhere and your body fall off, there is always the chance that the accelerator pedal linkage held on by baling wire will keep you from accelerating, especially when pulling into traffic |
 | Crushed lower radiator tank. Just takes less time to fill it. |
 | What's another body mount not connected? |
 | Ah, after all that, here is another hidden danger, Let's route the rubber fuel line on top of the left exhaust pipe, after all potential for explosion is not a concern for the person who "restored" this car |
 | Another view of the same pipe further down. The steel brake line is also laying on top of the exhaust and you can see how the fuel tank wiring has already melted away from the heat |
 | Now, look at this car after seeing the above pictures. Looks pretty good still? Not having a car properly inspected when buying long distance or locally can be potentially fatal to you and anyone else on the road. |
 | Interior |
 | 292 CID "Y" Block V8 motor |
 | Dash view |
 | Big gap between trunk and quarter along with the paint literally popping off. |
 | Very tight gap on the opposite side |
 | Windshield is being removed |
 | Painless Performance wiring has been laid out and routed to make sure all is there. |
 | Front chrome trim has been removed |
 | Upon removing the rear trim and lamps, we found a part of the trunk floor was never put back leaving the trunk open to the elements. |
 | Overall view of the car with it's trim removed. |
 | Interior is being stripped |
 | Engine and transmission have been removed |
 | Engine and transmission on the cart |
 | Interior now is completely barren of all parts. We will be sending the T Bird to be bead blasted. |
 | The new 9" Ford rear has arrived |
 | The TBird has arrived from being bead blasted. We were pretty sure the rear of the car was going to have a lot of problems but it turned out to be the opposite. |
 | The left side view. |
 | Another example of right approach and wrong execution. They took the time to purchase lower patches but did not fully weld them in. |
 | Here is a close up of the inferior welding |
 | WHAT IS THIS? Even bead blasting could not remove this stuff. It appears that there must of been a shortage of bondo so a floor tile latex cement was utilized all throughout. |
 | There is 1 spot of rust brazed closed in the trunk lid and then they just filled the rest of the holes. |
 | More rust filled with latex cement. |
 | More latex filler on the rear deck. |
 | This looks like Big Bird had an accident on top of the quarter panel. |
 | Welded a patch over something followed by a liberal dosage of latex cement |
 | Here is the top of the right fender at the windshield base. There is evidence of some sort of patch having been installed followed by a liberal beating and then a judicious amount of cement was poured on |
 | Here is the view from a distance. this just shows you cannot tell what is going on underneath the paint. We certainly have our work "cut" out for us! |
 | Now that we have removed the latex cement, we have to remove the rotted metal and prepare to make a new patch panel |
 | Here is the panel prior to removal |
 | We have removed the rotted metal |
 | Here are some chunks of latex cement that was removed from the TBird |
 | We have rebuilt the lower windshield channel, the top and side of the fender. This is a bare metal patch and you can see how smooth the body will be. |
 | The right fender factory leading is removed and new patch panels are being welded in. |
 | We have metal finished the park lamp patch panel to now be one with the fender |
 | Now all the dents and rot have been removed on the fender, the body work has been started on the right fender. |
 | The right front fender is starting to look normal |
 | The right side rear lower area was also done. |
 | The header panel work has started |
 | Now we have removed the factory leading, we made a new patch panel where needed and welded it into the fender. |
 | Here is the beginning of patching the left fender top and lower windshield channel area. |
 | A close up of the patch panel pregress to the left fender |
 | The left rear quarter panel has rust holes throughout |
 | The rear opening of the left quarter panel. |
 | More latex cement found in the tail lamp area. |
 | The upper left fender patch panel and windshield channel look factory new in bare metal now. |
 | Another view of the upper fender patch. Note how the small fender peak has been reproduced and appears to be original. This is how metal work is supposed to be done. |
 | The replacement quarter panel from Concours Parts in Nevada is being readied for installation. |
 | The left quarter has been fitted into the panel. |
 | Body work has been done to the left quarter. When we removed the existing quarter, we found the rocker, quarter and hinge pillar structure were not welded to the main body! |
 | Body work has also been done to the left door. |
 | Metal etch prime to the left side |
 | Another view of the left side being largely finished |
