Not sure how to really start this thread; but, since I usually start with a long story, short disclaimer. This time it'll be long story, long...
Honestly, I wanted to get this rust repaired around the windshield frame and a-pillar as soon as I could, but I didn't think I had the time, skill, or patience to follow through. What really sparked the entire repair was an innocent post asking a question about compatibility of parts. I was just looking around to see if anyone could tell me if the front windshield and a-pillar from a 58 would work on my Ranchero. One of, if not the first, people to reply was Terry_208. Not only did he give me the answer that I needed, he told me of a car he knew of, not to far from him, that might have the sheet metal that I needed.
Now to be honest, I honestly thought our conversation was going to end there. Why would a complete stranger, 3000 miles away, take time out of there day for another guys project. Not thinking anything would come of this, I gave him my phone number. Well a few days later I get a text message from Terry with some photos of the car and the sheet metal that I need. He was nice enough to negotiate the deal, cut it out, box up the clip, and ship it to Hawaii. A few weeks later the piece arrives and its perfect.
Terry, thanks for everything. This would not have been possible without you.
These are some photos of the existing damage that was in there. The second photo is the outer layer of the clip that Terry sent to me.
Here is the inner layer getting replaced and the new windshield frame piece getting fit up.
More fit up
The drip rail, drip rail corner piece, and starting the roof insert. This was a challenge. I am sure there are easier ways to make this piece but with the limited tooling and more important, skill, I have this proved to be the best method.
Had to add a couple of "extra" patch panels to remove some misalignment from overstretching the metal, but it's nothing a little epoxy filler can't take care of.
Epoxy primer and paint.
A new windshield with some polished stainless trim and she's ready for a cruise to the beach.
I still have plenty more rust to fix, the drip rail on the passenger side needs repair, hence the white roof. I also found some damage on the drivers fender, the headlight panels are rotten, the grill need some major work and there is more body filler starting to show all over the car. I figure I'll start working at it a little at a time, when I get a little more time and space, I'll explore removing the body from the frame.
It would certainly have it's challenges restoring a 57 Ford on the Hawaiian Islands, especially the sheet metal. Your Ranchero looks great and nice job on the dogleg, that's complicated piece to fabricate.
First, Thanks for updating us on your progress. I for one am really happy to see you decided to tackle it yourself, you're doing an amazing job. Looks great.
Secondly, kudos to Terry for getting that done for you. That's what this forum has been about for years.
Thirdly, when you get ready to tackle those headlight surrounds, give us a holler. They are available from EMS, but frankly, not well made, so takes some rework to the pieces before it's even started. I've got some ideas on a way to make it easier. Just let us know. On the other hand, if you can find some NOS original Ford (well made) panels, grab them. They are expensive but do come up occasionally.
Great job! You were so fortunate to get that patch panel. Terry, you did a really great thing!
Great efforts, well done !!!
That is a very difficult area to repair and the oem metal certainly helped a lot. Terry is one of those kind, helping guys here on this forum! Awesome !
You tackled this project like an expert (mostly), so there is no reason, why you wouldn't be able to do the rest of the car justice and also attack those other 'typical 57 spots'.
One thing, though. just imho. NEVER , EVER, pull the body off the chassis! You may regret that decision ( like me) as it opens a gazillion of other boxes and may take you years to get the car back on the road. Highly recommend keeping this a rolling project and enjoy it while you are driving and doing smaller repair projects. Please keep us posted with your efforts - neat beach cruise pics, surf and whatnot included ! :002:
Very nice work! Yup, many surprises with these old cars. It wouldn't be fun if there weren't a few.
Excellent job!
X 2 on an Excellent job! I might add that the "57 Gods" were looking out for smkeeman and Terry, in the fact that Terry found a "dogleg" that is not rusted out. That was a real find in my opinion.
I have to say Sean is very talented. He has sent me several "in progress" pictures, all spot on without a mis step.
I have to agree with G., don't remove the body from the frame unless absolutely required. It only took me 3 1/2 years to marry the frame and body back together. Keep it drivable as long as possible and then get all the pieces on hand for the re-install before separating the two.
How much of the rain gutter do you need, Sean? The donor car and has a good "A" pillar if anyone is interested. The car is slowly shrinking, as I remove pieces.
