Rust Repair!

[ew1usnr]

For the past year and half I have been trying to get everything working mechanically on my car. There were teething problems, but everything runs great now. The whole time my wife was asking:

"When are you getting it painted? When are you getting it painted? When are you getting it painted? When are you getting it painted?"

I took the leap and left it at a paint and body shop this past Monday. (It is a Maaco that was recommended to me by a friend who had his Corvette painted there. This particular shop has a good reputation with a lot of positive comments posted.) I pointed out some dime-sized rust bubbles along the quarter panels and they said that they would look at them. They e-mailed me photos yesterday and said that the rust turned out to be bigger than it had initially looked and offered a choice of repairing it with fiberglass or sheet metal. I did some internet reading last night and told them this morning at around 10:00 to repair it with sheet metal. They didn't waste time getting started. My wife went by there at 5:00 and took some pictures for me. They had already put the metal patches in place and they look good.

Falcon from side:
3350

Left quarter panel before:
3355

Left quarter panel patch:
3352

Right quarter panel before:
3353

Right quarter panel patch:
3354

[Gina K]

Lookin' good. Is the "Wonder Falcon"going to stay black?

[ew1usnr]

Hello, Gina.

I am definitely keeping The Wonder Falcon its original black. It is the first black car that I have had and the color has grown on me. The black is really dramatic and highlights the chrome.

I am updating the type of paint. The car would have had enamel paint when new and enamel paint would be period correct, plus it is the least expensive option at Maaco. But, enamel is the lowest in durability and gloss compared to the other paint choices. I selected the top of the line modern base coat / clear coat finish that offers the best durability and highest gloss. 95% of new cars come with two-step application base coat / clear coat finishes

The available choices were (working their way upward in price and warranty length):
3360

Enamel, Enamel with UV protection, Urethane (harder than enamel), Urethane + IC (integrated clear, meaning one-step paint mixed with clear coat), Base coat / clear coat (Dupont Nason paint), and base coat / performance clear coat with Dupont ChromaBase paint (twice as expensive as the Nason).

I selected the best:
3361

I asked to have the underside of the hood painted and said that I would take the car to shows. The manager said that they usually turn a car around in 3 or 4 days and asked if I would mind if he kept mine for a couple of weeks. I told him to take his time that I had another car. I think that he really does want to do an especially good job on this car. We shall see and I am hoping for the best. I should get the The Wonder Falcon back some time this coming week.

[dhbfaster]

Really looking forward to seeing the final product....(I wonder if your wife is related to mine?) I'm following the same philosophy...get mechanical all done first, then go to body, paint & upholstry. (and there's a lot of stuff to be done..) Are you also going to have them paint the engine compartment or trunk inside? Mine needs all that.
Do you mind if I ask which Maaco you went to? i know Kenny also had a recomendation and wonder if it's the same one.

[ew1usnr]

Do you mind if I ask which Maaco you went to? i know Kenny also had a recomendation and wonder if it's the same one.

Hello, dhbfaster.

It is located at 5409 Anderson Road, Tampa, Florida. (It is probably not the one that Kenny was recommending.) :)

The last time I had a car painted was my 1977 Dodge Colt in 1983. I tried to sand it myself, and bought a sandpaper disc that attached to my drill motor. I went over the car with it and then had it painted. It didn't turn out well. A girl told me that the car looked like it had a leather finish.

I didn't do any prep work myself on the Falcon because (based on my experience with the Colt), I figured that I would probably do more harm than good. Maaco said that they would just put masking tape over the side trim and window trim rather than remove it. That sounded good to me because if they pulled that stuff off, they might bend it or not be able to get it back on.

[redfalken]

i know Kenny also had a recomendation and wonder if it's the same one.

The local Maaco that gets good reviews and did Patrick's final base/clear is in Seattle, near Westlake & Mercer.

http://www.yelp.com/biz/maaco-auto-body-repair-shop-and-car-painting-seattle

[ew1usnr]

Are you also going to have them paint the engine compartment or trunk inside?

No, just the underside of the hood. Someone else had previously painted the engine compartment and the inside of the trunk. They look OK, but they unfortunately painted over all the wiring under the hood and inside the trunk with black paint while they were doing so. That has made tracing wires and figuring out color codes somewhat difficult.

The guy at Maaco sent me some updated photos today. They have finished the rust repairs and "will start sanding and prepping the rest of vehicle this week".

On the right and left quarter panels I asked him to keep the seam visible that runs along the top of the rocker panel to the rear fender. He traced a groove to replicate the original seam.

