Augusta Green '68 base

From dusty barn find to daily driver, it seems our cars are never really done. This is the place to share your progress on your project car. We will celebrate your victories and commiserate over your tragedies. But most of all this is a great place to learn!
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guitar74
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Joined: 11 Oct 2015, 16:55

Re: Augusta Green '68 base

Post by guitar74 » 01 Mar 2017, 10:07

You are knocking out out, brother (think Hulk Hogan)! It's kind of motivating seeing people tackle this kind of work on their own in their own garage. I'm gonna' fire up the ole Hobart this weekend and do some welding myself. Just not on my car.

Steve68Cougar
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Joined: 20 Nov 2016, 18:55
Location: Manhattan, KS

Re: Augusta Green '68 base

Post by Steve68Cougar » 01 Mar 2017, 20:29

Thanks. I've been waiting to work on it for almost 15 years, so I'm ready to get at it. Tonight I spent a little more time with the grinder, air saw and air chisel and got most of the rust removed:

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I still need to cut out some sizable sections on the frame rail and rocker panel in order to get all of the rust out of it. It's definitely looking like the other side did.

My welding is getting better, but it's still very amateurish. I've been switching back and forth between the MIG and TIG quite a bit. Stitch welding with a MIG seems to work pretty well, but sometimes I end up getting the TIG out to smooth it over.
68 Cougar -Augusta Green
08 Mustang Bullitt - Dark Highland Green

Steve68Cougar
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Posts: 185
Joined: 20 Nov 2016, 18:55
Location: Manhattan, KS

Re: Augusta Green '68 base

Post by Steve68Cougar » 04 Mar 2017, 17:04

I managed to get both 428's pulled apart today. The second block is already +.040" on the bore, so I'll have to get it sonic checked to see if it'll handle +.060. Even if that doesn't work out, I now have 2 crankshafts with this stamping:

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One of them is already -.010 and the other is standard yet. Both are in pretty good shape but will need to go another -.010. I'll start with the standard one and get it magnafluxed to make sure it's alright.
68 Cougar -Augusta Green
08 Mustang Bullitt - Dark Highland Green

Steve68Cougar
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Posts: 185
Joined: 20 Nov 2016, 18:55
Location: Manhattan, KS

Re: Augusta Green '68 base

Post by Steve68Cougar » 05 Mar 2017, 17:36

Today I got back to a little bodywork on the car. I replaced the rusted out section of the rocker panel:

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and an area that ends up being up at the top corner of the torque box:

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Next up will be cutting out the front outside corner section of the floor that meets up with the firewall.
68 Cougar -Augusta Green
08 Mustang Bullitt - Dark Highland Green

Steve68Cougar
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Posts: 185
Joined: 20 Nov 2016, 18:55
Location: Manhattan, KS

Re: Augusta Green '68 base

Post by Steve68Cougar » 13 Mar 2017, 21:37

Took a few days off and headed to Ashland, Kansas to join my wife in helping with the aftermath of the fires that went through there earlier in the week. Here's a picture I took while driving down the highway:

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The fire burned up about 750,000 acres (640 acres is a square mile) in Kansas and Oklahoma. There were several other fires, but this was the largest. My wife is a vet, so she was helping with animal welfare (to keep it from getting gruesome). I was just helping her out and shuttling some of the volunteers around. It was a tough week, and will continue to be for quite some time for those people.

I didn't take pictures of the floor section, but here's the frame rail that needed to get repaired:

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Here's the after shot:

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I got the torque box pushed up into place, so once I make sure my measurements are OK and the seams are tight, I'll start welding it in place. Here's a shot from the interior:

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I found out from the driver's side that notching the flap that goes on top of the inner rail and bending it back makes it easier to get the torque box in place. Actually, I'm not sure how you'd do it otherwise without cutting the pieces apart. I'll have to bend it back down into place and weld it back solid.
68 Cougar -Augusta Green
08 Mustang Bullitt - Dark Highland Green

Steve68Cougar
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Posts: 185
Joined: 20 Nov 2016, 18:55
Location: Manhattan, KS

Re: Augusta Green '68 base

Post by Steve68Cougar » 14 Mar 2017, 19:18

The firewall sheetmetal is turning out to be an extremely poor reproduction. One of the bends at the top is off by over an inch. I ended up cutting it in a couple of pieces and will splice it back together so it lines up with the factory sheetmetal. Here's the before:

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And here's the after:

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I still have some trimming on the firewall to do, along with the new pieces. Looks like I'll be getting a little more practice with the welder.
68 Cougar -Augusta Green
08 Mustang Bullitt - Dark Highland Green

Steve68Cougar
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Posts: 185
Joined: 20 Nov 2016, 18:55
Location: Manhattan, KS

Re: Augusta Green '68 base

Post by Steve68Cougar » 15 Mar 2017, 19:26

I got the firewall trimmed and the top patch is in place:

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and here's what it looks like from the inside:

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I still need to get the lower piece put in and finish up the welding, but it's looking like I'll need to do some modifications to the torque box in order to get it slid up a little higher for a better fit. I'm not terribly impressed with the accuracy of the "Spectra Premium" sheetmetal, although it may just be that my expectations were a little high.
68 Cougar -Augusta Green
08 Mustang Bullitt - Dark Highland Green

Steve68Cougar
Registered Member
Posts: 185
Joined: 20 Nov 2016, 18:55
Location: Manhattan, KS

Re: Augusta Green '68 base

Post by Steve68Cougar » 22 Mar 2017, 18:37

I was right that I needed to modify the torque box. I ended up cutting it apart and doing some rewelding. The top seam had to get the spot welds cut out and the seam was repositioned. Here's what it looks like welded back together:

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I don't have an "after" shot yet, but here's what the floor/firewall look like part way through the weld process:

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I added the torque box gusset to the front corner of the torque box this afternoon. I still need a lot of work with my welding, but it's at least starting to look a little better. Here's where I welded the seam on the trailing end of the gusset:

Image
68 Cougar -Augusta Green
08 Mustang Bullitt - Dark Highland Green

guitar74
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Re: Augusta Green '68 base

Post by guitar74 » 23 Mar 2017, 09:38

That shot of the burnt landscape sure brings home the reality of what happened there.I applaud you and your wife for taking the time to help those in need. If more people were willing to step out of their self centered bubble, it would make for a much better place to live.

You've certainly been busy on that '68! Thanks for the pics and the update.

Steve68Cougar
Registered Member
Posts: 185
Joined: 20 Nov 2016, 18:55
Location: Manhattan, KS

Re: Augusta Green '68 base

Post by Steve68Cougar » 01 Apr 2017, 18:02

The response to the fires from the agricultural community has been incredible. People have shipped hay and supplies from all over the country. They've been getting a decent amount of rain in that part of the country, so hopefully things will green back up quickly.

Back to the Cougar...

Progress seems to have slowed a bit, but I'm still moving forward. Today I got some of the shock tower reinforcement done. I bolted the export brace in place and welded the "dog bone" piece on the outside of the shock towers. Here's the driver's side:

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Eventually I'll get some more of the typical reinforcement parts made, but I haven't taken the time to get those made yet. I've been spending some amount of time trying to get things cleaned up so I can get it painted once everything's in place.
68 Cougar -Augusta Green
08 Mustang Bullitt - Dark Highland Green

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