It looks great, well done and choice of colors.
Thanks for sharing the photos of your work. I appreciate the challenge you took in replacing such a difficult piece. Looks great and makes me realize how fortunate we are here in the states to hit a salvage yard for parts on these classics. I wish you well on the other repairs as you tackle them. I enjoyed seeing the progress.
Thanks to everyone for their comments.
Rich, the headlight panels are one of the next projects. I talked to the guys at EMS, but have not ordered. When I to them, I'll reach out. I am looking forward to your ideas.
I appreciate the advice on the frame off. I love the fact that this is a roller and she cruises to shows on Saturday nights. The dream of pulling the body off is probably just that, a dream. It's one of those things that I've always wanted to do and never had the resources. That said, I don't know that I will ever actually do it. The frame is solid but needs cleaned and painted and there are some floor pans that need replaced, mainly the rear floor pans. Nothing that warrants separating the body and frame.
Terry I am good with the drip rail, I have enough left over from the clip you sent, I have just a small section to replace. If that donor has some floor pans or the headlight panels I would be interested in those.
There is more to come. I am not the best as posting, but I am making it a point to get better at it.
Great shot !
Just a cheap, real dirty tip here. If you want to omit the rusty bumper look without spending a fortune for rechroming, try aluminum plumbers tape. you can just stick it on, smooth it out with a rag and polish it a little and will do the trick on pics like these, just saying. Maybe you even love the weathered patina look, and it does look cool the way it is !
Beautiful back round, any car would look good, 57 that much better, been to the islands a few times never seen a 57 ranchero, very nice...
Quote from: djfordmanjack on 2022-06-15 15:32Great shot !
Just a cheap, real dirty tip here. If you want to omit the rusty bumper look without spending a fortune for rechroming, try aluminum plumbers tape. you can just stick it on, smooth it out with a rag and polish it a little and will do the trick on pics like these, just saying. Maybe you even love the weathered patina look, and it does look cool the way it is !
I've seen the tape used before. Chrome got us out of the question. There is no one in the islands to do it. It would cost me just as much to ship them out as it would to have them dipped. I'm thinking of powder coating them. There have been some nice gains in the "chrome" powder coat world over the last few years. I'm thinking if I add some black hues into the powder it should look nice.
Since most new cars for the past umteen years haven't had chrome bumpers, we've gotten use to it, so it's a lot easier to deal with something else than it would have been 20 years ago. jmho.
So I've been back at it the last month or so. Terry has been the moral support I've needed to help keep me moving. The rust repair is coming along and this next phase is nearing completion.
These first four are from about a month ago. It was tough going, every panel off revealed more and more rusty metal and work.
Here I actually started to make repairs. I formed the piece of the piece of the back cab wall by hand on my bench. Then replaced the wasted metal on the lower brace for back cab wall. All 14 gauge. All of the welding on the bench was TIG, I am still learning, but I really enjoy it. If I can get the fit up tight the welds lay so much better with much less grinding.
Bought some new tools to get this next part done. A shrinker/stretcher set. My wife and I were able to get that lower bracket curved right over the driveshaft tunnel.
I had some ideas to start on the rear floor pans in cab, I was going to cut the old pans out and replace with some flat pieces of metal, but as I was cutting I realized there was a brace under there the I didnt account for, so I scratched that plan, ordered some replacement rear pans from EMS and shifted my focus to the area under the bed.
These last 4 bring us up to the current status of the project. The floor under the bed is in. I've got some welds to grind down still but they are in and solid.
The rear floor pans showed up yesterday which was perfect timing. I got them trimmed up and dropped into place. I start welding them in tomorrow, probably.
I am on the fence on what to do with the bed. I am thinking about replacing all of the metal along the sides. The removable in the center are in fine shape but the rest is not very good. I'm not sure I'll be able to hammer form the 14 gauge with enough tolerance to satisfy me and 18 gauge is next to impossible to get here.
I can get a full sheet of 16 gauge, and I am thinking I will most likely go with that, It'll be plenty strong, and should be a little bit easier to work than that 14 gauge.
You have gotten a lot accomplished in the last couple months. Its looking good. The TIG definitely give a cleaner weld with less to grind.
