The Resurrection of 'Rusty' [the '59 Sport Fury]
big m
Posted 2010-06-03 8:40 PM (#226386)
Subject: The Resurrection of 'Rusty' [the '59 Sport Fury]



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This has been a while in the works, originally I had bought a '59 Sport Fury fifteen years ago, that was a drivable car. I knew it had some bodywork issues, and wanted to restore it to a better degree. I removed the body from the chassis, disassembled the chassis and running gear, overhauled the trans and engine, stripped, painted and reassembled the entire chassis.

Next, I hauled the body, fenders, doors, etc. to a well known media blaster, and they did an excellent job of getting down to bare metal, also showing some extremely amateurish gas welding repairs done years ago, literally thousands of holes drilled nearly everywhere to use a slide hammer to pull dents out, also hopelessly stretching the metal. I bought over $1000 worth of older repro sheetmetal sections, as I could not find usable factory sheetmetal anywhere, not a piece was even close to fitting, and I ended up throwing the towel in for the time being. Some years passed, I was also too busy to bother with the project, so it sat and sat. A customer offered me close to what I paid for the repop sheetmetal just for the roof, so I sold it, the trunk floor, doors, and everything else that was still good. Now I was left with a chassis, and no body parts.

About four years ago, a good friend of mine [the late Jim Paul] called me from an abandoned wrecking yard in upstate New York, asking if I wanted a '59 Fury convertible for $800 dollars. He sent me some photos, and it turned out to be a Sport Fury, but it suffered the usual rust damage from the New England climate. He shipped the car out to me free of charge, which helped. The car barely made it out here on the trailer, the remaining metal in the frame and lower body was either weak, or gone. The car broke apart into three large pieces once I cut the body mount bolts on the frame. A month after getting 'Rusty' here, a customer called me and said he had a '59 Fury coupe and was wanting to trade for a Chevelle. I had no such critters here, but asked if he'd sell the Fury outright. He didn't want much for it at all.

The car had been stored in an area where goats were kept, they had climbed all over the top of the car for years, every window was scratched badly from their hooves, the roof, decklid, hood and fenders were all dented on the top surfaces. The moldings had been removed some years ago, most were missing. The lower body was relatively sound, however, although the floors had a few weak spots. Yep. the perfect donor car for the convertible.

Photos are of the lonely chassis setting in the corner of the shop where it has for years, The convertible, and the donor body. Progress pics will be updated regularly.

---John



('59 SF chassis.jpg)



('59 SF convertible 002.jpg)



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Attachments '59 SF chassis.jpg (64KB - 469 downloads)
Attachments '59 SF convertible 002.jpg (51KB - 422 downloads)
Attachments '59 SF convertible 003.jpg (48KB - 393 downloads)
Attachments '59 SF convertible 005.jpg (142KB - 349 downloads)
Attachments '59 S.F. convertible 005.jpg (158KB - 416 downloads)
Attachments '59 S.F. convertible 006.jpg (138KB - 422 downloads)
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soiouz
Posted 2010-06-03 8:54 PM (#226390 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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I'm really looking forward to witness the progress you make on this. That's some project!
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B/G 61
Posted 2010-06-03 9:26 PM (#226399 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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WOW ! That's a LOT of work !!!!
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old mopar guy
Posted 2010-06-03 9:47 PM (#226400 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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John ! Your a better man than me! GOOD LUCK! Thats some taking on. HAPPY RESTORING! Victor..
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di_ch_NY56
Posted 2010-06-04 3:21 AM (#226423 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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John - I wish you good luck and happy restoring!
Dieter
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narleycharlie
Posted 2010-06-04 8:14 AM (#226434 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Can t wait to see more pics, thats going to be one BITCHIN ride when your done , not many people like 59 Plymouths , you buildin it cause you like or all the parts came together at the right time ?
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big m
Posted 2010-06-04 2:53 PM (#226486 - in reply to #226434)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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narleycharlie - 2010-06-04 5:14 AM

Can t wait to see more pics, thats going to be one BITCHIN ride when your done , not many people like 59 Plymouths , you buildin it cause you like or all the parts came together at the right time ?


I happen to be one of the select few that likes the '59's as much as the prior years. I guess I'd have to in order to consider doing this project!

---John
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big m
Posted 2010-06-04 3:02 PM (#226487 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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There was not much work involved in removing what wasz left of the body from the frame, just a lot of rust. Unless convertible specific, the lower body pieces were cut off and removed. The frame had major rust issues, so the hardtop frame will end up being used after all. The two extra body mounts and X-reinforcement were still good, and those will be added into the hardtop chassis later. For now, the frame will be positioned to hold the hardtop body in order to brace it up to prepare for removal of the roof.

---John



('59 S.F. convertible 001.jpg)



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Attachments '59 S.F. convertible 001.jpg (150KB - 368 downloads)
Attachments '59 S.F. convertible 002.jpg (153KB - 365 downloads)
Attachments '59 S.F. convertible 003.jpg (152KB - 363 downloads)
Attachments '59 S.F. convertible 004.jpg (148KB - 359 downloads)
Attachments '59 S.F. convertible 007.jpg (151KB - 348 downloads)
Attachments '59 S.F. convertible 008.jpg (144KB - 357 downloads)
Attachments '59 S.F. convertible 009.jpg (153KB - 386 downloads)
Attachments '59 S.F. convertible 010.jpg (147KB - 354 downloads)
Attachments '59 S.F. convertible 011.jpg (148KB - 336 downloads)
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big m
Posted 2010-06-04 3:13 PM (#226489 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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With the body braced up to keep it from folding, the spot welds holding the A-pillar to the cowl were drilled out. The rear of the roof was cut at the base of the C-pillar to allow removal.

The windshield frame was also removed from the convertible cowl by the same means.

---John



('59 SF windshield frame 001.jpg)



('59 SF windshield frame 002.jpg)



('59 SF windshield frame 005.jpg)



('59 SF windshield frame 007.jpg)



('59 SF windshield frame 009.jpg)



('59 SF windshield frame 008.jpg)



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Attachments '59 SF windshield frame 001.jpg (143KB - 352 downloads)
Attachments '59 SF windshield frame 002.jpg (147KB - 354 downloads)
Attachments '59 SF windshield frame 005.jpg (158KB - 350 downloads)
Attachments '59 SF windshield frame 007.jpg (146KB - 345 downloads)
Attachments '59 SF windshield frame 009.jpg (153KB - 344 downloads)
Attachments '59 SF windshield frame 008.jpg (140KB - 338 downloads)
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big m
Posted 2010-06-04 5:42 PM (#226498 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Now that the windshield frame is fitted and completed, sans for the leadwork over the seams, it's on to the rear tub of the car. More drilling out spotwelds and trimming on the convertible assembly, as well as removing the unnecessary hardtop sheetmetal in the main body-I have limited time to work on this, mostly evenings and once in awhile a weekend. Other projects take priority as wel sometimes.



('59 SF 007.jpg)



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Attachments '59 SF 007.jpg (154KB - 347 downloads)
Attachments '59 SF 008.jpg (139KB - 343 downloads)
Attachments '59 SF 009.jpg (149KB - 341 downloads)
Attachments '59 SF 010.jpg (152KB - 336 downloads)
Attachments '59 SF 011.jpg (149KB - 351 downloads)
Attachments '59 SF 012.jpg (141KB - 351 downloads)
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big m
Posted 2010-06-04 6:09 PM (#226503 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Convertible rear wheelwells are completely different than those on other models, and what was left of these was not enough to build on. The top of the original wheelwells were even rusted through. George McKovich had a pair that the top portion was better on, so I bought those to work with. Basically, the bottom couple inches were gone, so I used the bottoms of the hardtop's wheelwells and grafted the tops of the convertible ones on. Butt welding was used so there would be no noticeable overlap seam. I probably had 40 hours or better into each wheelwell to get them close to what was needed.

---John



('59 SF convertible 010.jpg)



('59 SF convertible 008.jpg)



('59 SF convertible 007.jpg)



('59 SF convertible 009.jpg)



('59 SF convertible 011.jpg)



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Attachments '59 SF convertible 010.jpg (152KB - 348 downloads)
Attachments '59 SF convertible 008.jpg (150KB - 344 downloads)
Attachments '59 SF convertible 007.jpg (143KB - 361 downloads)
Attachments '59 SF convertible 009.jpg (147KB - 351 downloads)
Attachments '59 SF convertible 011.jpg (149KB - 367 downloads)
Attachments '59 SF convertible 012.jpg (150KB - 351 downloads)
Attachments '59 SF convertible 013.jpg (147KB - 365 downloads)
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big m
Posted 2010-06-04 6:27 PM (#226506 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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There will be a need for clean metal on these wheelwells, as many pieces will need to be welded to them. I elected to use reverse electrolysis on these parts, as it does not remove metal like blasting does, and will remove the rust between two layers of sheetmetal. An old motel laundry tub suited this purpose, as it is non- conductive. A mixture of baking soda and washing soda with water provided the electrolyte. A battery charger positive lead was run to a series of re-bar pieces connected together with a conductive wire, and the negative lead was placed on the wheelwell.

Several days of running 5 amps through the liquid, and a nasty brown soup formed in the tub. I then flipped the part over to get everything a chance at the action. After removing, the wheelwells were covered with a black residue and light surface rust from the water. A wire brush was used to reveal the shiny metal beneath.

---John



('59 SF convertible 014.jpg)



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('59 SF convertible 018.jpg)



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Attachments '59 SF convertible 014.jpg (145KB - 339 downloads)
Attachments '59 SF convertible 006.jpg (152KB - 346 downloads)
Attachments '59 SF convertible 016.jpg (148KB - 404 downloads)
Attachments '59 SF convertible 017.jpg (150KB - 353 downloads)
Attachments '59 SF convertible 018.jpg (147KB - 352 downloads)
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deloverly
Posted 2010-06-04 7:01 PM (#226512 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Who's that short haired guy working on this car?
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whitedawg
Posted 2010-06-04 7:01 PM (#226513 - in reply to #226503)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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You sir are an artist

Alright John...were is road trip to this time?
Last time you did one of these it was for Mlisa "Excellent Adventure"
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royalbopper
Posted 2010-06-05 3:25 AM (#226544 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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John You are a true inspiration for all of us forwardlook suckers, with what we think is rusted out wrecks!

 

You are the god in my new religion!

Sigge!

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big m
Posted 2010-06-07 4:23 PM (#226865 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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The wheelwells are now tacked into place. Final welding and grinding will be done later, after everything is fitted.

Next bit of work will be to ready the rear section for installation, welding up some small holes, etc.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



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Attachments '59 SF convertible 001.JPG (159KB - 355 downloads)
Attachments '59 SF convertible 002.JPG (160KB - 326 downloads)
Attachments '59 SF convertible 003.JPG (160KB - 322 downloads)
Attachments '59 SF convertible 004.JPG (152KB - 361 downloads)
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big m
Posted 2010-06-07 4:35 PM (#226867 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I located the factory seam, and heated the solder with a brazing tip until it flowed from the junction. The spotwelds were then drilled out. I found a small stress crack beneath that I brazed back together. I did the same on the donor body, no surprises were found.

---John



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



('59 SF convertible 009.JPG)



Attachments
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Attachments '59 SF convertible 005.JPG (159KB - 326 downloads)
Attachments '59 SF convertible 006.JPG (154KB - 349 downloads)
Attachments '59 SF convertible 007.JPG (158KB - 334 downloads)
Attachments '59 SF convertible 008.JPG (152KB - 335 downloads)
Attachments '59 SF convertible 009.JPG (154KB - 334 downloads)
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big m
Posted 2010-06-07 4:47 PM (#226871 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Going together- This took two people to position onto the body. One of the employees,Rodger, was a big help here. The rear corners were brazed [as per factory] and a series of clamps kept the body alignment in check.

Mig welding the drilled out spotwelds, these will later be ground off flush. One problem I ran into was that the driver's side quarter panel wanted to oilcan inwards when the top seam was pinched together, after much consideration, I remembered the RH quarter on the original convertible had taken a hit at one time, and was tweaked. I found a bit of secondary damage on the deck panel, where the metal was pushed upwards. A bit of hammer and dolly work allowed it to settle back into place, and the left quarter panel no longer wanted to contract. Thank goodness!

---John



('59 SF convertible 010.JPG)



('59 SF convertible 011.JPG)



('59 SF convertible 012.JPG)



('59 SF convertible 013.JPG)



Attachments
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Attachments '59 SF convertible 010.JPG (165KB - 336 downloads)
Attachments '59 SF convertible 011.JPG (153KB - 338 downloads)
Attachments '59 SF convertible 012.JPG (150KB - 341 downloads)
Attachments '59 SF convertible 013.JPG (157KB - 343 downloads)
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big m
Posted 2010-06-07 4:51 PM (#226872 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I finished positioning and welding the stands and braces, these will just need a final grinding, to be done once the body is assembled and on a rotisserie. Looks like things are lining up the way they should, so it will be on to the next step.

---John



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



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Attachments '59 SF convertible 002.JPG (158KB - 360 downloads)
Attachments '59 SF convertible 003.JPG (163KB - 339 downloads)
Attachments '59 SF convertible 004.JPG (158KB - 335 downloads)
Attachments '59 SF convertible 005.JPG (155KB - 342 downloads)
Attachments '59 SF convertible 006.JPG (160KB - 352 downloads)
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big m
Posted 2010-06-07 4:59 PM (#226873 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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This is what I had to replicate for both sides. These are drains for the convertible top well, they channel the water away from the upholstered surfaces in the rear seat area. The one shown here is from the driver's side. The passenger side one was non-existent.

