Author Topic: Popbumper's '76 wagon - update (Read 80504 times)

popbumper · « **on:** August 16, 2008, 08:59:52 PM »

Update for August 16 2008

Hellfire Jim suggested that I tart a thread out here for my project, and it makes sense; I will park it here from now on. Now that my car is quite in the throes of teardown (well, interior at least), I need to document it here.

I will probably take some pics tomorrow, but tonite I got a few things done. All of the work I am currently doing is for prep to repaint the dash. I am also going to remove the windshield, to conquer the rust under the seal, and allow for painting of the dash top surface. Here is what was completed:

1) Removed headlight bezel and switch
2) CAN'T figure out how to remove the windshield washer bezel!!
3) Removed the speaker - not only was it off center and held on with ONLY the dash cap nut, but the cone was toast. Need to fix that !
4) Got three of the dash cap nuts off, and three screws (thanks for the tip, FRANK). One nut is STRIPPED (meaning, the screw and nut turn together - arghh), it will need to be cut off. The last nut is quite concealed under the dash A/C unit.
5) Jockeyed the under dash A.C unit to get at the dash cap nut. It's gonna be a bit more work.
6) Discovered some rust at the drivers air vent duct - looks unfriendly, I'll wait on this one
7) Pulled the corner vents/air vanes (thanks again FRANK for the tips)

The biggest challenge so far has been the dash cap removal. Everything else seems to be falling into place, I am keeping labeled sandwich bags of parts so everything stays together. Looking forward to pulling the cap, them going after the windshield, and getting the dash painted. Then comes dash cap restoration, replacement, putting the dash back together, fix the cowl rust - and then onto the doors.

Chris

popbumper · « **Reply #1 on:** August 17, 2008, 08:17:12 PM »

Update for August 17th 2008

Sorry, no pics - got so busy I ran out of light.

Did some more "dash digging" tonite, found more leaves and cleaned them out. In addition:

1) Still don't know how to remove the windshield washer bezel!!
2) REMOVED THE DASH CAP! This was quite an ordeal - the stripped screw, I had to put pressure against the cap to hold the screw so I could move the nut. My hands are too large to fit most anywhere in tight spots, so it was a fine balancing act of turning the nutdriver with my fingertips, and pressuting the dash cap with my other hand. Very tedious, but I did it. The other nut - I had to get the wrench between the dash and A/C unit, loosen it, and then back out the nut with a screwdriver... .hard to picture but can be done if you are patient. What a job!

The dash is gonna end up being pulled off, by golly. I can see where the screws that hold it in place are, though obviously the windshield is going to have to be pulled out. I >love< mechanical engineers. How they made all this stuff fit together is a small miracle.

BTW, the heater box is really intimidating me. I know it needs to come apart (I think it's full of leaves and junk), and looks like a real job. Having the dash out will probably help this effort.

Pics soon!

Chris

dick1172762 · « **Reply #2 on:** August 17, 2008, 09:18:55 PM »

Chris! Windshield does not need to be removed to remove the dash. The row of screws at the base of the windshield can be removed and replaced with out removeing the windshield. Biggest problem is all the controls and wireing must be removed first, and be ready, because that sucker weighs a ton. Take the steering out first too.

dick1172762 · « **Reply #3 on:** August 17, 2008, 11:13:02 PM »

Quote from: Pintony on August 17, 2008, 10:10:37 PM

Hey dick1172762,
Can you access the screws under the W/S gasket???
I did not know that!!!
COOL!!!
From Pintony

Yes! With a very long screwdriver or nut driver (Ford used both types of screws) I'v had to glue the screws to the tool at times, but it always worked. Be ready, because the spedo cluster will most likely fall apart when you remove it from the dash.

popbumper · « **Reply #4 on:** August 18, 2008, 08:50:35 AM »

Hey guys:

Thanks for the replies...I guess photos would be helpful at this point, but let me explain first:

1) The seats were already out, I took them out while working on the floor. At 6'4", I would definitely >not< fit in the front floorboards otherwise :lol:. It's hard enough as is!

2) Just about every accessory has already been removed - ashtray, glove box, radio, speaker, A/C panel, heater control bezel, instrument cluster, dash cap, control bezels, so there really is nothing impeding the removal EXCEPT that the dealer underdash A/C unit is really taking up a lot of room, and gets in the way of the heater box. Not sure how I'm going to get it out, I need to figure out what hose connections need to be removed first.

3) Steering - what all must be removed? Wheel and turn signal collar? MUST it be removed or can it stay in place?

Thanks guys. What an adventure!

Chris

FCANON · « **Reply #5 on:** August 18, 2008, 08:55:07 AM »

I just drop the stearing collum down to remove the dash. letting it rest ing the floor where it lays. 4 bolts to drop it

FrankBoss

popbumper · « **Reply #6 on:** August 18, 2008, 08:56:44 AM »

If it's that simple - excellent. Thanks!