James
Looking good, Sean. Keep after it. All the work will be worth it when you look back knowing what you've accomplished. The satisfaction you'll feel will be phenomenal!
Wow, you have gotten a crazy amount of work done on the Ranchero. Very difficult and hard to reach areas. Well done !
Looking very nice. I know it is a lot of work, as I've been through the same issues on my Ranchero. Keep after it, you'll get there!
John
Very nice! I was very lucky, my structure was very solid, you have tackled a project I might have turned down. As John said....keep at it, that light at the end of the tunnel is NOT an on coming train!
VERY NICE!!!
The work you have done is looking good, what a major project..
Great job Sean. With all the finish/pretty work left to do, you're at the stage that I miss the most about doing a build. Keep up the good work, glad Terry is lending support.
Well, I've been back at, slowly, but getting some things done. Floor pans forward of the rear axle are solid and in, back wall is in along with all of the brackets. So with that done I decided to pull the rest of the bed up, and like everything else so far I found a mess. The bed was rotten, but the "trunk" pans and rear body mount brackets were much worse. As of now I have the trunk pans and new body mount brackets fabricated with the drivers side installed. I'll start cutting the rest of the passenger side out shortly. Once all of that is done then I will address all of the weld grinding, epoxy filler, and paint that it needs to make it last forever. Then I get to fab up the four panels that make up the sides of the bed.
I just realized that I never uploaded final images of the rear floor pans and back wall.
As a fellow Ranchero owner all the work you've done is very impressive, I don't think I would have taken on such an involved project, way beyond my capabilities luckily mine was pretty solid except for one rocker and the bottom of the tailgate. Looks like you lucked on the spare tire well, one thing I've always wondered is why some Rancheros have the two openings in the bottom of the wall behind the seat, mine and a couple of Rancheros that I've parted out had a solid wall all the way down to the floorboard?
Quote from: 57chero on 2022-09-16 10:35As a fellow Ranchero owner all the work you've done is very impressive, I don't think I would have taken on such an involved project, way beyond my capabilities luckily mine was pretty solid except for one rocker and the bottom of the tailgate. Looks like you lucked on the spare tire well, one thing I've always wondered is why some Rancheros have the two openings in the bottom of the wall behind the seat, mine and a couple of Rancheros that I've parted out had a solid wall all the way down to the floorboard?
Good question, I was just thinking the same. Mine doesn't have the holes and a friends doesn't either. I have seen other pictures showing them so I don't know why the difference..
Amazing job. Looks great.
Obviously the Ranchero's bed was based on the floors of the station wagons, so that, with the double layer floors and panels, really creates a mess when water is coming in from a non enclosed compartment.
Interesting to note that your Ranchero was originally Inca Gold and Colonial White!
Quote from: hiball3985 on 2022-09-16 11:34Good question, I was just thinking the same. Mine doesn't have the holes and a friends doesn't either. I have seen other pictures showing them so I don't know why the difference..
Thats interesting. I've been trying to figure out why they were there and I was chalking it up to access to the body mount bolts. When I am finished with all of the grinding and painting, I am planning to make some removable covers out of sheet steel to close them up.
Quote from: djfordmanjack on 2022-09-16 13:15Obviously the Ranchero's bed was based on the floors of the station wagons, so that, with the double layer floors and panels, really creates a mess when water is coming in from a non enclosed compartment.
Interesting to note that your Ranchero was originally Inca Gold and Colonial White!
You have great eye for those details. Honestly, I was so focused in on the rust red color that was all over these panels that never really clicked. I searched some images of that color combo and it is nice. I am a long ways away from final paint but that returning to original is interesting thought.
Quote from: hiball3985 on 2022-09-16 11:34Good question, I was just thinking the same. Mine doesn't have the holes and a friends doesn't either. I have seen other pictures showing them so I don't know why the difference..
My Ranchero has the two openings. I've seen others both with and with out. Being that there is very limited storage space inside a Ranchero, I opted to make storage boxes that mount behind the two openings, that are accessed from the cab.When I get to the upholstery stage, I'll come up with some kind of access door. I can post some photos if anyone is interested.
John
My first thought was making speaker boxes to mount in the holes, only to find mine doesn't have them :005:
You're doing some excellent work! Keep the updates coming!