I made a mirror image of the first one for the passenger side, and brazerd them onto the convertible assembly.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



('59 SF convertible 009.JPG)



('59 SF convertible 010.JPG)



('59 SF convertible 011.JPG)



('59 SF convertible 012.JPG)



Attachments
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Attachments '59 SF convertible 001.JPG (154KB - 346 downloads)
Attachments '59 SF convertible 007.JPG (148KB - 350 downloads)
Attachments '59 SF convertible 008.JPG (146KB - 366 downloads)
Attachments '59 SF convertible 009.JPG (155KB - 364 downloads)
Attachments '59 SF convertible 010.JPG (150KB - 352 downloads)
Attachments '59 SF convertible 011.JPG (163KB - 349 downloads)
Attachments '59 SF convertible 012.JPG (166KB - 511 downloads)
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d500neil
Posted 2010-06-07 5:25 PM (#226876 - in reply to #226873)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Exner Expert 19,174 posts. Neil passed away 18 Sep 2015. You will be missed, Neil!

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John, can you IMAGINE what fun you'd have, if you could have received all these pieces, to assemble,
in individual NEW condition???

BTW, in 1957, Dodge prepared TSB showing (kinda) its dealers how they could construct/create your 59's
water drain 'trough", to channel water from the cars' interiors.

Those troughs were apparently put into production, but they certainly were 'sacrificial' constructions!







Edited by d500neil 2010-06-07 5:27 PM
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bad58mike
Posted 2010-06-07 6:57 PM (#226884 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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John you are a mad man, wow keep up the good work. I look forward to the next progress pics
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d500neil
Posted 2010-06-07 7:03 PM (#226885 - in reply to #226884)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Exner Expert 19,174 posts. Neil passed away 18 Sep 2015. You will be missed, Neil!

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It will take a while to media-blast the entire body, when he's done assembling it!



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Fins/413
Posted 2010-06-07 7:34 PM (#226891 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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Great thread John you make it look easy.
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Kenny J.
Posted 2010-06-07 7:59 PM (#226896 - in reply to #226503)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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big m - 2010-06-04 3:09 PM

The top of the original wheelwells were even rusted through. George McKovich had a pair that the top portion was better on, so I bought those to work with.
---John


I don't know where George comes up with some of the rare stuff that he does, John, but it's amazing, He's one of the really great people here!

K.

P.S.- I am still gonna convince you to put a stick in that '59!
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big m
Posted 2010-06-07 8:01 PM (#226898 - in reply to #226885)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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d500neil - 2010-06-07 4:03 PM

It will take a while to media-blast the entire body, when he's done assembling it!





Neil, there will be no heavy rust to deal with, nothing a light soda blast won't take care of. Keep your eyes on this thread!

---John
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Kenny J.
Posted 2010-06-07 8:02 PM (#226899 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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It has occurred to me, John, that you could have sent the car and parts to Northern Europe, along with a steamer trunk full of cash and received a complete, better-than-new '59 Plymouth convertible twenty four months later.

But what fun would that be?

K.
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big m
Posted 2010-06-07 8:04 PM (#226900 - in reply to #226896)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Kenny J. - 2010-06-07 4:59 PM

big m - 2010-06-04 3:09 PM

The top of the original wheelwells were even rusted through. George McKovich had a pair that the top portion was better on, so I bought those to work with.
---John


I don't know where George comes up with some of the rare stuff that he does, John, but it's amazing, He's one of the really great people here!

K.

P.S.- I am still gonna convince you to put a stick in that '59! :laugh:


LMAO Kenny!

I did just find another V-8 stick tranny in the building here, if you'd like, I'll hang on to it for you!

And yes- George is a great guy!!

---John
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Kenny J.
Posted 2010-06-07 8:05 PM (#226901 - in reply to #226486)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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big m - 2010-06-04 11:53 AM

narleycharlie - 2010-06-04 5:14 AM

............not many people like 59 Plymouths , you buildin it cause you like or all the parts came together at the right time ?


I happen to be one of the select few that likes the '59's as much as the prior years. I guess I'd have to in order to consider doing this project!

---John


So let's see.....there's Charlie, you, Roger, Tom and me........too bad we can't find a sixth person. That would be a WHOLE half dozen.

K.
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big m
Posted 2010-06-07 8:11 PM (#226903 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Rebuilding the quarter window frames- I salvaged what I could from the original convertible, although portions had to be made and fitted onto the good parts. The vertical braces and mounts for the quarter windows had to have rusty sections cut off and fabricated, as the photos will show.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



Attachments
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Attachments '59 SF convertible 001.JPG (158KB - 343 downloads)
Attachments '59 SF convertible 002.JPG (161KB - 340 downloads)
Attachments '59 SF convertible 003.JPG (156KB - 343 downloads)
Attachments '59 SF convertible 004.JPG (165KB - 338 downloads)
Attachments '59 SF convertible 005.JPG (148KB - 345 downloads)
Attachments '59 SF convertible 006.JPG (158KB - 348 downloads)
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big m
Posted 2010-06-07 8:18 PM (#226904 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Next was to make the necessary pieces to mount the quarter window housing, the rearward piece had a strange compound curve that was a hard thing to recreate, but with a torch [heating] and hammer and dolly [beating] I got one real close to the original. The brace towards the front needed to be removed to gain access to some spotwelds, and rejoined later.

---John



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



('59 SF convertible 009.JPG)



('59 SF convertible 010.JPG)



('59 SF convertible 011.JPG)



('59 SF convertible 012.JPG)



('59 SF convertible 013.JPG)



('59 SF convertible 014.JPG)



Attachments
----------------
Attachments '59 SF convertible 007.JPG (161KB - 338 downloads)
Attachments '59 SF convertible 008.JPG (159KB - 355 downloads)
Attachments '59 SF convertible 009.JPG (148KB - 341 downloads)
Attachments '59 SF convertible 010.JPG (154KB - 347 downloads)
Attachments '59 SF convertible 011.JPG (157KB - 337 downloads)
Attachments '59 SF convertible 012.JPG (166KB - 533 downloads)
Attachments '59 SF convertible 013.JPG (159KB - 333 downloads)
Attachments '59 SF convertible 014.JPG (162KB - 333 downloads)
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big m
Posted 2010-06-07 8:24 PM (#226905 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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After doing the driver's side, the passenger side went rather smoothly, and came out well. Now all the fabricating and piecing together has been completed, so on with the next phase, the cleaning.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



Attachments
----------------
Attachments '59 SF convertible 001.JPG (165KB - 337 downloads)
Attachments '59 SF convertible 002.JPG (164KB - 330 downloads)
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B/G 61
Posted 2010-06-07 9:34 PM (#226914 - in reply to #226901)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Kenny J. - 2010-06-07 8:05 PM

big m - 2010-06-04 11:53 AM

narleycharlie - 2010-06-04 5:14 AM

............not many people like 59 Plymouths , you buildin it cause you like or all the parts came together at the right time ?


I happen to be one of the select few that likes the '59's as much as the prior years. I guess I'd have to in order to consider doing this project!

---John


So let's see.....there's Charlie, you, Roger, Tom and me........too bad we can't find a sixth person. That would be a WHOLE half dozen.

K.


I like '59 Plymouths AND add me to the short, short list that wants John to use a 3 speed stick (you and me )


BTW, this is AWESOME - keep postin the progress !!!! You make me feel like a simpleton (and I'm holdin my head high!)

GREAT WORK ! ! ! !


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Kenny J.
Posted 2010-06-08 4:02 AM (#226934 - in reply to #226900)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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big m - 2010-06-07 5:04 PM


I did just find another V-8 stick tranny in the building here, if you'd like, I'll hang on to it for you!


---John


Great. Add it to my pile, along with that stick stuff from the trunk of that '62. It can come here with the Satellite, or maybe I can pick it all up in November.

K.
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Steppinout
Posted 2010-06-08 9:25 PM (#227058 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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This is the reason I love the Internet. Watching someone resurrect a car I have never dreamed of finding much less seeing. Very cool project and thank you for sharing with us. Really enjoy reading your posts.
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Sartana
Posted 2010-06-08 10:46 PM (#227072 - in reply to #227058)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Great thread! Keep the pictures and story coming. I too love the 59's as much as the rest, if not more.....
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Doctor DeSoto
Posted 2010-06-09 1:08 AM (#227097 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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John,

When you set your wheel tubs, were the outer body skins (wheel well lips) in place to use in locating the tubs ? If not,
how did you locate them ?
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57burb
Posted 2010-06-09 11:20 AM (#227118 - in reply to #227097)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



Expert

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The '59 Sport Fury convertible is one of the most classy, high-end Plymouths ever made. You're doing a great job on yours John!

Here's a little inspiration - as if you needed it. GO MAN GO!!



(1959PlymouthSportFuryConvertible.jpg)



Attachments
----------------
Attachments 1959PlymouthSportFuryConvertible.jpg (201KB - 339 downloads)
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B/G 61
Posted 2010-06-09 12:05 PM (#227127 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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Is that dash pad blue ? WOW
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big m
Posted 2010-06-09 1:10 PM (#227134 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Thanks for the positive comments!

---John
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big m
Posted 2010-06-09 1:21 PM (#227136 - in reply to #227097)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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Doctor DeSoto - 2010-06-08 10:08 PM

John,

When you set your wheel tubs, were the outer body skins (wheel well lips) in place to use in locating the tubs ? If not,
how did you locate them ?


The coupe's quarter panels as well as the wheel openings were in relatively good shap, so it provided a decent guide for the reinstallation of the inner wheelwells. I did have to make readjustments to the driver's side afterwards to make the top assembly fit properly.

---John
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Kenny J.
Posted 2010-06-09 1:54 PM (#227144 - in reply to #227134)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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big m - 2010-06-09 10:10 AM

Thanks for the positive comments!



Ya think we're gonna criticize somebody who is our main source of parts?
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wizard
Posted 2010-06-09 2:09 PM (#227145 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Board Moderator & Exner Expert 10K+

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John, are you sure that you dont have some Swedish blood in you? you're performing a fabulous work with that wreck. I'm really curious of how you're going to bath the body. Very interesting and informative thread - keep up your good work and keep us posted.

Edited by wizard 2010-06-09 2:10 PM
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big m
Posted 2010-06-09 8:43 PM (#227201 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I scraped any loose rust and undercoating, afterwards blowing out the dust with an air hose. Now it's time to bring in the bin. This fiberglass bin was used to haul tomatoes during harvest, and was left behind on a property I was cleaning up. Never knew I was going to use it for anything. After getting it set in place on the concrete floor, it was hosed out, and all possible leakage points sealed up with silicone.

Two of the center braces required removal to fit the body in, and about eight inches of water was added. A few more small leaks were found, and we wet-patched them. The one brace was put back into the bin after the car was set in, and a trucker's strap held the sides together where the last brace could not be put back in. The car was carefully lowered in with a forklift jib, and the carrying straps removed from the body. Water was now almost to the halfway point, and baking soda [lots of it] was mixed into the hose stream. With the water level now almost over the cowl, A positive cable from the battery charger was connected to the anode[junk exhaust pipes] and the negative cable connected to the cathode [body]. After a few hours, the water began to discolor. The next morning, I used two old gondola shelves connected together with a copper cable that i could move around the body at will. The final photos show definite rust water after only one full day.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



('59 SF convertible 009.JPG)



('59 SF convertible 010.JPG)



('59 SF convertible 011.JPG)



('59 SF convertible 012.JPG)



('59 SF convertible 014.JPG)



('59 SF convertible 015.JPG)



('59 SF convertible 016.JPG)



Attachments
----------------
Attachments '59 SF convertible 001.JPG (156KB - 388 downloads)
Attachments '59 SF convertible 002.JPG (156KB - 349 downloads)
Attachments '59 SF convertible 005.JPG (160KB - 361 downloads)
Attachments '59 SF convertible 006.JPG (150KB - 366 downloads)
Attachments '59 SF convertible 007.JPG (160KB - 352 downloads)
Attachments '59 SF convertible 008.JPG (152KB - 354 downloads)
Attachments '59 SF convertible 009.JPG (159KB - 342 downloads)
Attachments '59 SF convertible 010.JPG (150KB - 345 downloads)
Attachments '59 SF convertible 011.JPG (161KB - 393 downloads)
Attachments '59 SF convertible 012.JPG (159KB - 354 downloads)
Attachments '59 SF convertible 014.JPG (151KB - 351 downloads)
Attachments '59 SF convertible 015.JPG (164KB - 389 downloads)
Attachments '59 SF convertible 016.JPG (152KB - 428 downloads)
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1959Dodge
Posted 2010-06-09 8:53 PM (#227202 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Well, add 2 more fans of the 59 Plymouth Sport Fury Convertible fans.
Aivar, (He has a black 59 Sport Fury Convertible) I like it too so at least
8 fans.
Should you have any questions or need any measurements, I'm sure Aivar
would be willing to help!
Kent took a lotta measurements from my 59 Dodge Vert, last time He was here
but He is making a vert out of a hardtop.
Keep up the good work John, and maybe we can get a "Convertible Cruise"
planned, in the not too distant future!!

Gary
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wbower3
Posted 2010-06-09 10:42 PM (#227224 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


Walter passed away on Jul 29, 2014. We will miss you, Walt!

Posts: 5358
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John, the only thing I could possibly say about what you're doing with that '59 is "WOW"! And you gotta really like punishment. What a job. . . . . . . . .

Uncle Walt

Edited by wbower3 2010-06-09 10:43 PM
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deloverly
Posted 2010-06-09 11:41 PM (#227235 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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After this my desoto conv will be a snap! M'Lisa
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Fins/413
Posted 2010-06-10 8:05 AM (#227259 - in reply to #227235)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


Extreme Veteran

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M'Lisa he is making you wait shame, shame. I can't wait to see her when she comes out of the bath. That is a heck of a tub.
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Kenny J.
Posted 2010-06-10 3:36 PM (#227307 - in reply to #227259)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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John, you could offer a service with that tub. When you sell sheet metal, tell the buyer that for an additional 15% of the agreed price, you'll de-rust the parts before shipping.

So between this project and M'Lisa's Desoto, where does the 4-4-2 stand in the attack plan?