Chris

hellfirejim · « **Reply #7 on:** August 19, 2008, 06:59:59 AM »

Glad to see the you are knee deep in your project. This is going to be a big project but the trick I leanred is to just make it a series of small projects. When each small project gets done move to the next one until the big project is done. It will show progress and helps keep you from getting burned out.

jim

popbumper · « **Reply #8 on:** August 21, 2008, 09:29:26 PM »

Update for August 21 2008

Preface - it's either hot or rainy in Texas. After 30+ days of 100+ degree temps, we had five days in a row of downpours and clouds. No complaint, really, it was nice - except for having to sponge out the 1/4" of water in my floor pan every day (gotta fix the cowl)!!

Did not get much work done over the last few days as a result - you guys without garages understand. Regardless, prior to the rain, I was able to get a few more pieces out of the dash, and the dash cap removed. The cap was a real challenge; the last nut and screw turned together, forcing a wedge of something under the dash to get the nut to turn. And then, another nut was jammed between the underdash A/C unit and the dash, forcing me ti turn the nut with the end of a screwdriver - the slowest POSSIBLE way of turning a nut known to man.

Regardless, here are some reasonably >poor< pics of the removed dash cap and the nearly bare dash. The next goals will be:

1) REMOVE the entire dash. This requires the windshield to be taken out, which serves this purpose as well as allowing me to get to the cowl rust. Being a major job, I have to prep my garage (translation: make enough room in it for the Pinto >and< my wife's car - we have no basements in Texas) so that I can keep it rain free while the windshield is out.

2) RESTORE the dash cap - I have ordered materials to do so, though I am on the hunt for the right color corinthian vinyl, and have some possible leads. Sure, I'd like to go the "Just Dashes" route like Starsky and Hutch, but I'm doing this one on my own.

3) REPAINT the dash while out of the car, and address all the firewall/sound deadening/heater box/etc. issues while the dash is out.

It's gonna be a project filled winter, but I hope to come out ahead once Spring comes.

Chris

popbumper · « **Reply #9 on:** August 28, 2008, 07:42:24 PM »

Update for August 28, 2008

No pics right now, well, yeah, I took them but I have to modify them on my other computer and send to this one and I am too lazy tonite.

Got to messing around with the rear brakes tonite, figured I'd take a look at what was going on. Here's what I discovered:

1) Passenger side rear brake - pulled the drum to find the parking brake adjuster and spring fall off onto the ground. Shoes and drum look fine, but I really need to change >everything<. Gonna order parts tomorrow.

2) Drivers side rear brake - everything looks fine, but again, I'm going to pull all of it.

3) This is INCREDIBLE - remember, we're talking Texas here - the car has the ORIGINAL exhaust sytem on it. How do I know? The stinkin' muffler has the FORD logo stamped on it, as well as the date of "5 76" (which is the build date according to my build sheet), and the words "Made in Canada". Good grief!! How many of you guys have an ORIGIAL 30+ year old muffler? Maybe I need to change the pipes and restore the muffler itself, wow!! :hypno:

4) Everything else on the rear end is original (meaning, ripe for restoration, all surface rust but nothing critical). Undercoating and a life in the South SAVED this car!

5) I >DO< have a gas tank leak around the sending unit. Some of it has run down on the surface of the tank and it is definitely gas - I smelled it.

Goal for this winter: Finish the interior. Pull the rear end, blast/clean/paint the springs, build new brake lines, restore the rear end in entirety, paint everything fresh black, install all new brakes, install new shocks, pull the drive shaft and clean it up, put in new U joints, etc.

I >love< this stuff, what a blast!!

Chris

popbumper · « **Reply #10 on:** September 16, 2008, 08:58:56 PM »

Update for September 16 2008

OK. The weather is finally cooperating, the temps are outstanding. I have been cleaning the garage in anticipation for moving it inside, so I can get some stuff taken apart, and it won't be unsightly in the driveway. Up for grabs - windshield removal, which began tonite by pulling the windshield trim.

After obtaining the >very handy< tool from Harbor Freight, it was "relatively" easy. The amount of crap under the trim was staggering, mostly dead organic junk. The findings?

1) About 1/3 of the trim clips were rusted enough to disintegrate
2) The 6 clips at the bottom? Only one screw was so rusted that I will need to work it out with something besides a screwdriver
3) The two corner clips? One was intact, the other was broken
4) The rubber windshield seal is intact, but pitifully dry and cracked

SO, given that.....

Can I get trim clips from any source? Anyone have NOS ones they will sell?[/i][/b] I can derust some of the good ones I have, but there are not enough. Did Mustang or any other Ford use these (where repro parts might be available)?

