Perfect holes often become imperfect letters and emblems because letters and emblems aren't always perfect. Letters and emblems are typically made of die-cast metal (pot metal), and they're not always perfect. In fact, they're more irregular than regular. The pins (legs) that go into the sheetmetal are sometimes flawed and at odd angles. This makes the letter sit crooked on the fender, the hood, or the decklid. Sometimes installing the letter or the emblem can be a bear because the pins are not properly aligned.
If you have letters or emblems that won't line up, try several until the proper fit is achieved. Sometimes it takes numerous tries before you find that perfect fit. If you run into the same problem with reproduction letters and emblems, try a different brand or opt for good used pieces to achieve a perfect fit.
Generation OneDuring the first two model years, Mustangs rolled off the assembly line in two ways: standard and GT. We see a lot of restored Mustang GT models with crooked letters in the middle of the GT stripe. We'll show you measurements from politically correct examples, but let's look at standard '64 1/2 and '65-'66 examples first.
'6411/42There are subtle differences between the early '65 ('64 1/2) and later years.
'65-'66The '65-'66 standard Mustang emblems are similar to the '64 1/2 with the exception of the emblem size.
'65-'66 GTThis one tends to stump us because we see a lot of variations in those seven little letters on the front fenders. GT badge positioning is quite consistent. It should line up with the M on the left side and the G on the right side. The great challenge for restorers is positioning the MUSTANG letters correctly within the GT stripes. This takes an exceptional eye for detail and asymmetry.