Once I'm done with the Imperial, the blue wagon and the '57 Saratoga, I have to decide what to do next. If I ever get that far. Maybe finish the '59 Impala? Return my Satellite Sebring to the road? Or dive into the '59 Plymouth two door wagon?

Too many cars, not enough life left.

K.
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big m
Posted 2010-06-10 4:42 PM (#227321 - in reply to #227307)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Kenny J. - 2010-06-10 12:36 PM

John, you could offer a service with that tub. When you sell sheet metal, tell the buyer that for an additional 15% of the agreed price, you'll de-rust the parts before shipping.

So between this project and M'Lisa's Desoto, where does the 4-4-2 stand in the attack plan?

Once I'm done with the Imperial, the blue wagon and the '57 Saratoga, I have to decide what to do next. If I ever get that far. Maybe finish the '59 Impala? Return my Satellite Sebring to the road? Or dive into the '59 Plymouth two door wagon?

Too many cars, not enough life left.

K.


Kenny, the Hurst/Olds will be next. I need to find a 455 short block to rebuild properly, she does not trust the engine that is currently in the car, ever since it was installed about fifteen years ago it has had heating problems. She will be re-clearing the car and some minor touch up, but not a complete paint job. We want to have the car ready for the nationals up in Reno next summer. The DeSoto will be sometime after that.

---John
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big m
Posted 2010-06-10 5:02 PM (#227323 - in reply to #227202)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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1959Dodge - 2010-06-09 5:53 PM

Well, add 2 more fans of the 59 Plymouth Sport Fury Convertible fans.
Aivar, (He has a black 59 Sport Fury Convertible) I like it too so at least
8 fans.
Should you have any questions or need any measurements, I'm sure Aivar
would be willing to help!
Kent took a lotta measurements from my 59 Dodge Vert, last time He was here
but He is making a vert out of a hardtop.
Keep up the good work John, and maybe we can get a "Convertible Cruise"
planned, in the not too distant future!!

Gary


This car was also a solid black car with a red interior. Is Aivar's interior red as well?

---John
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60 dart
Posted 2010-06-10 5:26 PM (#227327 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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i sure like your style Big John---------------------------------------------------------------------------------------------------later
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ronbo97
Posted 2010-06-10 10:35 PM (#227374 - in reply to #227321)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


Expert

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Awesome job, John ! Looks like a lot more work than my 59 Dodge conv. needed.

Can't wait to see pics of the body when it emerges from the tank. Will you have to epoxy prime the body to keep it from re-rusting ?

Did the Plymouth convertibles have stronger (12ga.) rockers, sills and inner rockers, like the 59 Dodge did ?

I imagined you going into the local grocery store and ordering 100 cases of baking soda. LOL !

Ron

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deloverly
Posted 2010-06-11 12:09 AM (#227387 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Usually it was me raiding the Walmart at different times to get all he needed.

Kenny, My Hurst Olds (not 442 :}) is next like John said. John put a short block in it when I grenaded the engine in 1990. The overheating got so bad I can olny drive 3-5 blocks and the temp gauge goes beserk! The last show I drove it to it took us 3-3.5 hours to go 35 miles.

Ok, back to Toothless the Black Fury (aka Rusty).

M'Lisa
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59SportFury
Posted 2010-06-11 2:47 AM (#227398 - in reply to #227323)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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big m - 2010-06-10 11:02 PM

This car was also a solid black car with a red interior. Is Aivar's interior red as well?

---John


Aivar's interior is red, you can see some pics and a movie clip on the 59 Plymouth website http://59sportfury.net/showcase/SportFury/Lejins/index.html

Ron
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narleycharlie
Posted 2010-06-11 9:31 AM (#227415 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Wow John , you are making AMAZING progress , this 59 can ONLY be a keeper , cause NOBODY could afford the price tag , with all the labor you will have in it . Ain t nobody can look at a car again and say its too far gone .
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big m
Posted 2010-06-11 9:01 PM (#227499 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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After letting the car soak with a mild 5 amps passing through the electrolyte, We suspended three grids in series, on above the trunk floor, and two in the passenger compartment. These were connected together with a heavy gauge copper cable. Now, the electrolyte is allowing 40 amps to pass through. The water continues to get murkier, it's almost black now. This is the last 48 hours the body will be submerged.

---John
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big m
Posted 2010-06-11 9:02 PM (#227500 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Here are some photos-



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



Attachments
----------------
Attachments '59 SF convertible 003.JPG (157KB - 240 downloads)
Attachments '59 SF convertible 004.JPG (150KB - 238 downloads)
Attachments '59 SF convertible 005.JPG (165KB - 238 downloads)
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big m
Posted 2010-06-11 9:08 PM (#227501 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I drained the bin with a siphon hose to direct the water out of the building and into the gravel. The byproducts of this operation are not hazardous, except if I track rusty crud into the house! It took about ten hours to drain the majority of the water out. The photos show the amount of rust and crud that was released from the body of the car, and remember, it was scraped and blown out with air pressure before submerging it.

I used a garden hose to spray the majority of the rust out of the body, but more involved cleaning will be needed. You can actually see some shiny metal in the floors!

---John



('59 SF convertible 006.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



('59 SF convertible 009.JPG)



('59 SF convertible 010.JPG)



('59 SF convertible 011.JPG)



('59 SF convertible 012.JPG)



('59 SF convertible 016.JPG)



('59 SF convertible 017.JPG)



('59 SF convertible 018.JPG)



Attachments
----------------
Attachments '59 SF convertible 006.JPG (159KB - 250 downloads)
Attachments '59 SF convertible 007.JPG (163KB - 221 downloads)
Attachments '59 SF convertible 008.JPG (156KB - 243 downloads)
Attachments '59 SF convertible 009.JPG (157KB - 240 downloads)
Attachments '59 SF convertible 010.JPG (153KB - 234 downloads)
Attachments '59 SF convertible 011.JPG (158KB - 257 downloads)
Attachments '59 SF convertible 012.JPG (148KB - 262 downloads)
Attachments '59 SF convertible 016.JPG (159KB - 254 downloads)
Attachments '59 SF convertible 017.JPG (152KB - 235 downloads)
Attachments '59 SF convertible 018.JPG (161KB - 244 downloads)
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B/G 61
Posted 2010-06-11 9:22 PM (#227503 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



Expert

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Kenny J.
Posted 2010-06-12 1:04 AM (#227527 - in reply to #227500)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Looks like you're better at this than "Ultra None" was with the Tulsa car.

K.
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Fins/413
Posted 2010-06-12 7:54 AM (#227537 - in reply to #227527)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


Extreme Veteran

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That did a terrific job, I wish I had a mater bin.
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60 Plymouth
Posted 2010-06-12 8:11 AM (#227540 - in reply to #227537)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Posts: 1061
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Looking good John. I guess you know you have left it in to long when you only bring up the windshield surround
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hemidenis
Posted 2010-06-12 10:47 AM (#227555 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



Expert

Posts: 3721
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John
thanks for save this car, this type of "rusty" restoration was always reserved to late 60's 6 figures muscles. You actually saved 2 cars!!.
keep us posted!!!
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tnlowrider
Posted 2010-06-14 8:46 AM (#227792 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



Extreme Veteran

Posts: 500
500
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Wow John! You're my hero! You really took the reverse electrolysis bath to the next level! Wow! 40 amps! You were really cooking man!
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oldwood
Posted 2010-06-14 9:51 AM (#227802 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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Don't look behind you now but the DEA is wondering what your making. Great looking project.
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big m
Posted 2010-06-14 1:09 PM (#227831 - in reply to #227374)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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ronbo97 - 2010-06-10 7:35 PM

Awesome job, John ! Looks like a lot more work than my 59 Dodge conv. needed.

Can't wait to see pics of the body when it emerges from the tank. Will you have to epoxy prime the body to keep it from re-rusting ?

Did the Plymouth convertibles have stronger (12ga.) rockers, sills and inner rockers, like the 59 Dodge did ?

I imagined you going into the local grocery store and ordering 100 cases of baking soda. LOL !

Ron



Ron, I have not been able to ascertain if Plymouth also used the heavier gauge rockers, I have cut several convertibles up in the past, and don't ever remember seeing that, although you have to consider that these cars were complete rustbuckets. If anyone here on the site could chime in here, it would be much appreciated.

I'll have a lot of smaller areas to repair yet, so I won't be putting the car in primer until later. I will give the car a light soda or media blast just before that time.

---John
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big m
Posted 2010-06-14 1:13 PM (#227833 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I spent Saturday cleaning the loose paint and loosened rust from the body, now I know exactly what areas will need further repairs. It's interesting to see how any loose paint or undercoating fell away during the process, any remaining undercoating scrapes off easily now.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



('59 SF convertible 009.JPG)



Attachments
----------------
Attachments '59 SF convertible 001.JPG (153KB - 251 downloads)
Attachments '59 SF convertible 002.JPG (158KB - 239 downloads)
Attachments '59 SF convertible 003.JPG (163KB - 256 downloads)
Attachments '59 SF convertible 004.JPG (157KB - 230 downloads)
Attachments '59 SF convertible 005.JPG (148KB - 241 downloads)
Attachments '59 SF convertible 006.JPG (160KB - 243 downloads)
Attachments '59 SF convertible 007.JPG (162KB - 240 downloads)
Attachments '59 SF convertible 008.JPG (165KB - 261 downloads)
Attachments '59 SF convertible 009.JPG (156KB - 243 downloads)
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big m
Posted 2010-06-14 1:19 PM (#227836 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Here are more photos after wirebrushing the panels.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



Attachments
----------------
Attachments '59 SF convertible 001.JPG (160KB - 238 downloads)
Attachments '59 SF convertible 002.JPG (150KB - 250 downloads)
Attachments '59 SF convertible 003.JPG (154KB - 238 downloads)
Attachments '59 SF convertible 004.JPG (148KB - 231 downloads)
Attachments '59 SF convertible 005.JPG (163KB - 241 downloads)
Attachments '59 SF convertible 006.JPG (153KB - 245 downloads)
Attachments '59 SF convertible 007.JPG (167KB - 346 downloads)
Attachments '59 SF convertible 008.JPG (158KB - 235 downloads)
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christine-lover
Posted 2010-06-14 8:50 PM (#227889 - in reply to #227831)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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big m - 2010-06-14 1:09 PM

ronbo97 - 2010-06-10 7:35 PM

Awesome job, John ! Looks like a lot more work than my 59 Dodge conv. needed.

Can't wait to see pics of the body when it emerges from the tank. Will you have to epoxy prime the body to keep it from re-rusting ?

Did the Plymouth convertibles have stronger (12ga.) rockers, sills and inner rockers, like the 59 Dodge did ?

I imagined you going into the local grocery store and ordering 100 cases of baking soda. LOL !

Ron



Ron, I have not been able to ascertain if Plymouth also used the heavier gauge rockers, I have cut several convertibles up in the past, and don't ever remember seeing that, although you have to consider that these cars were complete rustbuckets. If anyone here on the site could chime in here, it would be much appreciated.

I'll have a lot of smaller areas to repair yet, so I won't be putting the car in primer until later. I will give the car a light soda or media blast just before that time.

---John


John-

Your doing a hell of a job on this car. Keep up the good work.

May I add, my 58 Plymouth Convertible has 12 gauge rockers/sill area, while the inners are thinner 18 gauge.
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Finsinthemirror
Posted 2010-06-14 10:26 PM (#227898 - in reply to #227889)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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This is probably a stupid question but I don't care. I'm constantly amazed by the skills of some of you guys and it makes me want to know more so I can get to that point eventually. When you dip the car like that and remove all corrosion protection, how do you respray material on the inner panels that are welded together and have very little room? Like the inner doors and rear wheel wells? Nice work!
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big m
Posted 2010-06-15 12:39 PM (#227958 - in reply to #227889)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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christine-lover - 2010-06-14 5:50 PM

big m - 2010-06-14 1:09 PM

ronbo97 - 2010-06-10 7:35 PM

Awesome job, John ! Looks like a lot more work than my 59 Dodge conv. needed.

Can't wait to see pics of the body when it emerges from the tank. Will you have to epoxy prime the body to keep it from re-rusting ?

Did the Plymouth convertibles have stronger (12ga.) rockers, sills and inner rockers, like the 59 Dodge did ?

I imagined you going into the local grocery store and ordering 100 cases of baking soda. LOL !

Ron



Ron, I have not been able to ascertain if Plymouth also used the heavier gauge rockers, I have cut several convertibles up in the past, and don't ever remember seeing that, although you have to consider that these cars were complete rustbuckets. If anyone here on the site could chime in here, it would be much appreciated.

I'll have a lot of smaller areas to repair yet, so I won't be putting the car in primer until later. I will give the car a light soda or media blast just before that time.

---John


Thanks for the information, Matt. That's a big help.

---John

John-

Your doing a hell of a job on this car. Keep up the good work.

May I add, my 58 Plymouth Convertible has 12 gauge rockers/sill area, while the inners are thinner 18 gauge.
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big m
Posted 2010-06-15 12:46 PM (#227959 - in reply to #227898)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Finsinthemirror - 2010-06-14 7:26 PM

This is probably a stupid question but I don't care. I'm constantly amazed by the skills of some of you guys and it makes me want to know more so I can get to that point eventually. When you dip the car like that and remove all corrosion protection, how do you respray material on the inner panels that are welded together and have very little room? Like the inner doors and rear wheel wells? Nice work!


Not a stupid question at all.

The reverse electrolysis does not have any lingering chemicals to cause corrosion, unlike most chemical dipping, although sealant and/or metal treatment will need to be applied to these hidden areas. There are long nozzles available to attach to a pressure pot to force the protectants into hidden seams and crevices. This step will be a ways down the road for this car.

---John
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d500neil
Posted 2010-06-15 3:11 PM (#227976 - in reply to #227959)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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...But, at least John doesn't have (yet) any blasting media depositions to try to remove, from the nooks/crannies.
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big m
Posted 2010-06-17 8:57 PM (#228331 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Next up will be to cut out the weak sections of floor in the car, and find some suitable replacements in the yard to use in their place.