Left quarter:
3367

Right quarter:
3369

They also repaired some rust on the tail:
3370

Here are the front end left and right. The car looks like a 1960's gasser hot rod with the front bumper removed:

3366

3371

[ew1usnr]

The paint shop has had my car for over three weeks now. I hadn't heard anything from them for a couple of weeks, so I stopped by today on my way home from work and saw that things are coming along very nicely. The manager (Danny) took me back into the shop and explained what they had been up to. He said that everyone who had been coming by to see their cars had been looking at my Falcon and asking if it was for sale!

Danny explained that they had hand sanded the car because they didn't know how much bondo it might have, and if they media-blasted it the bondo would be blown away. They sanded the hood, roof, and trunk down to bare metal and didn't find bondo, but he said that the paint had been really thick and that they had filled the shop up with dust from all the paint. He said that it looked that there had been maybe nine layers and that some of it had been lacquer (the car originally had baked enamel). He said that the thick paint was why the finish on mine had looked cracked and wrinkled.

They sanded the hood to bare metal and filled a number of small dents and dings to make it smooth.
3409

They also sanded the roof. He said that it had no dents. They will paint the bare metal with self-etching primer, and then sealer, then the base coat, and then clear coat, and buff it when they are finished.
3410

The manager said that the trunk lid was the most dented, but they had sanded it down and filled and smoothed all the dents. (The trunk lid was probably dented from 50 years of setting grocery bags on it.)
3411

[dhbfaster]

Exciting stuff...wow 9 layers! I thought mine would would have more paint than any other car out there but I've been trumped. It sounds like you're really getting your money's worth. Can't wait to see the final product, I hope mine will be ready to paint by Spring time.

Thanks for sharing!

[Luva65wagon]

It makes me SO NERVOUS seeing the trim and tailights, etc left on. I've seen so many post-paint job scuffs on these things. Tape won't keep a sander from sanding the trim. I know, most of it's hard to remove, but the taillights and grille are not hard to remove and would be better to paint below them than around them.

It's looking very good though - I hope it comes out to your liking.

[ew1usnr]

It makes me SO NERVOUS seeing the trim and tailights, etc left on. I've seen so many post-paint job scuffs on these things. I know, most of it's hard to remove, but the taillights and grille are not hard to remove and would be better to paint below them than around them.

True, but .... removing items has its own risks.

Point noted on the tail lights. I am not eager to insist that they be removed because that would require detaching the wires and all the wires were painted black when a previous owner painted inside the trunk. The paint guys will not want to get involved with figuring out the electrical wiring. It (hopefully) would not be terribly difficult for me to sort out in their parking lot before driving the car home, but it might be easier to avoid that issue by just taping the lights and carefully sanding around them.

It would be easy to remove the grill, but it looks like it would be OK to cover it with paper and leave it in place. I won't be painting behind the grill. They have already sanded the hood. They do need to sand the "lip" below the grill, but it doesn't seem necessary to remove the grill in order to do that.

For each trim item removed, there is a chance that it might get bent, screws or nuts or the part itself might be lost, or they might scratch the paint while re-attaching it.

The side trim strip on each side is held in place with probably twenty attachment points. The strips could be bent while trying to pull them off. The insertion holes could be rusted and make it difficult to re-attach the trim.

Removing things like roof-gutter trim, window and windshield trim, and door handles would be nice because it would avoid the scuff issue and allow painting beneath them. But, that would be a lot of additional work and time is money.

I am not expecting perfection out of this, but am hoping for something a good bit better than what I had going in. We shall see. The manager said that he expects to "start shooting color" this coming week.

[redfalken]

Well, do want you will but I agree with Roger on removing what you can of the trim. You'll be happier in the end. I've seen too many cars where you can tell things were masked when you look close and I just think "Why?"

As far as the taillight wiring goes, just use some masking tape and a Sharpie to label the corresponding terminals and you'll have both lights out in 30 minutes or less.

Just be careful with transporting the grille but I would remove that for sure. While the paint job is getting finished, use the time to put the trim on the bench and give it a spit shine. Maybe touch up the black paint if needed. If you pay attention when transporting, the risk of damage is minimal.

I would even take five minutes to remove the antenna bezel and drop the rest into the finder a little before they tape the hole. Just leave enough antenna sticking up to grab it when you're putting things back together.

I know I wouldn't want someone cutting and buffing around trim that I could easily remove. High RPM disks can suddenly skip and just a fraction of a second on the trim can leave a nasty mark! In a perfect world that wouldn't happen but why take the chance.

All of the side trim hardware to reattach it is available repop. I'd remove those if it was my car. Same with door handles. The stainless trim could be left on and masked. Stainless is pretty tough so risk of damage is minimal.

