KS Reproduction offers these partial rear framerails for repairing the most commonly rusted areas around the trunk floors. Full framerails also are available.
Sheetmetal work is always a painstaking process for the do-it-yourselfer and I admit I am not much of a bodyman. Certain processes are interesting to watch but difficult to understand. Forget paint and bodywork. I'd rather build an engine, whip up a custom interior, or even detail out an engine compartment. But when it comes time to grab a Sawzall and cut out a chunk of a car, and then weld in a replacement panel, forget it. I'll be the first to wimp out and state I'm far from qualified. My welding work is good for making a bracket or two, or perhaps qualifying as some wild art form, but I couldn't do the work you are about to see. That's why we brought our '66 hardtop project car to Classic Creations of Central Florida.
Well, now that all our regular readers know my automotive inadequacies, we can discuss the project at hand this month. Frame-rails they sound real close to the word floorpans and are just as critical in a unibody-designed car such as the Mustang. Our hardtop needed most everything in the KS Reproduction catalog and even more metal from Goodmark Industries, as well as custom-formed sheetmetal patches. However, we wanted to get started with the most critical areas first, which encompass the rear framerails, floorpans, and rear quarters.
You will be seeing articles on all these areas in the upcoming months as the hardtop progresses, which is going nicely compared to our recently completed Project '68. We have many supporters to thank, including Classic Creations for its extensive help, support, and sarcastic commentary, as well as many vendors who have come forward with suggestions, help, and parts. What would be nice is to hear from you our valued readers as to this project's direction. What do you think of our direction and option choices? Would you do something different? Let us know and if we get enough answers, we can publish a poll and perhaps even take you up on one of your suggestions.
1 Once again, Danny Gaydos of Classic Creations takes his Sawzall to the rear flanks of our '66 hardtop. Cutting away the quarter isn't necessary to install a framerail section, but since our hardtop needs new quarters, we cut away the rusted ones for better photography. | 
2 With the old quarter cut away, we could easily see the poor patch job attempted by the previous owner. The lower patch was overlapped not butt welded. | 
3 This type of overlap welding leaves an air gap where moisture can accumulate and build rust again, not to mention the overlapping requires more body filler and finishing work. |
4 The trunk dropoff had been replaced by a section of galvanized metal and would need replacing with the correct part as well, so Gaydos trimmed it off, including the outer wheelhouse, for access to the framerail. Again, this would not be required if the surrounding metal were in good condition. | 
5 Using a hammer and large chisel, Gaydos separates the inner bumper support from the taillight panel. We will be welding in new supports, so the old ones will completely come off with the rails. | 
6 With the body properly supported by jackstands and the rear end supported by a floor jack, the rear shackle can be unbolted from the framerail. Notice we are working on only one side. This way the car doesnit get too much metal cut off and begin to sag or become misaligned. |
7 Now using the Sawzall, Gaydos simply cuts through the rusted trunk floor and the framerail together. Notice that the fuel tank has been removed here as well. | 
8 Once the rear cut has been made all the way through, the only thing holding the framerail to the car is the lower trunk reinforcement under the taillight panel. The right side has been patched with galvanized sheetmetal as well and is trimmed with a cutoff wheel. Later, the lower reinforcement will be replaced before the new rail is installed. | 
9 After making a few last hits with the hammer and chisel, the bad section of framerail, trunk floor, and trunk dropoff come out together. |