Build project - 1962 wagon deluxe

[Gitanesteel]

Went through the car today and gathering a list of parts needed. Tackling the suspension first. For ease we will replace the lower control arm. My understanding is the stud on the upper ball joint is too small for later spindles. I assume if I put a 63-65 upper control arm on with the larger stud the spindle has to change also. If that’s the case I'll probably just pay the higher price for the 60-62 upper ball joints and shaft kit as the spindle is in great shape.

We were unable to remove the left axle shaft so are regrouping to see what we need for a tool to remove that.

The wheel bearings are in really good shape and will get repacked with grease.

I took the slot mags with me but will need to get some "long shank" lugs nuts to work. I did receive center caps for the wheels but now need to find some proper size decals for the caps.

We looked at the 79 Mustang 200 6 cylinder to be used. It looks to have the higher mount starter so shouldn't interfere with the center link. We have the 170 block that came out of the car and can swap the oil pan and oil pick up tube from that.

Little steps and speed bumps. Pretty normal I guess.

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[Gitanesteel]

One other question regarding the steering wheel. There are cracks where the spokes meet the rings and also at the center base. Has anyone repaired these cracks with an epoxy and then repainted the steering wheel.

[Falcongek]

One other question regarding the steering wheel. There are cracks where the spokes meet the rings and also at the center base. Has anyone repaired these cracks with an epoxy and then repainted the steering wheel.

Yes I did. It turned out pretty good. Now after 25 years some cracks have reoccurred, but not as noticable as the original cracks.

There is a tutorial on line on how to do it, it was linked to the tffn start page.

Rinke

[Gitanesteel]

Well, this past weekend I finally got some time to drive to my parents south of Spokane and then spend a few days with my dad at my brother's (he has the wagon in his shop) and start some work.

We had done a lot contemplating what we want the car to be and in the end decided on mostly stock for the suspension and have it be a mellow cruiser. After all, I already have a V8 Falcon. I had ordered bushings, lower control arms, wheel cylinders and brake shoes, shocks and a dual mast cylinder. My dad picked up new bearings and seals for the wheels.

Friday morning was deconstruct day. At 57 this is my first time going through a car and it's a little overwhelming since I am not the most mechanically inclined. I got some guidance from my brother who was recovering from surgery and my dad and will lean on them more. I'll also hope to lend a hand to my brother as he builds his 63. Dad helped where he could. We got the fenders, grille, bumper off and called it a day a little earlier so we could drive to the country body shop we want to use for paint. Unfortunately, he wasn't there so we didn't get a chance to talk about the work on the car. We also finally decided on the color - 1999 Aston Martin darker metallic blue.

Saturday morning we continued taking the car apart with the drivers side suspension as well as a few other miscellaneous parts. In the afternoon we were ready to put a lower control arm. Now for the fun part - I had misread the date code on my photo of the vin tag date code because the photo wasn't real clear. I had determined the production date of Dec 31, 1961. Unfortunately, it's really Aug 31, 1961. Kind of a big deal because that means it has the smaller upper ball joints and also lower ball joints. I had ordered the lower control arm that had the bigger ball joint "post". So, my stock spindle didn't fit. I already had upper ball joints on order (just not received yet). That set back had us shut down for the day to contemplate our next course of action.

After much discussion on Saturday night and some evaluation of the spindle we decided to try and have a machinist ream the lower part of the spindle for the new lower ball joint. Frankly, I like the beefier look of the Moog part and we determined the increase would be .1 to .12 of an inch so the tolerance on the spindle should be fine.

I came home Sunday evening cutting my trip a day short. My dad is more comfortable working one side at a time so we didn't take the right side suspension apart yet. I had ordered a new upper control am shaft kit and we tried it on the upper control arm for fit - perfect. I brought the upper control arm and sway bar home to clean up and paint. I also brought the headlight bezels (really nice shape) to clean up and the grille to clean and paint the black spots on the grille.

So, this morning I found out that the upper ball joints were out of stock with no date on when the manufacturer was planning on making more. I called Russ Wall and discussed the issues and he said I just need the 63-65 upper control arm, strut rod and spindle and I should be good to go. Hoping that's true as I'll order them in the morning. I'm hoping to go back in a couple of weeks and we'll start putting the drivers side together and help my brother put the rear end back in his 63 if his leaf springs are back.

Unfortunately, I won't be getting anything done from Feb to May with my daughter playing her first season of college softball while we're traveling every weekend to catch games.

Photos below including some of the upper cowl area at the windshield pillar and the lower portion of the a pillar showing how solid they are.

I readily welcome advice on how to clean the cowl panel out. There's a lot of mouse crap in there.







Just some clean up needed here of the surface rust:

[Gitanesteel]

I do like the look of the Moog lower control arm:

[Gitanesteel]

Need help on this "regulator"? It was bolted on the left side of the core support just above the horn. Is it a horn relay?

[Gitanesteel]

Finally, could it really be that the last time this wagon was licensed for the road was 1969? Crazy to think. The odometer reads 81216 so I suppose it's possible.

[Falcongek]

That could be true, My car also sat for at around 30 years in a basement before I pulled her out in 2002.

[Jeff W]

Hi Scott, yes that is the horn relay. When purchasing a new one (if needed) beware they come with either two mounting tabs (like yours) or a single mounting tab. Either will work electricity but the single will leave you with extra hole in the radiator support.