So, just my 2¢. Paint is a pricey piece of the restoration process that you won't want to redo anytime soon. Not a good place to skimp IMHO.

[pbrown]

Agreed on removing what you can. The tail lights and grill for sure. There is a panel under that grill that can't be painted properly with the grill in place. The tail lights come out so easily. It would take longer to mask them than to remove.

[doghows]

Pull it pull it pull it. 10 minutes for the grill 15 max for tail lights youll be happy you did.

[Jeff W]

I had the same side trim on my 63 Futura. It did have the rust you mentioned originating from the holes for the trim mounting hardware. I know this because it spread beyond the edge of the trim and started bubbling the paint on the visible part of the panel.

The car was from Wisconsin... the rust belt. I don't know if Floria has similar challenges.

On the other hand you have to draw the line somewhere or every project would become a complete restoration.

Good luck and enjoy the fresh paint.

[ew1usnr]

Thanks for the input guys.

I will defer to your advice and collective wisdom and call the shop tomorrow morning and request that the remaining trim items be removed.

Hopefully, this will not open cans of worms. Jeff is indeed correct when he said: "... you have to draw the line somewhere or every project would become a complete restoration."

In retrospect, I wish that I had thought to take off all the trim myself before taking it to the paint shop. It makes things a bit awkward to want to start working on the car once it is in someone else's garage.

[falcon cobra]

The bottom line is you are paying for it and want the best job you can get. go in and remove the parts, you will thank yourself for it...:BEER:..jh

[ew1usnr]

I will get scolded, but here it is. The side trim is staying on.

The side trim is attached at the leading and trailing edges from inside the doors and quarter panels with nuts. See points "A", "C", "D", and "D".
3412

Here are details showing the nuts A, C, and D. To get at those nuts to remove the trim, I would have to remove all the interior panels, including rear seat, arm rests, window cranks, etc.
3413

PLUS, (and maybe I am wrong) it looks like I would also have to remove both front fenders to get at the nuts that hold the "spear head" in place. Removing the trim would involve an enormous amount of work and the car has already been sanded anyway.
3414

On a more positive note, the tail lights have been removed and the grill and antenna will be removed.
3415

The manager said that their next step will be to spray the car with grey epoxy primer. From a comment on the internet:
“Epoxy is probably the most versatile undercoat there is. It provides a tough, durable, waterproof, anti-corrosion layer on your panel and most premium quality epoxies will give you a 7-day recoat window.”

[doghows]

I can understand the side trim but good job on getting the grill and taillights pulled. Those were easy areas to remove that trim would be a bugger. Since your staying the same color it should be fine after all were not going to pebble beach. lol

[Luva65wagon]

Sorry for opening the can of WIAI, but you'll be happier and that's what's important. Much been there done that being spoken around here, which is what we're trying to, as a club and forum, keep others from learning the way that is hard. Of course there is a line many of us have never found (:doh::doh::doh:) but I really think painting a car requires some level of line crossing.

You may also offer to do your own masking of what is left. Good luck!

[ew1usnr]

Sorry for opening the can of WIAI, ...

Thanks, Roger. What is a can of "WIAI"?

I stopped by today to see how things are going. They have sprayed the car with grey primer. The manager says that he wants to allow the primer "time to shrink" before he sprays the next coat. It looks really smooth.

3420

[redfalken]

Thanks, Roger. What is a can of "WIAI"?
3420

While I'm At It :ROTFLMAO:

[Luva65wagon]

Thanks, Roger. What is a can of "WIAI"?

Kenny had it right. It was a blog I did a while back too, which you commented on:

http://www.rainierfalcons.com/forums/blog.php?b=24

There is no cure.

[ew1usnr]

Hello, Roger.

You crack me up. "As I'm under the back-end, lying there... as I often do... on the cold concrete..."

The "as I often do ..." is what I find amusing.

You really do have a beautiful engine. I like the strap that holds up the heater hose.

Dennis in Tampa.

[Luva65wagon]

You crack me up.

I like the strap that holds up the heater hose.

Joy to the world...

The strap I make and have made for others too. If you want one, I'll send one across the country for your car. Consider it a present from the club you'd like to join if only the commute wasn't such a pain.

[dhbfaster]

How's the paint job coming along?

[ew1usnr]

Hello, Don.

I sent the shop an e-mail last Wednesday and reminded them not to forget to paint the underside of the hood. The manager responded: “No worry Sir, I won’t forget. I have been letting your vehicle bake out in the sun, giving the primer time to do its job. I haven't been able to start blocking as of yet but will get started soon.”

The part about "baking in the sun" might sound odd, but we have had record high December temperatures with it being sunny and in the mid-80's.

