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1965-1968 Ford Mustang Core Support Replacement

The sheetmetal repairs on our '66 continue with a new core support, inner fender apron, and front framerail patch
April, 2000
By Mark Houlahan
Photography by Chuck James
1966 Ford Mustang Hardtop Restoration Completed Core Support Replacement
Our '66 has a fresh nose and... 
   
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1966 Ford Mustang Hardtop Restoration Completed Core Support Replacement
Our '66 has a fresh nose and is straight as an arrow. Making sure the unibody is straight and properly welded together makes bolt-on sheetmetal installation that much easier.
1966 Ford Mustang Hardtop Restoration Measuring For Straightness
1 To obtain the proper measurements,... 
   
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1966 Ford Mustang Hardtop Restoration Measuring For Straightness
1 To obtain the proper measurements, Danny Gaydos of Classic Creations diagonally measured the engine compartment from one fixed point to another, and then repeated the measurement for the other side--effectively checking the front end to verify if it is out of specs.
1966 Ford Mustang Hardtop Restoration Removing Inner Fender
2 After Gaydos recorded the... 
   
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1966 Ford Mustang Hardtop Restoration Removing Inner Fender
2 After Gaydos recorded the measurements, he used a Sawzall to cut away the cancerous metal at the inner fender by the shock tower. Notice the coil spring cover has had the nearer-most bolts removed before cutting. Make sure you wear eye and ear protection while cutting.
1966 Ford Mustang Hardtop Restoration Removing Core Support
3 After sectioning the bad... 
   
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1966 Ford Mustang Hardtop Restoration Removing Core Support
3 After sectioning the bad metal at the center of the core support, Gaydos removed the second half of the rusted core support to complete the major cutting operations.
1966 Ford Mustang Hardtop Restoration Removing Paint And Rust
4 Using a wire wheel, Gaydos... 
   
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1966 Ford Mustang Hardtop Restoration Removing Paint And Rust
4 Using a wire wheel, Gaydos removed the old paint and sealer to expose the original spot welds for the inner fender apron and the core support. This step is necessary to accurately locate and drill out the spot welds.
1966 Ford Mustang Hardtop Restoration Drilling For Spot Weld Locations
5 Gaydos located the original... 
   
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1966 Ford Mustang Hardtop Restoration Drilling For Spot Weld Locations
5 Gaydos located the original spot welds and drilled through only the top layer of metal. The drilling operation is a skill that takes time to master. If you have little patience or "feel" for drilling, then we suggest a special spot weld cutting drill bit.
1966 Ford Mustang Hardtop Restoration Removing Final Piece Of Core Support
6 Once the spot welds are... 
   
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1966 Ford Mustang Hardtop Restoration Removing Final Piece Of Core Support
6 Once the spot welds are drilled out, the remaining pieces of core support can be separated from the inner fender. Here Gaydos grabbed the end of the strip of core support and pried it away.
1966 Ford Mustang Hardtop Restoration Removing Remaining Metal From Crossmember
7 The same steps in photos... 
   
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1966 Ford Mustang Hardtop Restoration Removing Remaining Metal From Crossmember
7 The same steps in photos 4, 5, and 6 are used to separate the remaining old metal from the right shock tower and the first crossmember.
1966 Ford Mustang Hardtop Restoration Removing Remaining Metal From Shock Tower
Separating the old metal from... 
   
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1966 Ford Mustang Hardtop Restoration Removing Remaining Metal From Shock Tower
Separating the old metal from the shock tower brace.

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