---John
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narleycharlie
Posted 2010-06-19 8:45 AM (#228545 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Man , that is a good feeling to walk into your yard and have your pick of what you need , not having to go running all over town . I had that luxury when I was doing my engine swap , I had 2 other old Mopars in my yard that I was able to pick apart for all the little Mopar specific clips , connectors , linkages , you name it . It is a good feeling and a big plus in your favor . Keep pluggin John , we re all tuned in for the next episode , right here on the Bat Channel .
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1959 Belvedere Conv
Posted 2010-06-22 12:20 AM (#229005 - in reply to #227374)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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Ron, I will check the Rockers on my 59 Belvedere convert, I have the top of the passenger side Rocker open right now as I was about to weld in a new cap to them and then set the replacement floor in place on top of that cap before welding it all up.

Will advise if the Plymouth has this convert only re-enforcement. I know my 70 Cuda Convert had extra re-enforcing in the rockers (uni-body car) but didn't even think to really look at how the 59 rocker structure was layed out and supported by other metal parts coming together. Figured the X-frame would give it rigidity.

Keep up the good work John!
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mogge65
Posted 2010-06-22 11:44 AM (#229072 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Great job so far John, keep the up the spirit! Morgan

Edited by mogge65 2010-06-22 11:45 AM
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big m
Posted 2010-06-22 2:10 PM (#229090 - in reply to #229072)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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mogge65 - 2010-06-22 8:44 AM

Great job so far John, keep the up the spirit! Morgan (O)


Thanks, Morgan!

---John
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narleycharlie
Posted 2010-06-23 9:12 AM (#229244 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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John, I know your probably going to use original sheetmetal from your yard , but I did notice surfing through RockAuto , they do sell floors and inner and outer rockers . I was really surprised to see the inner rockers , gotta get me some of them .

I notice in a lot of instances where the floors are good but are heavily pitted , what does a restorer do in those cases , I m sure you will change them out , but in other instances is it normal to load it up with filler primer and be done with it . Was just wondering what people may do in those circumstances .
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big m
Posted 2010-06-23 12:39 PM (#229258 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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The heavily pitted and pinholed sections of the floor I will replace. There is a process where zinc is electrically sprayed over the panels, and it will fill holes up to a quarter inch, and can be filed smooth afterwards. Light pitting the filler primer will take care of, as long as the metal is prepped correctly.

---John
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Greg P.
Posted 2010-06-28 9:31 AM (#229982 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Fantastic work. Your project is an inspiration! Makes mine look so easy in comparison.
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big m
Posted 2010-07-07 4:46 PM (#231519 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I removed the majority of the floorboards, as a good part was thin from pinholes and rust. There was quite a buildup of crud hidden beneath, a combination of dirt, sand, and rust residue.





('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



Attachments
----------------
Attachments '59 SF convertible 001.JPG (157KB - 235 downloads)
Attachments '59 SF convertible 002.JPG (158KB - 216 downloads)
Attachments '59 SF convertible 003.JPG (150KB - 222 downloads)
Attachments '59 SF convertible 004.JPG (151KB - 225 downloads)
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big m
Posted 2010-07-07 4:57 PM (#231521 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Notice one of the body mounts was missing in the photos above? When I cut the floor around it, I found it was no longer attached! Only one tiny tack weld right from the factory. All the other mounts and outriggers were in excellent condition, and cleaned up easily. I will treat these with OverRust before installing the replacement floor section. I did find a few pinholes in the inner rockers, but the surrounding metal was solid, so I'll mig weld them in.

Note that the frame is being used as a jig to keep everything in place while doing this.

---John



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 009.JPG)



('59 SF convertible 010.JPG)



('59 SF convertible 011.JPG)



Attachments
----------------
Attachments '59 SF convertible 005.JPG (162KB - 219 downloads)
Attachments '59 SF convertible 006.JPG (153KB - 227 downloads)
Attachments '59 SF convertible 009.JPG (152KB - 222 downloads)
Attachments '59 SF convertible 010.JPG (148KB - 224 downloads)
Attachments '59 SF convertible 011.JPG (148KB - 225 downloads)
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ronbo97
Posted 2010-07-07 10:17 PM (#231589 - in reply to #231519)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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When I did the floors on my 59 Dodge convertible, I left the 'tunnel' and rockers intact, in addition to using the frame as a jig, to keep things from twisting up. My 'tunnel' was solid without any pinholes, while the floors were a mess and were replaced with rust free ones from Kansas.

The rockers, sills and inner rockers were eventually replaced due to rust and damage, but not before the floors were welded in place.

Ron

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B/G 61
Posted 2010-07-08 2:17 AM (#231613 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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Everytime I "check in" and see the progress you are making, I think how amazing this project is, how amazing the work you
are doing is, and how much I am enjoying this thread. Just thought I'd type it this time around. Keep up the fantastic job !!!!





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Fins/413
Posted 2010-07-08 7:39 AM (#231626 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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This is the tread I check first when I log in, well done.
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Doctor DeSoto
Posted 2010-07-08 10:34 AM (#231636 - in reply to #227831)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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big m - 2010-06-15 10:09 AM

Ron, I have not been able to ascertain if Plymouth also used the heavier gauge rockers, I have cut several convertibles up in the past, and don't ever remember seeing that, although you have to consider that these cars were complete rustbuckets. If anyone here on the site could chime in here, it would be much appreciated.

I will give the car a light media blast just before that time.

---John


***************************************************************

As far as I know, ALL convertibles got the heavy gauge rockers. While I never cut up a Dodge, I have been able to
inspect those from the other marques.

About that "media blast" ...... just place a radio near the car and turn on NPR or MSNBC. The liberal media will do
plenty of "blasting" about you not just scrapping this hunk of junk and buying a Prius. Honestly John, I am embarrassed
and ashamed over this horrific waste. Think of all the ghetto addicts you could help support with government programs
if you directed your funds and energy to those most deserving !

What is wrong with you, man ?
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big m
Posted 2010-07-08 4:15 PM (#231660 - in reply to #231636)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Doctor DeSoto - 2010-07-08 7:34 AM

big m - 2010-06-15 10:09 AM

Ron, I have not been able to ascertain if Plymouth also used the heavier gauge rockers, I have cut several convertibles up in the past, and don't ever remember seeing that, although you have to consider that these cars were complete rustbuckets. If anyone here on the site could chime in here, it would be much appreciated.

I will give the car a light media blast just before that time.

---John


***************************************************************

As far as I know, ALL convertibles got the heavy gauge rockers. While I never cut up a Dodge, I have been able to
inspect those from the other marques.

About that "media blast" ...... just place a radio near the car and turn on NPR or MSNBC. The liberal media will do
plenty of "blasting" about you not just scrapping this hunk of junk and buying a Prius. Honestly John, I am embarrassed
and ashamed over this horrific waste. Think of all the ghetto addicts you could help support with government programs
if you directed your funds and energy to those most deserving !

What is wrong with you, man ?


Brent, you do have a great sense of humor! LOL!

---John
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Doctor DeSoto
Posted 2010-07-09 2:03 AM (#231744 - in reply to #231660)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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If I didn't laugh at the stuff I have to deal with, I'd end up killing people !


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agirlandher58
Posted 2010-07-10 3:07 PM (#231900 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Golly Big M,I thought I had body work to do...but your really doing it do it!!! Way to go looking darn good!!! Keep posting those photos.
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big m
Posted 2010-07-11 2:42 PM (#232040 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Thanks, Teffany, and it's good to see you back on your own car!

---John
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big m
Posted 2010-07-15 1:48 PM (#232767 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I cut the floors from a '59 Chrysler out in the yard, scraped the undercoating from the surface, and drilled the spotwelds out to remove the rockers and underpinnings from the floor stamping. In the process, I found several areas that will need repair due to alkali being packed between the mounts and floor.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



Attachments
----------------
Attachments '59 SF convertible 001.JPG (147KB - 209 downloads)
Attachments '59 SF convertible 002.JPG (151KB - 216 downloads)
Attachments '59 SF convertible 003.JPG (162KB - 232 downloads)
Attachments '59 SF convertible 004.JPG (161KB - 236 downloads)
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ronbo97
Posted 2010-07-15 2:47 PM (#232772 - in reply to #232767)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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Hmmm...aren't 59 Chrysler floors different from 59 Plymouth, longer and wider with different stampings ?

Ron

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big m
Posted 2010-07-15 5:51 PM (#232834 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Ron, the width is exactly the same, at 63 1/2", The front floors are identical stampings, although, the rears are longer with different stampings. The floors past the door jambs are in good condition in the Plymouth, so I will not be needing those areas.

---John
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d500neil
Posted 2010-07-16 8:24 PM (#232976 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Exner Expert 19,174 posts. Neil passed away 18 Sep 2015. You will be missed, Neil!

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An interesting point of reference is how shallow the seat troughs are on the 59 floor pans, compared to the 57-58 boys.





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Fins/413
Posted 2010-07-17 6:55 AM (#233012 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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It's nice to see a 59 floor that is solid. What kind of spot weld drill do you use its getting a heck of a workout.
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60 Plymouth
Posted 2010-07-17 8:01 AM (#233019 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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John that is one helluva job. Looks great!!!!
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ripperace
Posted 2010-07-18 7:13 AM (#233113 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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You've got a bigger set than I do John! I can't believe the progress you've made with this machine! Plus all the work your putting into building the car...Astounding. Can't wait to see her finished!

Ripper
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big m
Posted 2010-07-18 1:05 PM (#233138 - in reply to #233012)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Fins/413 - 2010-07-17 3:55 AM

It's nice to see a 59 floor that is solid. What kind of spot weld drill do you use its getting a heck of a workout.


Some of these were done with a simple 7/16" drill bit, while others I used a carbide burr in a high speed drill motor.

---John
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big m
Posted 2010-08-02 6:09 PM (#235430 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I cut out the small areas where I had found rust, cut out patches, and butt welded them in. Then it was to grinding the welds flush, and cleaning up the edges to ready for installation. After flipping the floor section over, all undercoating and grease was removed, and the areas where the floor was to meet the underbracing wire wheeled, and treated with Over-Rust [similar to POR 15]

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 004.JPG)



('50 Ford 011.JPG)



Attachments
----------------
Attachments '59 SF convertible 001.JPG (157KB - 201 downloads)
Attachments '59 SF convertible 002.JPG (152KB - 209 downloads)
Attachments '59 SF convertible 004.JPG (158KB - 212 downloads)
Attachments '50 Ford 011.JPG (150KB - 211 downloads)
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big m
Posted 2010-08-02 7:46 PM (#235442 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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The body support was welded back on, and the seat reinforcements were also rewelded to their supports, as the welds on them had broken. The underpinnings were also metal treated after cleaning, and the floorboard was lifted in place. I used a plasma cutted to trim the existing floor, using a straightedge on both sections to avoid any large gaps. Screwdrivers worked well to align all the mounting holes, and bolts were placed in them to keep the alignment. Clamps were used to hold the firewall seam right to where it needed to be, and a few tack welds were done to hold it in place.

---John



(big m 2 263.jpg)



(big m 2 264.jpg)



(big m 2 265.jpg)



(big m 2 266.jpg)



(big m 2 267.jpg)



(big m 2 268.jpg)



(big m 2 269.jpg)



(big m 2 270.jpg)



Attachments
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Attachments big m 2 263.jpg (72KB - 201 downloads)
Attachments big m 2 264.jpg (68KB - 213 downloads)
Attachments big m 2 265.jpg (58KB - 199 downloads)
Attachments big m 2 266.jpg (48KB - 203 downloads)
Attachments big m 2 267.jpg (51KB - 188 downloads)
Attachments big m 2 268.jpg (65KB - 241 downloads)
Attachments big m 2 269.jpg (58KB - 253 downloads)
Attachments big m 2 270.jpg (74KB - 223 downloads)
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phurious
Posted 2010-08-02 7:50 PM (#235443 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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John, You're a brave soul...
Keep up the great work!
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big m
Posted 2010-08-02 8:50 PM (#235447 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Thanks, Ron!

Love that photo of your reflection in your fender ornament!!

---John
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sidesho_bob1961
Posted 2010-08-03 6:28 AM (#235488 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Any beginner "body men" out there that want to see how it's done.....here's a perfect example!!! Keep up the good work, John!!!
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Fins/413
Posted 2010-08-03 7:35 AM (#235490 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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Great work as usual, do you weld with gas?. Those leaf springs across the frame look like they would make a good seat.
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Doctor DeSoto
Posted 2010-08-03 10:50 AM (#235507 - in reply to #235490)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Looks like you are ready for paint !

What colors will you go with when the messy part is done ?

Which do you think we be done first, your car, or my shop ?
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big m
Posted 2010-08-03 12:56 PM (#235518 - in reply to #235490)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Fins/413 - 2010-08-03 4:35 AM

Great work as usual, do you weld with gas?. Those leaf springs across the frame look like they would make a good seat.


Eric, I use a Millermatic 250 mig welder with gas.

I had replaced my Fury's springs earlier this year, and the chassis was as good a place for me to set the old ones down and forget to put them away. LOL!
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big m
Posted 2010-08-03 1:21 PM (#235524 - in reply to #235507)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Doctor DeSoto - 2010-08-03 7:50 AM

Looks like you are ready for paint !

What colors will you go with when the messy part is done ?

Which do you think we be done first, your car, or my shop ?


The car will be solid black, with a red interior. I hope to have all the metalwork and solder done so I can get it protected in sealer before our rainy season hits. I'm sure you'll have your shop well on its way by then!

---John
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Rebels-59
Posted 2010-08-07 2:52 PM (#236011 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Board Moderator & Exner Expert 10K+

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Some Inspiration for Ya John.. Just so you can see the Light at the end of the Tunnel..

http://www.forwardlook.net/forums/forums/thread-view.asp?tid=32078&...
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Windsor59
Posted 2010-08-08 5:11 PM (#236133 - in reply to #236011)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Hi John!
You do a very nice metall work, It being a great car. Good Luck!
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HemiEd
Posted 2010-08-11 2:00 PM (#236494 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]


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Like everyone else, thanks John, for sharing this. Just read the whole thread, and am anxious to see more.

