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  • Station Wagon - Rear End Final Assembly

    Today I did the final assembly on the rear end for my Station Wagon. Here are a few pics. All went well and no issues.

    The gears all assembled and wired, all with one wire (takes a bit of time, but makes me feel good)



    Driver side assembled.


    and finally the whole thing back together, it's been a while.



    I used new...
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  • rusty
    started a blog post Test pouring a rod cap.

    Test pouring a rod cap.

    Poured a rod cap to see how well the mold is going to work. I need to do a little machining on the mold parts to vent the hot gases before the next test. Got a good chemical bond of the babbitt to the cap. Other than the venting I'm pleased with the way it worked.
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  • rusty
    started a blog post Removing door hinges on the 28 Coupe.

    Removing door hinges on the 28 Coupe.

    I needed to remove the center and bottom hinges to weld cracks in the door frames of both doors. Drilled 1/8" pilot hole then 3/16" and finished with a 5/16" to remove the head of the rivet. I used a punch to remove what was left of the rivet in the door frame. While fastening the hinges back on the doors I found there is not enough clearance between inner door panel and window channel...
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  • John Duden
    started a blog post Rear of cab reassembled

    Rear of cab reassembled

    Took the rear of the cab out and blasted it and reinstalled it. Starting to look like a cab again! Rear of the subframe where the brackets attach were not in the best of shape so I welded the brackets to the subframe for extra support. I decided to order the whole back cab patch panel as hay will take care of 80% of the dents and the rusted out bottom. Gonna have to take the whole cab out and sandblast...
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  • rusty
    started a blog post Working on the passenger door dents today.

    Working on the passenger door dents today.

    Had a lot of high spots that needed major shrinking with the acetylene torch. Used a slapping spoon and dolly to raise the low spots. Now I'm waiting for my new shrinking disc for my grinder to arrive.
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  • rheacox
    started a blog post Trip to the machine shop

    Trip to the machine shop

    I delivered the block and head to the shop on Friday. This shop is a time capsule. The owner has been in business for over 50 years and said he hadn't done a 144 in probably 40 years but he used to do a bunch of them in the 60's. I think I went to the right place :).

    He went over the pluses and minuses of the Ford sixes and talked my ear off about getting a Falcon or Comet in one afternoon...
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  • Getting the rods ready for babbitt pouring.

    Removed the old babbitt with torch and a wire brush, brushed on a coating of zinc ammonium chloride, used torch and stainless steel wire brush to tin the rods and caps.
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  • rusty
    started a blog post Finished welding drivers door patch panel today.

    Finished welding drivers door patch panel today.

    This may be the last patch panel to weld on the body depending on what I find for a trunk lid. Feels like I just passed a major milestone for this project.
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  • rheacox
    started a blog post Engine teardown

    Engine teardown

    Tore the 144 down over the weekend and found basically what I was expecting. Nothing perfect but not bad either. Everything was caked in sludge and the timing chain had a ton of slop but everything else seemed decent. No abnormal wear in the bearings and the endplay was still within the .012 spec the manual calls out. Bores looked okay too.

    This is the first time this engine has been...
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  • rusty
    started a blog post Passenger door patch panel.

    Passenger door patch panel.

    Finished welding the passenger door patch panel today.
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  • John Duden
    started a blog post Cowl section reinstalled

    Cowl section reinstalled

    Took the subframe and cowl section out last night and sandblasted it, sprayed it with primer to seal it up. Had to do some fitting of the new front subrails to fit inside the subrail extensions. Double checked my measurements and put a tac weld to hold them in the correct position. Clamped them together tightly and drilled the holes and set the rivets! The drivers side extension was more cracked up...
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  • rusty
    started a blog post Installing passenger door patch panel.

    Installing passenger door patch panel.

    Got the patch panel tacked in place and ready for welding. Bought the patch panels from Snyder's it was a nice fit.
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  • rusty
    started a blog post Started working on drivers door this afternoon.

    Started working on drivers door this afternoon.

    Removed 7 inches from bottom of drivers door skin. Tomorrow I'll drill the rivets and remove center and bottom hinges. Then both doors will be ready for final sandblasting.
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    Last edited by rusty; 04-06-2021, 04:21 PM. Reason: Added pictures of the tool I made to make the offset where the patch panel will attach.

  • Station Wagon - Front Spring Part 2

    More work on the front spring. As suggested by L Jones I made a leaf from one of the left over leaves. Marked the donor leaf with the leaf I was trying to match.


    You can see the scratch marks after I pulled the pattern back.

    Cut the leaf with my Makita grinder equipped with a cut off wheel. Not an exact match, but I can still make a few modifications as I get the spring...
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    Last edited by Jwmckenzie; 04-05-2021, 03:10 PM.

  • rusty
    started a blog post More work on the passenger door.

    More work on the passenger door.

    Shrinking stretched metal, repairing damage around hinges and getting ready to install patch panel. I need to sandblast and paint the inner part of the door frame with POR 15 before I install the patch panel. Drivers door needs the same treatment.
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    This gallery has 3 photos.
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    Last edited by rusty; 04-05-2021, 05:46 PM.
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