Thanks as always. Windshield comes out next, then I can fix the cowl hole.
Then the dash gets pulled and repainted.

Chris

oldandcrotchety · « **Reply #11 on:** September 17, 2008, 08:01:45 AM »

I have some that look like that, new left over from my old body shop days. How many you need?

popbumper · « **Reply #12 on:** September 17, 2008, 09:08:54 AM »

Oldandcrochety:

Thanks for the offer. I could probably use ten of them, but I don't know how many you have. Let me know what you can do, I greatly appreciate it.

Chris

oldandcrotchety · « **Reply #13 on:** September 17, 2008, 09:47:17 AM »

Give me your mailing address.

popbumper · « **Reply #14 on:** September 17, 2008, 10:37:28 AM »

Just sent you an email, thanks!

chris

oldandcrotchety · « **Reply #15 on:** September 17, 2008, 01:47:32 PM »

Clips left out on the mail truck about 1:30.

popbumper · « **Reply #16 on:** September 17, 2008, 02:29:27 PM »

Wow - that's very helpful and fast. Thanks so much.

Chris

popbumper · « **Reply #17 on:** September 22, 2008, 09:47:16 PM »

Update for September 22nd

When last visited, I had just removed the windshield trim and discovered some uglies underneath - rusted trim clips, a few missing screw heads, and a corner clip that was unuseable.

"Oldandcrochety" was kind enough to send me some clips - these were not the same style, but nonetheless he was generous in doing so for free. The ACTUAL reproduction clips can be found at a place in Texas, called "Latemodelresto ration.com". If you search under 1976/Ford/Mustang/clip, they have these clips, new, for $3.95/pack of 13. Needless to say, I was thrilled to find these new!!

Then, lo and behold, another member stepped forward selling the corner clips - on the same day. Man, what luck. Bought them! The windshield clip issue is SOLVED, and everything in that area is going to be perfect.

In the meantime, I had been working on my dash cap, getting it ready for vinyl re-wrap. I am posting another thread about dash cap restoration.

Chris

discolives78 · « **Reply #18 on:** September 29, 2008, 11:51:09 PM »

my car has the original muffler, ford logo, made in canada and all, the whole exhaust system is original except for the catalytic converter, had it replaced 4 years ago because i thought it was plugged but turned out to be the carb, don't envy the dash issues, I had to replace the defrost ducts in mine because they were chewed through by mice. mine has no rust around the windshield or cowl ( God blessed the desert! ) I'm about 6'4" too, so the seats have to come out to get under the dash. of course my car doesnt have air conditioning, so its a bit less cluttered

popbumper · « **Reply #19 on:** October 13, 2008, 07:39:24 PM »

Update for October 13, 2008

Today was the first day since I got the car that I literally spent the whole day working on it (our workplace had a Holiday). In fact, my old bones are so tired right now, I won't be up late tonite!!

Todays menu:

1) Finished both rear brakes. Thanks again, Fred, for the brake drum, it really helped.
2) Changed out both rear shocks
3) Replaced the aging rear brake hose and the axle vent tube. While I hate to put new parts on a rusty axle, these things need done.
4) Bled the rear brakes. No leaks, and I have recovered use of my parking brake.
5) Replaced the master cylinder. Now I gotta tell ya, this was a >pain<, not because of the difficulty, but because of it's tight location. I really had to dink around with stuff. And the push rod to the pedal? That was weird, never having done one before. The other master cylinder was SHOT, the brake fluid was full of rust and sediment, and just looked awful.

Now, being overly ambitious, I ventured farther to bleed my front brakes and change out the hoses. Wow, first time I took off my front tires....

Mechanically, >everything< is wasted. I'm not only talking brakes, I am talking grease fittings, rubber pieces, boots, etc. Good grief, I >absolutely< need a front end rebuild - and new rotors - and new calipers - and new hoses, etc..

It started getting dark, I needed to eat dinner. I had to give up, and STILL NO BRAKES!!! Boy, it's frustrating to work the whole day and not feel like you got anything accomplished. We had to let the car back out of the garage and let gravity (carefully) do its thing. She sits, as usual, with bricks behind the wheels on the sloped drive. This car is a friggin piece of work, I must be a glutton for punishment.

More later on this developing story.....

Chris

discolives78 · « **Reply #20 on:** October 13, 2008, 09:16:39 PM »

The deeper you dig in the car, the deeper you have to dig in your pocket! I spent all day at u-pull-it, got a bunch of parts (check my thread) and when I got home all I had a chance to do to my car was change the windshield washer bottle! Truck full of parts and ran out of time.

Tomorrow or Saturday or something is another day

At least when(ever) its done, you'll feel a sense of accomplishment .