A 59 Fury, is one of few cars left on my list, that I have never owned, that I have always wanted.

Edited by HemiEd 2010-08-11 2:01 PM
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56fireflite
Posted 2010-08-16 4:09 AM (#237051 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Just spent a very nice half hour reading the whole thread....WOW!
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big m
Posted 2010-08-23 4:22 PM (#238059 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Front floors are now completely welded in, time to grind off the excess welds before progressing to the trunk area.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



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Attachments '59 SF convertible 001.JPG (162KB - 187 downloads)
Attachments '59 SF convertible 002.JPG (156KB - 198 downloads)
Attachments '59 SF convertible 003.JPG (158KB - 225 downloads)
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sidesho_bob1961
Posted 2010-08-24 10:32 AM (#238143 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Piecing together very nicely, John!!! Keep inspiring us all!!!
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big m
Posted 2010-08-24 2:17 PM (#238183 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Thanks, Bob!

---John
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MoparBrew
Posted 2010-08-29 6:37 PM (#238919 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Wow!!! I think it's going to be great!! Everytime I see something of this level of craftsmanship being performed by John or Wizard or somebody else....I feel like such a hack. My friends say I'm good....I will never let them see this thread :}..........Ralph from Brooklyn
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abqcarl
Posted 2010-09-12 7:51 PM (#241178 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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John-

As someone who has worked in the restoration industry, all I can say is WOW! I am so impressed with what you have done here. I cannot imagine undertaking such a project, but I am glad that there are people with the intestinal fortitude to do so. All of a sudden, DeSoto looks like a walk in the park compared to your car. All it needs are outer rockers and a bit of patching in the lower quarter panels. You have inspired me with your work. Keep it up!!

CaptCarl
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big m
Posted 2010-10-21 7:32 PM (#246529 - in reply to #238183)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I finally got a chance to do a bit on the car. Getting the place cleaned up for the party has been an undertaking in itself!

Here are the replacement 12 gauge rocker panels. These were made with a hydraulic metal brake, as the gauge of the steel was a bit too thick to use a mechanical brake.

To get the dimensions of these parts correct, I cut a cross section from an undamaged rocker panel from another Mopar. You can visually see the difference in what was specified for a convertible versus a coupe or sedan.

---John



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(004.JPG)



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Attachments 004.JPG (160KB - 228 downloads)
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Furyous_Don
Posted 2010-10-21 9:59 PM (#246549 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Wow, I just finished reading this thread too. Many others have said it, but I gotta do it too. Hats off to you, John, you are a major inspiration.
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1959Dodge
Posted 2010-10-21 11:11 PM (#246554 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Here's some more inspiration for ya John. I have interior shots too.
This is a 59 Sport Fury with the 361 4 barrel engine.
Enjoy!!
Nice job you are doing, when you are done we will have to get the
convertibles together for a cruise!!! It will have to be "Soon" as
I'm even older than Neil!!!!!

Gary



(My Classic Car, Aivar's 1959 Plymouth Sport Fury Conv-1-3 modified.jpg)



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Attachments My Classic Car, Aivar's 1959 Plymouth Sport Fury Conv-1-3 modified.jpg (185KB - 212 downloads)
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1960DesotoAdventurer
Posted 2010-10-22 11:00 AM (#246589 - in reply to #246529)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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big m - 2010-10-21 7:32 PM

I finally got a chance to do a bit on the car. Getting the place cleaned up for the party has been an undertaking in itself!

Here are the replacement 12 gauge rocker panels. These were made with a hydraulic metal brake, as the gauge of the steel was a bit too thick to use a mechanical brake.

To get the dimensions of these parts correct, I cut a cross section from an undamaged rocker panel from another Mopar. You can visually see the difference in what was specified for a convertible versus a coupe or sedan.

---John


John,your work is amazing!
I've had to weld in a new trunk pan and drivers side floor pan in the past,but nothing on the scale of what you're doing!
Wish I had a shop like yours!

What's that "over rust" stuff like? Does it have to be top coated like Por-15 to protect it from UV rays?

I can only imagine how much work it must be clearing room for your party,if you need to clear some more space I'd be happy to store that '58 Plymouth at my place!

Edited by 1960DesotoAdventurer 2010-10-22 11:05 AM
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MOPAR-TO-YA
Posted 2010-10-22 12:25 PM (#246599 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]


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Good heavens John! three pages here and I cannot believe I missed all of them till now. Maybe I have Plymouths on my
" ignore " list! I stand in awe at people that have the ability and the dedication to take on a prject like this. Mo-Power- To- YA, and you can bet I will be looking for your progress pics......................MO
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Fins/413
Posted 2010-10-24 3:45 AM (#246808 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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Beautiful job on those rockers, they ought to stiffen her up.
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ronbo97
Posted 2010-10-24 3:35 PM (#246864 - in reply to #246808)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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Real nice job on those rockers, John. I did mine in the same manner.

Did you press them yourself, or have a shop make them for you ?

Ron

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big m
Posted 2010-10-25 12:38 PM (#246990 - in reply to #246864)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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ronbo97 - 2010-10-24 12:35 PM

Real nice job on those rockers, John. I did mine in the same manner.

Did you press them yourself, or have a shop make them for you ?

Ron



A local shop here did these for me. I have only a mechanical sheetmetal brake, which would not work on this gauge of steel.

---John
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d500neil
Posted 2010-10-25 3:44 PM (#247000 - in reply to #246990)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Exner Expert 19,174 posts. Neil passed away 18 Sep 2015. You will be missed, Neil!

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The belly section-shape of the new rocker looks to be spot-on, but the door sill area looks to be a little long/wide,
compared to the OEM rocker section.

I had to buy two sets of aftermarket outer quarter panels , a couple years ago, when I replaced Horrie's driver's-side
outer rocker panel....(after it had been custom-formed, in so-so/fairly-good-but-not-great configuration, in 1981, when
aftermarket panels were not available, when I repaired his hidden/covered-over rust-out areas)....because both sets
of those panels had serious pressing-shape flaws in them.

My shop decided to use the better of the two, and just to section-in its belly and lower area into the existing rocker panel,
rather than to try to 'make' the entire piece be correctly shaped.




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big m
Posted 2010-10-25 4:39 PM (#247006 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Neil,
I think what you are seeing is an optical illusion as the sample piece is laying at a different angle. They line right up when placed end to end.

---John
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d500neil
Posted 2010-10-25 4:52 PM (#247009 - in reply to #247006)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Exner Expert 19,174 posts. Neil passed away 18 Sep 2015. You will be missed, Neil!

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Well, that's good to know; the aftermarket panels are somewhat less than perfectly shaped.






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Resurrector
Posted 2010-11-13 12:05 AM (#249358 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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WOW...your level of determination and skill is off the charts, John...you're a cornerstone of this forum. Reading all this makes me want to rip into my ragtop project full speed ahead!! Thank you for posting this, a massive help to so many!
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big m
Posted 2011-04-26 6:59 PM (#270113 - in reply to #249358)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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An update on this project-
I have taken a lot of other projects in the time between working on this last, and now. I was called by an estate attorney for the late Leon Shelhorse, who ran Williams Auto Body and towing, and was the local AAA garage since 1957. He closed down in the early '80's. I leased his property fifteen years ago, and helped him to sell some of the collector cars he had stored on the properties he owned. When I bought my ranch, I moved my personal cars out, and he called in a scrap outfit that crushed most of the remaining cars, mostly from the sixties aznd seventies. Some cars were left behind, as well as an assortment of 2-ton trucks, piles of junk, and lots of trash. The attorney gave me salvage rights on the tow yard, and the body shop, in order to clean it up and help sell it for the heirs. I only saved a few vehicles, as they had some value, and scrapped the rest. The body shop had been plagued with midnight visitors [thieves] for years, and any of the easy to remove and sell tools were long gone. I did get some vintage equipment, a safe from the 1800's, and Leon's personal hand made toolbox, although all that was left inside was a Mopar door handle tool, and three small lead paddles.

I got to thinking, that this would be an excellent box to keep all my specialty body tools in, and keep them separate from my mechanic tools. Now I have place for everything that is organized better. The top lid of the box holds my solder files, and each drawer holds my body picks, spoons, slapping files, dollies, hammers, etc.

Soon I will be back to work on the '59, and now have a better way to keep my body tools organized for the job.

---John



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b5rt
Posted 2011-04-26 9:51 PM (#270125 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Expert

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I believe these tools will be in good hands! Great work John. You should consider yourself a Master Craftsman.

And I happen to like the 59 Fury's. Great choice and what dedication you have.
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MOPAR-TO-YA
Posted 2011-04-27 1:36 AM (#270145 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]


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John. If that door handle tool looks like the one used back in the day, It will bring over $200 on e-bay! A table knife with the tip bent at 90 dergee works just fine for me thankyou!......................MO
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big m
Posted 2011-04-27 10:43 AM (#270167 - in reply to #270145)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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MOPAR-TO-YA - 2011-04-26 10:36 PM

John. If that door handle tool looks like the one used back in the day, It will bring over $200 on e-bay! A table knife with the tip bent at 90 dergee works just fine for me thankyou!......................MO


Steve-
I'd been using a bent Taiwan screwdriver to release the handles for years. Never thought about using a table knife!

---John
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big m
Posted 2011-12-02 1:50 PM (#298237 - in reply to #270167)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I finally got caught up enough to resume work on this car.
12 Gauge rocker panel installation- Now, I cut the original 18 gauge rockers from the body with the body firmly positioned on the frame. There was no rust found, but wanted the stronger panels to reduce body flex that convertibles can suffer from. Next, the inside was wire brushed, and a dolly and hammer was used to smooth out the inner panel. A grinder removed the nubs left from the spot welds, and a wire wheel removed any loose residue. Next, the surfaces were coated with the Over-Rust to treat the metal before installing the new panels.

The replacements were then cut to size, and mated to the car body.

---John



(59 SF convertible 001.JPG)



(59 SF convertible 002.JPG)



(59 SF convertible 003.JPG)



(59 SF convertible 005.JPG)



(59 SF convertible 006.JPG)



(59 SF convertible 007.JPG)



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Attachments 59 SF convertible 001.JPG (159KB - 156 downloads)
Attachments 59 SF convertible 002.JPG (158KB - 157 downloads)
Attachments 59 SF convertible 003.JPG (162KB - 162 downloads)
Attachments 59 SF convertible 005.JPG (156KB - 172 downloads)
Attachments 59 SF convertible 006.JPG (147KB - 173 downloads)
Attachments 59 SF convertible 007.JPG (162KB - 200 downloads)
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big m
Posted 2011-12-06 2:09 PM (#298799 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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With both sides of the rocker panels now complete, I assembled the rotisserie I had bought last summer. It was made by a fellow down south of here, he markets them here as a 'Carotator'. It was very easy to assemble, and the steel is heavy gauge, I would recommend them to anyone. I have lots of finish work to do, as well as lots of grinding. Not to mention, I have decided to replace rather than patch the trunk pan, as it it heavily pitted. I have a reasonably solid '57 pan cut out of a car I scrapped recently that I will use.

I used a series of blocks on jacks, and barrels, to set the car body up by myself.
---John



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 002.JPG)



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Attachments '59 SF convertible 003.JPG (156KB - 163 downloads)
Attachments '59 SF convertible 004.JPG (158KB - 173 downloads)
Attachments '59 SF convertible 005.JPG (150KB - 192 downloads)
Attachments '59 SF convertible 006.JPG (157KB - 177 downloads)
Attachments '59 SF convertible 007.JPG (154KB - 169 downloads)
Attachments '59 SF convertible 002.JPG (164KB - 195 downloads)
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muddy
Posted 2011-12-07 5:24 AM (#298906 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


Veteran

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That rotissary looks the goods John,it would be very handy in my shed!
Great to see you back into "Rusty"mate,It's better than any serial on tv,thats for sure!
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dukeboy
Posted 2011-12-07 6:47 AM (#298907 - in reply to #298906)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Looking good John. Every time I need some inspiration, I take a look at this thread.
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big m
Posted 2011-12-07 1:39 PM (#298939 - in reply to #298906)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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muddy - 2011-12-07 2:24 AM

That rotissary looks the goods John,it would be very handy in my shed!
Great to see you back into "Rusty"mate,It's better than any serial on tv,thats for sure!


Thanks, Grant! Hopefully I can stay on it for awhile this time instead of bouncing between other projects.

---John
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big m
Posted 2011-12-07 1:40 PM (#298940 - in reply to #298907)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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dukeboy - 2011-12-07 3:47 AM

Looking good John. Every time I need some inspiration, I take a look at this thread.


Thanks, Chaney! I really enjoy watching your build threads as well.

---John
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big m
Posted 2011-12-07 1:42 PM (#298941 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Another minor dilemna- Where to put the frame until I can use the croossmember and extra mounts in the donor frame. This thing is rusty, and could easily be considered scrap, so I do not want to put it outside where one of the guys may toss it in the scrap bin, but it will be in the way inside. I used a couple come alongs and raised it to the ceiling, and chained it up out of the way until I am ready for it.

---John



('59 SF convertible 002.JPG)



(Deal Wrecking 001.JPG)



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Attachments '59 SF convertible 002.JPG (164KB - 168 downloads)
Attachments Deal Wrecking 001.JPG (167KB - 323 downloads)
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d500neil
Posted 2011-12-07 4:08 PM (#298963 - in reply to #298941)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Exner Expert 19,174 posts. Neil passed away 18 Sep 2015. You will be missed, Neil!

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John, there have been some OEM correct MoPar convertible mufflers on the 'Pay, recently.