 | Metal work to the left rear body panel. You can see the difference on the left where we have worked our magic. |
 | We now are calling this car "The Home Improvement Project" In the backside of the rear body panel where the fuel tank neck goes, we found it to be rotted and bondoed back together with window screen mesh. Floor tile latex cement and window screen mesh truly is a home improvement project! |
 | Latex cement was chiseled out and the area was properly patched |
 | Patch after being welded in makes it difficult to tell there was ever a patch in that area in bare metal! |
 | Factory leading in the rear quarter was removed as there was rust all throughout it. |
 | Here is the chassis with the body removed |
 | The body sitting on a body cart |
 | Now that the body is off, we can see the butchery in the floors. |
 | Even the transmission tunnel has not escaped the rivet monster. |
 | More flooring improperly installed. Rivets do not hold together a floor very well. |
 | We have removed the steel cover that was placed on the frame to cover the rotted frame. |
 | Now that the leaf spring bracket has been removed, the extent of the rotted frame is revealed. |
 | The other side of the frame rail reveals cracked welds where the frame rail is splitting apart. |
 | Another view of the rotted frame. |
 | A close up of the rot. |
 | Here we are making a new plate steel patch |
 | Bottom of the rail patch has been welded in. |
 | Hard to tell that the patch has been welded in. The side rail requires patching also. |
 | Right side of the passenger compartment floor was riveted and seam sealed together. This hole was created just by removing the rivets and seam sealer. |
 | Drivers side floor also had judicious use of seam selaer and rivets. |
 | The drivers side rear floor where it meets the wheelhouse was held together by 5 pieces of tin, rivets and at least a tube or two of seam sealer |
 | Here is the piece as it comes out. |
 | Here is the piece removed and the back side of the multiple parts held together by fragile parts. |
 | These parts were were in the driver side floor and the seat also bolted in where this panel was. |
 | The passenger side heat duct was rotted out, filled with bondo and brass brazing. |
 | Here is the backside of the apron panel removed. Not a professional job. |
 | Here is the front side. Not very pretty. |
 | After installation of the reproduction panel, the apron looks much better and is structurally sound. |
 | Here is the trunk floor patched back together |
 | The firewall heater opening has been closed off in preparation of the a/c system from Hot Rod Air coming in. |
 | Here the body is placed back onto the freshly painted chassis. Final fitment of the panels will follow. |
 | Here is the underside. Nice improvement! |
 | Another view of the body |
 | Engine compartment has been painted also. Fitment of the hood is now being done to ensure good gaps |
 | We now are addressing the suspension rebuild. We are starting with the disassembly of the lower control arms and will bead blast them followed up by priming and painting. |
 | Here is the Moser 9" Ford rear axle assembled with Master Power Brakes rear disc brake kit supplied by Concours Parts |
 | Test fitting the new wire wheels reveals a clearance issue with the disc brake calipers. It is always a good idea to test fit your parts early on. |
 | Another view of the rear with the disc brakes |
 | After bead blasting the front suspension parts, we assembled them and will now get them ready for painting. |
 | After body working the front suspension parts, they are primed |
 | We also painted the center hats on the rear disc brake rotors for some added style |
 | Front coil springs and steering parts are painted in a stainless gray for a nice contrast |
 | Fuel tank supplied by Concours Parts has received a coating |
 | The gap on the left is closed up to be consistent |
 | The rear of the trunk line is also closed up and is consistent |
 | Upper control arm has been painted |
 | Lower control arm has also been painted |
 | Rear axle has been painted. My reflection is visible. Not bad for a rear axle! |
 | The long and tedious road to repairing a badly rusted and damaged body. It also does not help that the last person in it did such a horrible job. |
 | Front disc brake suspension has been assembled. |
 | Finishing touches to the body continue |
 | It gets really ugly before it gets better |
 | This is a way to check your contours from side to side to ensure conformity. |
 | These gaps are much better now. |
 | 2 technicians working an average of 60 hours a week each for the past several months and we are still at it. |
 | Almost ready for final sanding |
 | Bodywork is completed. |
 | Ready for edging in color |
 | We rolled it to the mechanical side of the shop for the assembly to begin |
 | The fuse block, wiring harness, defroster ducts and brake pedal support are being installed. |