I stopped by today to see what was going on. They have sanded the primer and said that the next step will be to spray it with sealer.
3430

They noted the imperfections on the hood with colored circles. It looks like they are paying attention to detail.
3431

Here are more circles marking imperfections on the roof.
3432

[ew1usnr]

I stopped by today to see how things were going. They have applied the black paint and the manager said that they will wet-sand and buff it to smooth out any imperfections. They have also painted the underside of the hood.

3484

The car had a layer of dust on it, so it is not shiny in the picture. It looks a lot nicer "in person". All the previous little dings have disappeared and the black is really black. It is really beginning to look like it is supposed to look. Pure inky-black sexiness. It will look like a little sports car when they are finished.

[doghows]

Looking good Dennis. I know how happy I was to see color on mine it gives you a good warm and fuzzy.

[dhbfaster]

Getting close! Glad you took those tail lights off. Anxiously awaiting to see the final product now..

[Luva65wagon]

Very nice. We're all waiting to see it outside some other monument somewhere. Maybe the Space Needle!

[ew1usnr]

I picked up the car from Maaco yesterday and took these pictures this morning.

3491

Look at my reflection in the hood!
3493

The trunk lid:
3492

The hood:
3490

Reflection next to hood scoop.
3494

[Jeff W]

Yippie! That looks great. Fresh paint is one of the most satisfying points of any freshening. Not much else left other than the master cylinder and enjoyment. Congratulations. :banana:

[redfalken]

Exciting times! Looks like they did a great job. With a fresh paint job you can almost envision what it looked like when they first drove it off the lot.

[doghows]

Wow that is sweet. I know when mine finally got color there was no better feeling in the world. Congrats.

[SmithKid]

I think when I got mine running with the fresh engine, it equaled getting the paint on, but it IS great when your plans come together!!! It looks super! Congrats!

[ew1usnr]

Thanks, guys!

I went and looked at this car a year and a half ago based on its description of "Road ready and needs nothing".

My brain disconnected from reality when I first saw it. It had been a long, long time since I had gotten excited about any car, but I was like the kid in the movie Christine when he said "Whatever you are asking for her, its not enough".

Well, I got it home and found that it was just plain worn out. Everything had to be replaced or re-done. It had me taking things apart that had me worried that I would never be able to put back together again. It led me to studying carburetor flow volumes, gear ratios, cam shafts, engine weights, compression, torque, horsepower, on and on. It made me understand how the Ford engineers had tried to thread the needle between performance and economy, and why that had caused them to select the particular power train components they did. The original design seemed to me to be perfect, so I tried not to change anything and instead just put everything back the way it was supposed to be.

This car really led me down the rabbit hole over the past year and a half, but it now runs perfectly. Its styling and proportions are (in my opinion) absolutely gorgeous and it is a joy to drive.

3499

[Gina K]

Sounds like love to me❤️!

[Luva65wagon]

That's the problem with those dark black cars. All those reflections when you're trying to take a picture!

:banana:

Naw... it looks really good. I hope you find it holds up well too. I've seen other Maaco jobs here that have, so I'm sure it will.

[dhbfaster]

"Road Ready and Needs Nothing"...yea, that's pretty much what my Dad said about my car too! (That and "it wasn't like that when I had it- it mush have happened in transit.") (And this was from my Dad...)
It's great to see yours come together. Really enjoyed the pictures and watching the progress and seeing the beautiful final product. Since you're a member now, you'll have to drive it up to show us in person. No Excuses!

One of these days I'm going to get my thread going...:3g:

[ew1usnr]

Here are some shots that I took with a different camera when I picked the car up from Maaco:

The car came with a flat right-hand mirror that I couldn't see anything out of. I thought about adding a convex wide-angle mirror, but then decided not to bother. I can just turn my head and look instead of relying on a mirror, the car did not come with a right-hand mirror (or any outside mirror for that matter), and it looks better without it (in my opinion).
3506

I bought my vintage driver's side mirror off e-bay. It has a nice looking stylized Falcon emblem on it. Look at the crease in the center of the front edge of the hood. I had never noticed that until the car was repainted. The crease lines up with the center of the grill to give the front a definite Thunderbird-ish appearance. The glossy paint really highlights all the curvy sheet metal.
3511

More curves. I like the bright-metal trim rings that they put around the tail lights.
3507

The styling is nice from every angle.
3510

3508

[ew1usnr]

The manager from Maaco called and asked that I e-mail him photos of the Falcon to put in the Maaco national company magazine. Maybe they will use it as a centerfold!!?

That's the manager standing next to the car.

3519