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big m
Posted 2011-12-07 6:11 PM (#298968 - in reply to #298963)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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d500neil - 2011-12-07 1:08 PM

John, there have been some OEM correct MoPar convertible mufflers on the 'Pay, recently.







Neil, do you happen to have the auction number by chance? If so, thanks in advance!!

---John
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oldwood
Posted 2011-12-07 7:34 PM (#298975 - in reply to #298968)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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You have taken the old saying "you have a lot of junk hanging around" to a new level!!!

Edited by oldwood 2011-12-07 10:04 PM
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d500neil
Posted 2011-12-07 8:05 PM (#298980 - in reply to #298975)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Exner Expert 19,174 posts. Neil passed away 18 Sep 2015. You will be missed, Neil!

Posts: 19171
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I'll see what I can do.....





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big m
Posted 2011-12-28 1:41 PM (#301344 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Expert 5K+

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I received my recast steering wheel back from Koch's. They did a good job on it overall, they were originally going to cast the clear plastic and repair the handgrips, but they recast the handgrips as well, and may I add, at no extra cost!!

---John



('59 SF convertible 004.JPG)



('59 SF convertible 003.JPG)



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Attachments '59 SF convertible 004.JPG (145KB - 161 downloads)
Attachments '59 SF convertible 003.JPG (161KB - 180 downloads)
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Windsor59
Posted 2011-12-28 1:52 PM (#301346 - in reply to #301344)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Look great steering wheel (If same firm new rechromed the steering frame?). Hope I can see your Sport Fury in live when I go to CA.
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BarnFind57
Posted 2011-12-28 2:03 PM (#301351 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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That wheel looks nice.


I am familiar with Koch's... they do some really nice work.

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Matthew Keij
Posted 2011-12-28 5:07 PM (#301371 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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What color is that steering wheel?
Also what was your plan for the interior color? I forgot
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FIN ME
Posted 2011-12-29 8:38 AM (#301436 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Incredible work, John!

I especially like that circular badge that was STILL hanging desperately on to the rear fin in the first "before" pictures. It's a wonder it was still there, and that no one had picked it off over the years.

This car is going to be absolutely wonderful when you are done. I also like the '59's.

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big m
Posted 2011-12-29 1:54 PM (#301452 - in reply to #301346)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Windsor59 - 2011-12-28 10:52 AM

Look great steering wheel (If same firm new rechromed the steering frame?). Hope I can see your Sport Fury in live when I go to CA.


The chrome ring was in good condition, although the plastic had disintegrated. It was not necessary to re chrome it.

Look forward to meeting you in January when you visit too!

---John
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big m
Posted 2011-12-29 1:56 PM (#301453 - in reply to #301351)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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BarnFind57 - 2011-12-28 11:03 AM

That wheel looks nice.


I am familiar with Koch's... they do some really nice work.



Thanks, Rick. I had met them several years ago when they were buying core steering wheels. I had a good feeling about the way they were doing things.

---John
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big m
Posted 2011-12-29 1:58 PM (#301455 - in reply to #301371)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Matthew Keij - 2011-12-28 2:07 PM

What color is that steering wheel?
Also what was your plan for the interior color? I forgot


Hi Matthew,

The color of the interior was red, with a black exterior and dash. The sterering wheel handgrips are gray, as is the center pad for it.

---John
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big m
Posted 2011-12-29 2:01 PM (#301457 - in reply to #301436)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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FIN ME - 2011-12-29 5:38 AM


Incredible work, John!

I especially like that circular badge that was STILL hanging desperately on to the rear fin in the first "before" pictures. It's a wonder it was still there, and that no one had picked it off over the years.

This car is going to be absolutely wonderful when you are done. I also like the '59's.

(O)


Thanks! I was surprised the badges were still on the quarters, but the yard where the car was found was deep in the forest in upstate New York, and not visible from any roadway. My late friend Jim found the yard by word of mouth, and sent the car out to me.

---John
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Matthew Keij
Posted 2011-12-29 3:21 PM (#301463 - in reply to #301455)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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big m - 2011-12-29 1:58 PM

Matthew Keij - 2011-12-28 2:07 PM

What color is that steering wheel?
Also what was your plan for the interior color? I forgot


Hi Matthew,

The color of the interior was red, with a black exterior and dash. The sterering wheel handgrips are gray, as is the center pad for it.

---John


Johnnie,
The Sport Fury steering wheels were black, brown, green or blue.
Just a note for originality
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61forfun
Posted 2011-12-29 4:10 PM (#301468 - in reply to #301463)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Hey Matt- ran across this add, maybe a source for parts if you are in need

http://portland.craigslist.org/clk/pts/2763159573.html
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big m
Posted 2011-12-29 5:34 PM (#301485 - in reply to #301463)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Matthew Keij - 2011-12-29 12:21 PM

big m - 2011-12-29 1:58 PM

Matthew Keij - 2011-12-28 2:07 PM

What color is that steering wheel?
Also what was your plan for the interior color? I forgot


Hi Matthew,

The color of the interior was red, with a black exterior and dash. The sterering wheel handgrips are gray, as is the center pad for it.

---John


Johnnie,
The Sport Fury steering wheels were black, brown, green or blue.
Just a note for originality


Thanks for the info, Matt. This one was the same color as what I removed from this car originally, so the steering wheel may have been changed out years ago.

---John
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big m
Posted 2011-12-29 5:36 PM (#301486 - in reply to #301468)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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61forfun - 2011-12-29 1:10 PM

Hey Matt- ran across this add, maybe a source for parts if you are in need

http://portland.craigslist.org/clk/pts/2763159573.html


DesotoPat sent me that link yesterday, and I have arranged to buy that particular car.

---John
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Fins/413
Posted 2011-12-29 6:04 PM (#301490 - in reply to #301486)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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Well done, save another from the crusher
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carjock
Posted 2011-12-31 9:24 AM (#301644 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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Amazing talent and capability shown here, John. But will the "numbers match" when you are done? Neil will want to research it!
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big m
Posted 2012-01-02 1:30 PM (#301858 - in reply to #301644)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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carjock - 2011-12-31 6:24 AM

Amazing talent and capability shown here, John. But will the "numbers match" when you are done? Neil will want to research it!


LOL!

Thanks, Jim!

---John
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jeff0547
Posted 2012-01-03 2:26 PM (#301964 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]


New User

Posts: 1

I'm really impressed with what you're doing. I only wish that I could have the skill and talent to do it, too. I love following these threads about anyone who has the tenacity or the stubborness to re-build a ragged out, rust bucket. Here is one I found on the Team Impala board. Same kinda work.
This guy really wanted a '61 Impala convertible, but couldn't afford one. When he found this one, he bought it.
Here's the URL:
http://www.impalas.net/forums/showthread.php?t=686

I thought you might enjoy it, so Happy reading .... it's a long one, but worth it.




__________________
Jeff
in SW FLA
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muddy
Posted 2012-01-04 6:48 AM (#302058 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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Just read the Impala story...WOW!!....that bloke must have REALY wanted a '61 rag top!He realy is doing it the hard way,to start off with a car that ruff!!
Storys like his and John's here are realy inspiring stuff to people like me,who have never tackled projects on this scale before.
WOW again!
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big m
Posted 2012-01-04 1:25 PM (#302109 - in reply to #301964)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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jeff0547 - 2012-01-03 11:26 AM

I'm really impressed with what you're doing. I only wish that I could have the skill and talent to do it, too. I love following these threads about anyone who has the tenacity or the stubborness to re-build a ragged out, rust bucket. Here is one I found on the Team Impala board. Same kinda work.
This guy really wanted a '61 Impala convertible, but couldn't afford one. When he found this one, he bought it.
Here's the URL:
http://www.impalas.net/forums/showthread.php?t=686

I thought you might enjoy it, so Happy reading .... it's a long one, but worth it.




__________________
Jeff
in SW FLA


Thanks for the link, Jeff. Lots of hard work went into that car, no doubt!!

---John
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Windsor59
Posted 2012-01-04 3:31 PM (#302123 - in reply to #302109)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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What work he puts into his Impala.
Difficult to understand for us northerners that you can not find a better project in the U.S..
To me there seems to be many more items which
Or am I wrong? (Ok I know some model is where rare...)
Sure, similar to work on this Impala 61 John (Big M) Sport Fury conv 59
Wish I were as handy with sheet metal like them.

Edited by Windsor59 2012-01-04 3:48 PM
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60 dart
Posted 2012-01-04 4:16 PM (#302135 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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musta wanted a 61 real bad but the end results will be fantastic . a good dose of fortitude in that project . i always thought the 61 was one of the best lookin chevrolets and a rag to boot ----------------------------------------------------later
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big m
Posted 2012-01-11 12:18 PM (#303200 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I had a trunk floor cut out of a car I scrapped a year or two ago, it had a two inch rust hole next to the fuel filler tube which is why I could never sell it. Just a bit extra labor to repair, and convenient in that it was already out.
Next photos show the donor pan, separating it from pieces I will not be using, and repair of the rust hole before installation.

---John



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('59 SF convertible 001.JPG)



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Attachments '59 SF convertible 001.JPG (151KB - 151 downloads)
Attachments '59 SF convertible 002.JPG (157KB - 158 downloads)
Attachments '59 SF convertible 003.JPG (156KB - 159 downloads)
Attachments '59 SF convertible 004.JPG (157KB - 156 downloads)
Attachments '59 SF convertible 005.JPG (166KB - 298 downloads)
Attachments '59 SF convertible 006.JPG (159KB - 158 downloads)
Attachments '59 SF convertible 007.JPG (156KB - 156 downloads)
Attachments '59 SF convertible 001.JPG (159KB - 140 downloads)
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big m
Posted 2012-01-11 12:27 PM (#303202 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I positioned the rear half of the body on horses to prevent undue stress on the body before cutting the trunk out. Photo of the trunk before removal, shows the thin metal.
---John



('59 SF convertible 008.JPG)



('59 SF convertible 001.JPG)



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Attachments '59 SF convertible 008.JPG (159KB - 148 downloads)
Attachments '59 SF convertible 001.JPG (160KB - 147 downloads)
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big m
Posted 2012-01-11 12:33 PM (#303205 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Cutting the old trunk pan out, and preparing for the installation of its replacement-
---John



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



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Attachments '59 SF convertible 002.JPG (155KB - 140 downloads)
Attachments '59 SF convertible 003.JPG (156KB - 153 downloads)
Attachments '59 SF convertible 004.JPG (157KB - 140 downloads)
Attachments '59 SF convertible 005.JPG (159KB - 147 downloads)
Attachments '59 SF convertible 006.JPG (165KB - 146 downloads)
Attachments '59 SF convertible 007.JPG (150KB - 148 downloads)
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big m
Posted 2012-01-11 12:37 PM (#303207 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Cleaning rough edges and any loose rust, then treating the metal, then setting the pan in place. I found a rust hole in behind the trunk catch support, I will repair this before installing the replacement support.

---John



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



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Attachments '59 SF convertible 002.JPG (151KB - 150 downloads)
Attachments '59 SF convertible 003.JPG (156KB - 145 downloads)
Attachments '59 SF convertible 001.JPG (160KB - 157 downloads)
Attachments '59 SF convertible 002.JPG (153KB - 149 downloads)
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BarnFind57
Posted 2012-01-11 12:43 PM (#303208 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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Impressive, John.....


I am looking forward to seeing this one on the road nearly as much as my own,

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christine-lover
Posted 2012-01-11 12:55 PM (#303212 - in reply to #303208)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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Nice job John. Your making good progress all the time. Seeing your updates gives more inspiration. I put mine on hold for a bit, have some family issues that arised.
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mogge65
Posted 2012-01-11 1:17 PM (#303215 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Thank´s for sharing John, you are making good progress!



(postcard_4.JPG)



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ccpanel
Posted 2012-02-04 7:03 PM (#306432 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]


Member

Posts: 9

Location: nor-cal
OH MY WORD!!!!

I just HAVE to come visit and I am only 90 minutes away... this is insane! taking a pile of rusty metal and recreating what took 100 ton presses 10 seconds...

All I can say is WOW!!!

Dang John-super impressive.

BTW-wanna share that tomatoe bin-great idea BTW-never thought of that use for one of these.

this inspires me to maybe restore my dads 55 2dr imperial. or maybe his 4door.

both are in PRIME concourse shape compared to what you are doing!

Buddy of mine in Tahoe owns a restored "christopher" which I have always admired..

BTW-I work in Chico and we have a laser and waterjet cutter. Laser rated up to 1/2" and waterjet to 18"-yep inches...
PM me if you need some parts cut. we also have a hyd press that will do 10'x0.50" mild steel.
Mark
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big m
Posted 2012-02-06 12:37 PM (#306634 - in reply to #306432)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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ccpanel - 2012-02-04 4:03 PM

OH MY WORD!!!!

I just HAVE to come visit and I am only 90 minutes away... this is insane! taking a pile of rusty metal and recreating what took 100 ton presses 10 seconds...

All I can say is WOW!!!

Dang John-super impressive.

BTW-wanna share that tomatoe bin-great idea BTW-never thought of that use for one of these.

this inspires me to maybe restore my dads 55 2dr imperial. or maybe his 4door.

both are in PRIME concourse shape compared to what you are doing!

Buddy of mine in Tahoe owns a restored "christopher" which I have always admired..

BTW-I work in Chico and we have a laser and waterjet cutter. Laser rated up to 1/2" and waterjet to 18"-yep inches...
PM me if you need some parts cut. we also have a hyd press that will do 10'x0.50" mild steel.
Mark


Thanks, Mark,

Give me a call, you are welcome to wander here and have a look around at the cars anytime I am open for business- [530] 473-2225

I'll let you know if I need something precision cut also.

