If you've been around classic Mustangs for any time at all, you know bumper replacement isn't always an easy task. If you're lucky enough to have N.O.S. or rechromed original bumpers, replacement is straightforward because Ford bumpers have original stampings and are close to a perfect fit. However, despite how much we tend to romanticize Ford bumpers, they weren't always easy to install either because, similar to reproductions, stampings could be irregular.
We're going to show you how to install, and more importantly, how to adjust, classic Mustang bumpers without it being obvious that you've had to adjust them. Installation can be challenging because no two bumper stampings are the same. Front bumper installation is likely the most challenging because it's what people see first, and be it a factory or reproduction bumper, you're going to have a tough time getting it to conform.
Ford vs. Reproduction
Reproduction bumpers have been around for as long as there have been Mustangs. In 1965, reproductions were called "replacement" bumpers. Just because you've found what are believed to be Ford bumpers doesn't mean they're from Ford. Replacement, alternative, non-Ford bumpers have been around since these cars were new. When you're paying for Ford bumpers, make sure you're getting them.
Virginia Classic Mustang graciously...
Virginia Classic Mustang graciously provided the bumpers and hardware necessary to dress out a '65-'66 Mustang. Although we're working on a '66 Mustang, bumper basics remain the same for '65-'70s in front and '65-'73s in back. For '71-'73s, front-bumper installation is more like a Fairlane's or Torino's.
This is a wavy washer, which...
This is a wavy washer, which installs between the bumper and bracket with the wavy side toward the bumper. These washers prevent cracking because they take up shock and vibration. They also allow the bumper to conform to irregularities in the bracket and bumper. Don't use a regular flat washer for this purpose.
This '67 Mustang illustrated...
This '67 Mustang illustrated parts breakdown demonstrates everything you're going to need for front-bumper replacement and shows how it all goes together. Don't forget those important detail items, such as bumper bracket insulators and valance guards.
Install these bumper-to-fender...
Install these bumper-to-fender brackets before the bumper goes on. We're using new Scott Drake hardware, which is virtually invisible and great if you're restoring a daily or occasional driver. For concours cars, you can clean up and reuse your original brackets, or you can use hardware from AMK Products, which is more original in appearance. Don't forget the rubberized nut-plate at the fender, which prevents paint damage.
When you install the bumper,...
When you install the bumper, make sure all bumper brackets are loose to give you wiggle (adjustment) room. Loosen bumper brackets at the framerail. All bolts get those wavy washers mentioned earlier. Install all the bolts but leave them loose.
With the bumper loosely installed...
With the bumper loosely installed and all the bolts in place, you're ready to adjust. It really is all about bumper spacing. You want the same spacing between the bumper and fender on both sides, which will vary depending on which bumper you have-especially with a reproduction bumper. Spacing must also be uniform between the bumper and stone guard, which is tricky to pull off. If you must shim, use a flat washer between the wavy washer and bracket, never between the wavy washer and bumper. Count on bumper-to-fender bracket alignment issues and finite adjustment. This goes for Ford bumpers as well as reproductions.
The last adjustment and tightening...
The last adjustment and tightening step is the bumper-to-fender bracket. You want uniform spacing on both sides, but it's going to be hard to get because bumper stampings vary. Slowly tighten the bolt inside the fender and watch the rubber grommet. Don't overtighten or you could crack your paint.
Rear bumpers also get wavy...
Rear bumpers also get wavy washers for flexibility. Install the wavy side toward the bumper.
Because no two bumper brackets...
Because no two bumper brackets are the same, expect some confusion and frustration while you determine which is right for your bumper. Be prepared to switch sides and use shims to achieve proper fitment. This is a Ford bumper bracket with a reproduction bumper.
Note how contorted this rear...
Note how contorted this rear bumper bracket is. Be prepared to use shims or go shopping for another bumper bracket.
License lamp installation...
License lamp installation is next. We ran into size issues where the light grommet penetrates the tail panel. Our light grommet is larger than the hole; this is no fault of the grommet, but instead the reproduction tail panel. We drilled out the hole to accommodate the grommet. By the way, a new bulb is included with the light. Plug in the light inside your trunk.
Gary Mattson installs and...
Gary Mattson installs and fit-checks our rear bumper. Our first fitment was terrible, calling for shims and adjustments. Your objective needs to be proper fitment without anyone seeing the shims. They must go between the wavy washer and bumper bracket.
Our initial bumper fit-check...
Our initial bumper fit-check is way off. Don't take your marbles and go home. Be prepared to make adjustments.
This Ford-illustrated parts...
This Ford-illustrated parts breakdown doesn't show all the hardware. However, it demonstrates the basics. The easiest bumper installations come from using Ford bumpers, either rechromed or N.O.S. Reproduction bumpers can work well with patience and persistence.
These "shims" are nothing...
These "shims" are nothing more than flat washers. Add shims (all it normally takes is one per bumper bolt/wavy washer) between the wavy washer and bracket depending on which way you want the bumper to turn. Too far out at the top, like ours, calls for a shim in the bottom bumper bolt to angle the bumper in at the top. Add shims at the top bolts to angle the bumper out at the top. Never use shims between the bumper bracket and tail panel.
We added one shim to each...
We added one shim to each side bottom, which got our bumper flush, with finger width gapping on each side. More adjustment is still required.