Chuck

popbumper · « **Reply #21 on:** October 14, 2008, 10:13:11 AM »

Yup, you have been a busy boy!! Wow, this morning I just found a source (80 miles away - no biggie) for parts '76 and '74 wagons. Looks like I will be taking a drive tomorrow afternoon. Boss is out of town, I am not very busy, and the thought of extra parts has me pretty excited.

Have fun!!

Chris

popbumper · « **Reply #22 on:** November 09, 2008, 10:40:00 PM »

Update for November 9th, 2008

We have had the NICEST Fall weather I have seen in 14 years of being in Texas, and I should have a LOT more done!! :embarrassed:

Well, needless to say, I have something to report...as of this afternoon I HAVE A WORKING BRAKE SYSTEM AGAIN!!! Man, oh man, I think I am a brake expert now, after three attempts at bleeding, three master cylinders (orig, 1 rebuilt, now a new), a different proportioning valve, all new rear hardware, all new rubber hoses, new rear cylinders, and a whole bunch of frustration, I pulled the wagon out of the garage onto the inclined drive and was able to stop again. I took my baby out in the street, up to the front of the house, turned around again, and parked her. It was SO GOOD to drive again!! :amazed:

That was the most frustrating thing I have ever been through!! Now, I can move forward (literally and figuratively) and get some more done. NEXT WEEK'S GOAL - attack the cowl hole before rainy season gets here.

Then - the gas tank gets pulled and the leak at the sending unit gets fixed.

Then - the windshield comes out and gets a new seal, while the dash gets repainted.

Then...stay tuned.

Chris

75bobcatv6 · « **Reply #23 on:** November 10, 2008, 01:58:19 AM »

Remember chris you still have a roof rack to install =) and pics to get up so i can see

popbumper · « **Reply #24 on:** November 10, 2008, 11:13:15 AM »

Yes I do!! As soon as I get it, it's another short project I can get done quickly. I will definitely share pics. Thanks again!

Chris

popbumper · « **Reply #25 on:** January 01, 2009, 12:12:32 PM »

Well, shame on me, it's been a long time for an update. I have been busy with other things, the weather has been cold (for Texas), and I was laid off back on November 17th. This year? Find a new job and really get cracking on the Pinto.

OK - update (late) for December 30th. The weather was beautiful (low 70's), and with the help of a friend on the Maverick/Comet forum (local guy named Gene), I was able to tackle some more needed work on the wagon. Gene runs a welding business, and it was far easier to trailer the wagon and take it over to his place (it's about 4-5 miles away).

Once we got there, we literally pulled the car back on the trailer, let it overhang, and went to work on the gas tank. I had been wanting to remove it since there was obvious leaking - around the sending unit, or so I thought. Turns out that the tank had a number of pinholes (and one hole about 3/16" in diameter) that someone had previously patched with BONDO! We pulled the tank to also find a COLONY OF ANTS living in the space between the tank and the spare tire well - weird.

While I was under there, I figured why not pull the bumper off, because the bumper insert and related hardware are so rusty. Having done this, I took all the parts to have them sandblasted, including the filler tube, rear bumper shocks, gas tank straps, bumper insert, and license plate backer. These will all be cleaned then painted with POR-15 before reinstallation .

I have to repair the tank, line the interior (it was power washed at a car wash), and rebuild it with all new parts from SSCenterprises (vent valve, filler neck gasket, etc.). I also ordered a brand new sending unit (NOS- $75), because the one in my tank was shot.

I am happy to be making progress again. Next step? Getting the rear end pulled - and either restoring it, or possibly replacing it with a larger 8" unit that has disc brakes.

Thanks for looking!

Chris

75bobcatv6 · « **Reply #26 on:** January 01, 2009, 12:23:02 PM »

if you do rear disc go with the 95 gt mustang rearend. =) and im glad to see the roof rack is on the car now =)

popbumper · « **Reply #27 on:** January 01, 2009, 03:32:38 PM »

That's not your roof rack - that's the original - it's all bent up, you cannot see it!

Chris

75bobcatv6 · « **Reply #28 on:** January 01, 2009, 09:40:33 PM »

aww lol. ok ok. well either way its good to see you moving on the project again. for me atm im at a stall till i have better cash flow. (I.E the g/f gets back to workin and i get a little of my money back)

popbumper · « **Reply #29 on:** January 01, 2009, 11:28:47 PM »

My cash flow ain't exactly liquid until I get another job. Right now I am spending some hobby money I have saved up - little bit here and there - I'll hit the wall again soon. Once I get the tank repaired, and everything back together, I need to start focusing on the rear end - and the interior - and the rust in the engine compartment - and removing the dash - and replacing the window rubber - etc etc etc etc etc etc...... :surprised:

Chris

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Author Topic: Popbumper's '76 wagon - update (Read 80504 times)

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