---John
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Lisa P
Posted 2012-02-06 2:34 PM (#306646 - in reply to #306634)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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John, I bet you'll have that piece with the trunk latch striker welded in the right place on the first attempt! It took me about 20 tries before I got it in the right spot. That was harder than pulling the body off the frame! I too have a rust converter for treating the metal but wasn't having much luck welding the treated metal-do you turn up the heat to get a good weld in these cases?
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big m
Posted 2012-02-06 5:32 PM (#306659 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Hi Lisa,

Just be sure that the metal is clean where it is to be welded. A good file works well to remove anything on the surface of the metal that may affect a good weld.

I still need to find the trunk latch support in one of the parts cars, but haven't had time to do so yet.

---John
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d500neil
Posted 2012-02-06 8:10 PM (#306683 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Exner Expert 19,174 posts. Neil passed away 18 Sep 2015. You will be missed, Neil!

Posts: 19171
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Lisa's comment sounds like you should remove an entire section, surrounding and including that latch support, so that
that complete ensemble could, then, be welded into the body as a unit which is 'pre-aligned'.



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big m
Posted 2012-02-29 1:45 PM (#310129 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Expert 5K+

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Still working to smooth out the welds, have about 60% of the underside presentable now. I removed a trunk latch support from a parts car, but found a mouse nest in behind it that caused rust on the lower areas of it. Also I had a rust hole in the project car body that needed to be repaired before installing the support. Patch pieces were cut, and fitted, then butt welded to the body and the support, then ground smooth.



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Attachments '59 SF convertible 012.JPG (157KB - 159 downloads)
Attachments '59 SF convertible 011.JPG (163KB - 146 downloads)
Attachments '59 SF convertible 010.JPG (157KB - 145 downloads)
Attachments '59 SF convertible 009.JPG (157KB - 142 downloads)
Attachments '59 SF convertible 001.JPG (163KB - 156 downloads)
Attachments '59 SF convertible 002.JPG (158KB - 153 downloads)
Attachments '59 SF convertible 003.JPG (159KB - 151 downloads)
Attachments '59 SF convertible 004.JPG (163KB - 157 downloads)
Attachments '59 SF convertible 005.JPG (156KB - 149 downloads)
Attachments '59 SF convertible 007.JPG (162KB - 158 downloads)
Attachments '59 SF convertible 008.JPG (155KB - 152 downloads)
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Lisa P
Posted 2012-03-01 12:12 AM (#310209 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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It looks great John!
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big m
Posted 2012-03-01 3:50 PM (#310283 - in reply to #310209)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Lisa P - 2012-02-29 9:12 PM

It looks great John!


Thanks, Lisa!

I cheated on the trunk latch support location, I measured another car in the yard. I can see how easy it could be to center it with the rear license plate light, but the light is off to one side, rather than centered.

---John
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BarnFind57
Posted 2012-03-01 3:59 PM (#310286 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Elite Veteran

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^^^^ I noticed that on my '57... I thought I was imagining it at first, slowed down, looked again.... like you said, it's off to one side.

Looking Great, John. Lots of work, but it will be worth it in the end. I have brought back a couple of REALLY rusty rides, but never went past a "rat" stage... I just straightened and fixed rot and the crucial structural stuff. Enjoying watching this thread.

Keep it up!

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mogge65
Posted 2012-03-02 10:33 PM (#310492 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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red



(1959Plymouth.jpg)



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big m
Posted 2012-05-15 7:29 PM (#321283 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Expert 5K+

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Finally it feels like I am getting somewhere.
I decided to tackle the rust out on the driver side lower quarter, both the inner and outer skins had suffered from rust out.
I removed a section from a car in the yard that appeared to have a good lower area. After seperating the inner from the outer section, I found rust pitting. After an agressive cleaning, multiple pinholes appeared in the metal. I carefully welded each pinhole up with the mig welder, cooling the metal down constantly with a wet rag.

Next was to clean and fit the inner piece, to ready it for butt welding.

---John



('59 SF convertible 001.JPG)



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Attachments '59 SF convertible 001.JPG (159KB - 126 downloads)
Attachments '59 SF convertible 003.JPG (158KB - 141 downloads)
Attachments '59 SF convertible 002.JPG (149KB - 144 downloads)
Attachments '59 SF convertible 004.JPG (153KB - 149 downloads)
Attachments '59 SF convertible 005.JPG (150KB - 133 downloads)
Attachments '59 SF convertible 007.JPG (159KB - 131 downloads)
Attachments '59 SF convertible 008.JPG (163KB - 139 downloads)
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big m
Posted 2012-05-15 7:37 PM (#321287 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Next was to cut the repair sections to fit the body, the inner panel was completed first, so that both the inner and outer welds could be smoothed.

Then the outer panel was tacked and stitch welded slowly in place, the metal being continually cooled with a wet rag.
---John



('59 SF convertible 009.JPG)



('59 SF convertible 010.JPG)



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('59 SF convertible 014.JPG)



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Attachments '59 SF convertible 009.JPG (155KB - 141 downloads)
Attachments '59 SF convertible 010.JPG (156KB - 157 downloads)
Attachments '59 SF convertible 011.JPG (155KB - 135 downloads)
Attachments '59 SF convertible 014.JPG (148KB - 128 downloads)
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big m
Posted 2012-05-15 7:40 PM (#321288 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Completed repair, needing only minor finish work-



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



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Attachments '59 SF convertible 001.JPG (164KB - 133 downloads)
Attachments '59 SF convertible 002.JPG (165KB - 128 downloads)
Attachments '59 SF convertible 003.JPG (155KB - 130 downloads)
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big m
Posted 2012-05-15 7:44 PM (#321289 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Expert 5K+

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Next was to repair the dogleg areas on both sides. The rust was cut out, and repair pieces fabbed from the leftover piece of the quarter panel section from the donor car-
---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



Attachments
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Attachments '59 SF convertible 001.JPG (150KB - 130 downloads)
Attachments '59 SF convertible 002.JPG (156KB - 136 downloads)
Attachments '59 SF convertible 006.JPG (164KB - 114 downloads)
Attachments '59 SF convertible 003.JPG (154KB - 129 downloads)
Attachments '59 SF convertible 004.JPG (161KB - 135 downloads)
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big m
Posted 2012-05-15 7:50 PM (#321293 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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The right side quarter panel had some small holes at the bottom, it would have been easy to fabricate a piece to fit this area, however bondo was discovered above it, and an inch thick in places- After grinding the filler out, I found the metal had been worked and stretched badly, in fact it looked as wavy as a potato chip. Ungood.

I searched the back lot, but every panel that looked decent had either been patched or also had quantities of rust. I found a Savoy that looked like it had a good section, and spent two hours extracting it from the corner of the yard.



('59 SF convertible 007.JPG)



('59 SF convertible 009.JPG)



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Attachments
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Attachments '59 SF convertible 007.JPG (148KB - 128 downloads)
Attachments '59 SF convertible 009.JPG (166KB - 186 downloads)
Attachments '59 SF convertible 010.JPG (156KB - 135 downloads)
Attachments '59 SF convertible 011.JPG (157KB - 137 downloads)
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big m
Posted 2012-05-15 7:55 PM (#321294 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I cut the outer quarter skin off, but it too had had poor work performed to it, and the lower section was straight, but had rust in behind the massive amount of undercoat that had gathered there. Before i cut the piece off, there were no pinholes or paint bubbles, but looking at the back side, the story was different. This was my last option, so I had to go with it.



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



Attachments
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Attachments '59 SF convertible 001.JPG (151KB - 132 downloads)
Attachments '59 SF convertible 002.JPG (149KB - 130 downloads)
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big m
Posted 2012-05-15 8:01 PM (#321296 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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After spending some time welding up all the pinholes and grinding it smooth, the repair piece was now ready. I decided to clean the inner panel and treat it before welding the repair piece in, and then I found numerous pinholes in it. I had to make a piece to duplicate the original, as the donor car had nothing there. I butt welded it in, and smoothed the welds. Next, i worked the stretched outer panel by heating and cooling it, and hitting it with a slapping file when hot. This shrunk the metal back successfully, to continue the repair.

I fitted the outer piece, tacked it, then stitch welded it in. The repair is completed except for some minor finishing work.

---John



('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



('59 SF convertible 009.JPG)



Attachments
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Attachments '59 SF convertible 004.JPG (152KB - 134 downloads)
Attachments '59 SF convertible 005.JPG (158KB - 127 downloads)
Attachments '59 SF convertible 006.JPG (163KB - 126 downloads)
Attachments '59 SF convertible 007.JPG (155KB - 135 downloads)
Attachments '59 SF convertible 008.JPG (147KB - 140 downloads)
Attachments '59 SF convertible 009.JPG (165KB - 127 downloads)
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dukeboy
Posted 2012-05-16 12:36 AM (#321341 - in reply to #321296)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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John, I all too well know what it is to do what you are doing right now, and I gotta say VERY well done! I also know what a PITA it is to post that many pics, but glad you did.
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BarnFind57
Posted 2012-05-16 6:35 AM (#321362 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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Alright, John...

Truth....


Have you started walking around it making little motor sounds?


Looking nice, as always.

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Lisa P
Posted 2012-05-16 12:20 PM (#321413 - in reply to #321362)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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John, it looks like you're really getting things done now! Thanks for all of the work you do documenting the repairs, I go over it many times to learn how to tackle items like this on my own.
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wizard
Posted 2012-05-16 2:17 PM (#321428 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Go, go, John ny go - http://www.youtube.com/watch?v=Y3haYAbqKjA
Really nice to see the transformation of Rusty - keep us posted
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big m
Posted 2012-05-17 4:35 PM (#321625 - in reply to #321341)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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dukeboy - 2012-05-15 9:36 PM

John, I all too well know what it is to do what you are doing right now, and I gotta say VERY well done! I also know what a PITA it is to post that many pics, but glad you did.


Thanks, Chaney!!

---John
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big m
Posted 2012-05-17 4:42 PM (#321628 - in reply to #321362)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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BarnFind57 - 2012-05-16 3:35 AM

Alright, John...

Truth....


Have you started walking around it making little motor sounds?


Looking nice, as always.


LOL Rick!

It finally feels like I am getting somewhere, but there is still a lot to do at this point.

---John
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big m
Posted 2012-05-17 4:44 PM (#321629 - in reply to #321413)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Lisa P - 2012-05-16 9:20 AM

John, it looks like you're really getting things done now! Thanks for all of the work you do documenting the repairs, I go over it many times to learn how to tackle items like this on my own.


Heck, Lisa,

If this was your project, it probably would have been completed already!

Your DeSoto restoration was an inspiration to many on this site.

---John
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big m
Posted 2012-05-17 4:45 PM (#321630 - in reply to #321428)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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wizard - 2012-05-16 11:17 AM

Go, go, John ny go - http://www.youtube.com/watch?v=Y3haYAbqKjA
Really nice to see the transformation of Rusty - keep us posted


Good choice in music, Wiz!!

---John
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big m
Posted 2012-05-17 4:48 PM (#321631 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Now removing the rust residue left from the reverse electrolysis, along with two layers of old paint. It will be easier to spot any high or low spots in the panels now.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 010.JPG)



('59 SF convertible 011.JPG)



('59 SF convertible 012.JPG)



Attachments
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Attachments '59 SF convertible 001.JPG (149KB - 123 downloads)
Attachments '59 SF convertible 002.JPG (160KB - 130 downloads)
Attachments '59 SF convertible 004.JPG (151KB - 133 downloads)
Attachments '59 SF convertible 005.JPG (163KB - 129 downloads)
Attachments '59 SF convertible 006.JPG (146KB - 127 downloads)
Attachments '59 SF convertible 007.JPG (160KB - 125 downloads)
Attachments '59 SF convertible 010.JPG (155KB - 128 downloads)
Attachments '59 SF convertible 011.JPG (163KB - 121 downloads)
Attachments '59 SF convertible 012.JPG (158KB - 132 downloads)
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ronbo97
Posted 2012-05-17 5:34 PM (#321637 - in reply to #321631)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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John -

Been meaning to ask this:

The inner 'scaffolding' that you're using to keep the body from collapsing into itself: How did you determine the correct dimensions for each of the braces and cross-braces ?

Ron

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big m
Posted 2012-05-17 5:55 PM (#321642 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Ron,

I made those braces up in a hardtop body that was in good shape, using steel square tubing. These will fit any 2-door '57-59 Mopar, other than Imperial.

---John
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big m
Posted 2012-06-05 12:07 PM (#324452 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Been hard at work massaging out ripples and high spots in the metal, most I removed with shrinking and dollying, but the dogleg area had a low spot that wouldn't budge. This was the piece I made and fitted in, so apparently the contour was off enough to create this slight depression. I broke out the lead and tinning supplies, also filling the seam on the windshield frame as the factory would have done.
---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



('59 SF convertible 009.JPG)



('59 SF convertible 010.JPG)



Attachments
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Attachments '59 SF convertible 001.JPG (156KB - 190 downloads)
Attachments '59 SF convertible 002.JPG (156KB - 202 downloads)
Attachments '59 SF convertible 003.JPG (150KB - 186 downloads)
Attachments '59 SF convertible 004.JPG (153KB - 194 downloads)
Attachments '59 SF convertible 005.JPG (157KB - 196 downloads)
Attachments '59 SF convertible 006.JPG (163KB - 202 downloads)
Attachments '59 SF convertible 007.JPG (158KB - 209 downloads)
Attachments '59 SF convertible 008.JPG (159KB - 195 downloads)
Attachments '59 SF convertible 009.JPG (160KB - 201 downloads)
Attachments '59 SF convertible 010.JPG (163KB - 209 downloads)
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big m
Posted 2012-06-05 12:11 PM (#324454 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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More grinding and cleaning of welds continued on the bottom of the car, just about done with that part now. I probably have about 120 hours in that work alone in this project.
Quarter panels are now quite straight, as the bare metal shows. I still have a lot to do on the top side of the car yet, I will sandblast the body when the metalwork is complete, and then get it in primer to work on the chassis.