 | We custom cut a firewall pad and are getting ready to install the a/c evaporator case. |
 | The a/c condenser and horns have been installed |
 | Stock radiator installed |
 | Hot Rod Air A/C evaporator is installed |
 | Dash has been covered. The front has been taped in anticipation of trimming the heater control panel opening for the new A/C control panel. |
 | 4 port bulkhead has been installed. |
 | Vacuum control relays for the a/c have been installed. New Painless wiring is starting to be laid out. Flaming River tilt column has also been test fitted. |
 | Engine compartment has had preliminary wiring run. New dual cylinder brake master cylinder from Master Power Brakes has also been installed. |
 | New speedometer and gauge parts from Concours Parts has been installed in the freshly restored cluster housing. |
 | Another view of the freshly restored cluster |
 | Dash is being assembled with new parts from Concours Parts. |
 | New A/C control panel opening has been trimmed in the dash and the dash trim. New stereo also has been installed |
 | The 351 Windsor engine donated by us, Edelbrock aluminum heads doneated by Edelbrock Corporation which was assembled by RPM Performance utilizing various donated internal parts has appeared. |
 | Milodon donated us their road racing pan. This pan was necessary for fitment into the TBird chassis as the later Ford stock oil pans create clearance issues in the early TBird chassis |
 | Now in epoxy prime, mechanical assembly can start |
 | Here the engine is being test fitted numerous times and checked for level. |
 | The first problem encountered is the lack of clearance for the left exhaust due to interference with the factory steering box. |
 | We found a set of headers that are the closest but will require modification |
 | We have bent a new tube that will provide the clearance needed. |
 | Here is the header with the new section. |
 | The freshly rebuilt AOD transmission from Phoenix Transmissions has arrived |
 | Here is the newly modified header refinished in high heat paint. |
 | Modification of the 1979 motor mounts to fit the 1955 chassis has begun |
 | After many fitments, the final grinding of the welds is taking place. |
 | Flaming River's Italian Mahogany steering wheel is a work of art! |
 | Newly fabricated and installed motor mounts have been painted. |
 | Engine fitment is tight |
 | Here is the driver side of the engine from a lower view |
 | A lower view of the engine and transmission. Looks like it belongs there! |
 | Rear view of the transmission in it's new home. |
 | The rear flexible brake line is installed. We now have brakes! |
 | Fuel tank and lines are installed! |
 | Holley carburetor, distributor and March pulleys are installed. Hot Rod Air compressor also has found a home. You can see the Painless Wiring that will be routed soon. |
 | Fuel pump being hooked up |
 | A/C condenser fan installed |
 | Due to clearance issues, we are having to install the fan in front of the radiator utilizing custom brackets |
 | Here is the header installed after modification. Tight fit but it works! |
 | Trunk lid being readied for installation |
 | Engine is looking good now! |
 | We have lights! |
 | Dash, steering column, transmission shifter and a/c ducting are all getting finished out |
 | New exhaust and driveshaft being installed |
 | Rear exhaust pipes installed |
 | TBird loaded up to go to the exhaust shop to have the new head pipes made so the headers can connect to the stock mufflers |
 | Inside of vehicle looks great out in the daylight |
 | Back from the exhaust shop, we can see the new head pipes. |
 | Our intrepid mechanic assigned to the building of this car is driving it for the first time off the trailer back into the shop |
 | Door panel assembly begins |
 | Difficult to assemble door panels look great once installed |
 | Hood finally gets installed and aligned |
 | Gillin Custom Designs made up this very simple, yet cool, trunk kit |
 | Interior assembly progresses |
 | New windshield and rejuvenated moldings are installed |
 | Here is Gil putting the final touches on the trunk lid |
 | The TBird is close to completion. The deadline is approaching for SEMA, however. This photo was taken Friday, October 19, 2007 |
 | Here we are at a stopover in Utah with the TBird safely stowed inside the trailer. |
 | On display at the Concours Parts booth at SEMA |
 | Another shot on display |
 | Rear view |
 | Brian and Larry from Concours Parts, Sgt. McLoughlin and Melvin (left to right) at SEMA |
 | Sgt. McLoughlin gets to sit in his car for the first time since completion |
 | Sgt. McLoughlin, Melvin and Chris Kersting (President of SEMA) at the news conference |
 | Melvin, Sgt. McLoughlin and Barry Meguiar on set at Car Crazy |
 | Sgt. McLoughlin and Melvin Benzaquen at SEMA in Las Vegas after Sgt. McLoughlin was presented with the car. Sgt. McLoughlin presented Melvin with a cross that had been cut out of the World Trade Center structural steel beams by the 9/11 rescuers. |