---John



('59 SF convertible 014.JPG)



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('59 SF convertible 016.JPG)



('59 SF convertible 001.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 011.JPG)



Attachments
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Attachments '59 SF convertible 014.JPG (156KB - 202 downloads)
Attachments '59 SF convertible 015.JPG (156KB - 197 downloads)
Attachments '59 SF convertible 016.JPG (164KB - 199 downloads)
Attachments '59 SF convertible 001.JPG (162KB - 200 downloads)
Attachments '59 SF convertible 003.JPG (164KB - 180 downloads)
Attachments '59 SF convertible 004.JPG (165KB - 208 downloads)
Attachments '59 SF convertible 011.JPG (154KB - 213 downloads)
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dukeboy
Posted 2012-06-05 12:18 PM (#324455 - in reply to #324454)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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John, you keep messin' round you gonna end up with a car!
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wizard
Posted 2012-06-05 1:45 PM (#324461 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Surely you know this John, but better safe than sorry - be careful if you're gonna sandblast the sheet metal - if the jet gets the sheet metal too hot, the heat will warp it out of shape. It's a painstaking work you're doing and I follow it with great interest!!
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ronbo97
Posted 2012-06-05 4:26 PM (#324473 - in reply to #324461)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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I love looking at this thread ! Nice work, John. You're obsessed ! 

As a suggestion, it would be nice to see a top-down photo. If you stand on a ladder and shoot down, it'll give us an idea of what you've done and what's left.

Ron
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big m
Posted 2012-06-05 5:05 PM (#324479 - in reply to #324461)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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wizard - 2012-06-05 10:45 AM

Surely you know this John, but better safe than sorry - be careful if you're gonna sandblast the sheet metal - if the jet gets the sheet metal too hot, the heat will warp it out of shape. It's a painstaking work you're doing and I follow it with great interest!!


Thanks, Sven! Any blasting I do will be for the body supports and floors that have rust residue, should be quite quick, as there hasn't been much that was not replaced.

---John
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big m
Posted 2012-06-05 5:09 PM (#324480 - in reply to #324473)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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ronbo97 - 2012-06-05 1:26 PM

I love looking at this thread ! Nice work, John. You're obsessed ! 

As a suggestion, it would be nice to see a top-down photo. If you stand on a ladder and shoot down, it'll give us an idea of what you've done and what's left.

Ron


Thanks, Ron!

I'll do that, I have a loft up above the car where I can take a photo from. I still have some work on the top well to do, also the trunk weatherstrip gutters.

---John
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ronbo97
Posted 2012-06-05 5:23 PM (#324481 - in reply to #324480)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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big m - 2012-06-05 5:09 PM I still have some work on the top well to do, also the trunk weatherstrip gutters. ---John


The trunk lid weatherstrip channel should be a no-brainer since it's the same on all 59 Plymouths. And as a bonus, it's just spot-welded onto the body. I wouldn't even try to repair what's currently in place, since you probably have many donor cars.

Ron
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1958 Plymouth Infina
Posted 2012-06-05 7:06 PM (#324488 - in reply to #324481)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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That's an awesome car lot of work on it so far!
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lawrence
Posted 2012-06-05 10:55 PM (#324514 - in reply to #324481)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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ronbo97 - 2012-06-05 5:23 PM
big m - 2012-06-05 5:09 PM I still have some work on the top well to do, also the trunk weatherstrip gutters. ---John


The trunk lid weatherstrip channel should be a no-brainer since it's the same on all 59 Plymouths. And as a bonus, it's just spot-welded onto the body. I wouldn't even try to repair what's currently in place, since you probably have many donor cars.

Ron
                                                           

I'll bet Big M pondered that same notion.  

 s**t dingle dangle

 

 



Edited by lawrence 2012-06-05 10:57 PM
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Fins/413
Posted 2012-06-06 7:24 AM (#324536 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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A great thread and great work John.
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big m
Posted 2012-06-06 8:28 PM (#324621 - in reply to #324536)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Fins/413 - 2012-06-06 4:24 AM

A great thread and great work John.


Thanks, Eric!

---John
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big m
Posted 2012-06-14 5:43 PM (#325603 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Next will be to either repair, or fabricate a new convertible pump mount, as this one looks like swiss cheese. I derusted it with reverse electrolysis, so at least there will be no surprises.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



Attachments
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Attachments '59 SF convertible 001.JPG (162KB - 190 downloads)
Attachments '59 SF convertible 002.JPG (157KB - 204 downloads)
Attachments '59 SF convertible 003.JPG (156KB - 181 downloads)
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57plymouth
Posted 2012-06-14 6:19 PM (#325610 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Not much to work with on the end there.
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big m
Posted 2012-07-03 5:14 PM (#328233 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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A little bit of good ol' American ingenuity-
I saved the upright sides, as they were not rusted badly, found a store shelf in the scrap pile that was the same gauge steel, and made the lower platform. I welded the uprights on my new piece, and cut a rectangular hole in the center.

Agsain, I raided the scrap pile and found part of a junk steering column that was just about the curvature I needed. I cut a section out, and formed the curved ends to duplicate the original, and welded it into place. A bit of metal finishing, and its hard to tell all this was done.

---John



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(021.JPG)



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('59 SF convertible 019.JPG)



Attachments
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Attachments 020.JPG (153KB - 187 downloads)
Attachments 021.JPG (159KB - 194 downloads)
Attachments '59 SF convertible 016.JPG (149KB - 199 downloads)
Attachments '59 SF convertible 017.JPG (146KB - 188 downloads)
Attachments '59 SF convertible 018.JPG (159KB - 188 downloads)
Attachments '59 SF convertible 019.JPG (157KB - 204 downloads)
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matt
Posted 2012-07-03 5:36 PM (#328235 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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It's always a pleasure to see craftsman at work,
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1961plymouthfury
Posted 2012-07-04 1:10 PM (#328339 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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How more you need to do before you are done?
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big m
Posted 2012-09-22 12:05 PM (#340067 - in reply to #328339)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I took a break from cleaning out the barn to do a bit more on the body. Up to the convertible top well I had a bit of finish work to do, mainly making up the end caps that go over the top main pivot. I saved the old pieces for templates, and used some mild steel to make a new one for the one side. The piece was then butt welded in, and the factory seam was then finished with solder.



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('59 SF convertible 039.JPG)



Attachments
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Attachments '59 SF convertible 001.JPG (151KB - 190 downloads)
Attachments '59 SF convertible 002.JPG (157KB - 188 downloads)
Attachments '59 SF convertible 003.JPG (154KB - 163 downloads)
Attachments '59 SF convertible 004.JPG (162KB - 182 downloads)
Attachments '59 SF convertible 005.JPG (159KB - 197 downloads)
Attachments '59 SF convertible 036.JPG (159KB - 191 downloads)
Attachments '59 SF convertible 037.JPG (156KB - 193 downloads)
Attachments '59 SF convertible 039.JPG (154KB - 187 downloads)
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big m
Posted 2012-09-22 12:11 PM (#340068 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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On to the other side- There was a bit more hammer and dolly work required on this side, but I was able to use the original end cap as the rust was minor. I cleaned up the edges, and fitted the small piece, and welded it in. Then the seam was leaded in, rough filed, and checked. Next was to smooth the area out.



('59 SF convertible 040.JPG)



('59 SF convertible 041.JPG)



('59 SF convertible 042.JPG)



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('59 SF convertible 044.JPG)



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Attachments '59 SF convertible 040.JPG (157KB - 178 downloads)
Attachments '59 SF convertible 041.JPG (145KB - 193 downloads)
Attachments '59 SF convertible 042.JPG (161KB - 185 downloads)
Attachments '59 SF convertible 043.JPG (144KB - 166 downloads)
Attachments '59 SF convertible 044.JPG (157KB - 180 downloads)
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slow2learn
Posted 2012-09-26 1:50 PM (#340706 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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I like you're style make do and mend works for me, does the electrolysis get all the rust of and what do you use to kill the flash rust? I have started to use the molasses 9-1 water solution seems to be working well but am concerned about the flash rust hoping for some advice from somebody who has actually had to deal with it to cold in my shed for epoxy.
Thanks for the inspiration.
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BarnFind57
Posted 2012-09-26 3:26 PM (#340717 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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Alright, John.. the truth...

You're already driving this car, right????

You're just releasing the pics as a teaser, I assume???


Looks killer, man. Nice work, as always.
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big m
Posted 2012-09-26 4:34 PM (#340725 - in reply to #340706)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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slow2learn - 2012-09-26 10:50 AM

I like you're style make do and mend works for me, does the electrolysis get all the rust of and what do you use to kill the flash rust? I have started to use the molasses 9-1 water solution seems to be working well but am concerned about the flash rust hoping for some advice from somebody who has actually had to deal with it to cold in my shed for epoxy.
Thanks for the inspiration.


I have that problem, this being an open barn and not climate controlled. I simply spray a light oil such as WD-40 or similar penetrant on the surface to keep the oxygen away. I will be doing a light blasting to the body and spray with epoxy primer before I seal the body up and start on the chassis.

The reverse electrolysis does leave a rusty residue, but it's easily removed with a wire brush or scotch-brite pad.

---John
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big m
Posted 2012-09-26 4:39 PM (#340727 - in reply to #340717)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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BarnFind57 - 2012-09-26 12:26 PM

Alright, John.. the truth...

You're already driving this car, right????

You're just releasing the pics as a teaser, I assume???


Looks killer, man. Nice work, as always. :cool:


I wish I could say I was getting close, Rick, but time to work on it seems to be getting scarcer and scarcer. I hauled in probably fifty cars in the last two months, with no signs of slowing down. Seems a lot of folks that have been hoarding cars, are now getting rid of their collections.

---John
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Leadfoot1000
Posted 2012-09-27 12:20 AM (#340776 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Hey John, you have some serious metal working talents! And you need them all for a project of that magnitude. I'm learning a lot reading this thread. Thanks for taking the time to share your restoration story...Steve
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big m
Posted 2012-09-27 3:32 PM (#340837 - in reply to #340776)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Leadfoot1000 - 2012-09-26 9:20 PM

Hey John, you have some serious metal working talents! And you need them all for a project of that magnitude. I'm learning a lot reading this thread. Thanks for taking the time to share your restoration story...Steve


Thanks, Steve, I'm glad you enjoyed reading it.

---John
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Peter Panov
Posted 2012-10-17 9:55 AM (#343432 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]


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I am amazed from the efforts, time and energy some people like you are doing to save a nice old car.
Of course these nice car deserves all the efforts. And then you deserve to drive and enjoy them.
Regards
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big m
Posted 2012-10-18 5:52 PM (#343622 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I decided rather than to replace sections of the trunk weatherstrip gutter, that I would repair what I had, as there was just the seams, and a small area where the rust had 'dog-eared' the edge. I used brass rod in order to do this. I also used an 80 grit disc toremove high spots from previous welds.



('59 SF convertible 024.JPG)



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('59 SF convertible 027.JPG)



('59 SF convertible 032.JPG)



('59 SF convertible 031.JPG)



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Attachments '59 SF convertible 024.JPG (153KB - 191 downloads)
Attachments '59 SF convertible 025.JPG (155KB - 181 downloads)
Attachments '59 SF convertible 027.JPG (151KB - 187 downloads)
Attachments '59 SF convertible 032.JPG (160KB - 191 downloads)
Attachments '59 SF convertible 031.JPG (159KB - 172 downloads)
Attachments '59 SF convertible 033.JPG (149KB - 192 downloads)
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Desotorandy
Posted 2012-10-18 8:35 PM (#343646 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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WOW! what an inspiring story,such awesome work,the compliment "great job" just dosen't seem good enough :O) Can't wait to see more.
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59 in Calif
Posted 2012-10-18 10:07 PM (#343659 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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GREAT WORK, John !! I see progress since the last time I was there. One of these days you will be riding in style !! Jerry
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MOPAR-TO-YA
Posted 2012-10-19 1:00 AM (#343689 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]


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John, Don't you think if you did a restoration on Miss Belvy, it would be easier? I know you will get this car done someday, and when you do, you can honestly say you hand-built it 8-) ........................MO
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big m
Posted 2012-10-23 2:25 PM (#344350 - in reply to #343646)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Desotorandy - 2012-10-18 5:35 PM

WOW! what an inspiring story,such awesome work,the compliment "great job" just dosen't seem good enough :O) Can't wait to see more.


Thanks for the compliment, Randy!
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big m
Posted 2012-10-23 2:26 PM (#344351 - in reply to #343659)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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59 in Calif - 2012-10-18 7:07 PM

GREAT WORK, John !! I see progress since the last time I was there. One of these days you will be riding in style !! Jerry


Thanks, Jerry! Have you made any progress on the Dodge recently?
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big m
Posted 2012-10-23 2:28 PM (#344352 - in reply to #343689)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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MOPAR-TO-YA - 2012-10-18 10:00 PM

John, Don't you think if you did a restoration on Miss Belvy, it would be easier? I know you will get this car done someday, and when you do, you can honestly say you hand-built it 8-) ........................MO


Thanks, Steve, and you do realize, we'll be taking our usual cross-country trip once it's roadworthy, and coming to visit ya again.

---John
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big m
Posted 2012-11-16 2:12 PM (#347414 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I found numerous rust holes in the drain channel for the convertible top well. I considered cutting this section from one of the '63 Chrysller 300 converts in the yard, but after making measurements, they were far too different. I decided to cut the decay out, and make the piece myself. I definitely did not want water draining into the interior afterwards!

I measured the arc of the piece I woulld need too fit in as the base of the gutter, and cut one out with a plasma cutter from a sheet of scrap steel. This would then be fitted to the car.



('59SF convertible 001.JPG)



('59SF convertible 002.JPG)



('59SF convertible 004.JPG)



('59SF convertible 005.JPG)



('59SF convertible 006.JPG)



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Attachments '59SF convertible 001.JPG (147KB - 187 downloads)
Attachments '59SF convertible 002.JPG (154KB - 177 downloads)
Attachments '59SF convertible 004.JPG (153KB - 187 downloads)
Attachments '59SF convertible 005.JPG (153KB - 179 downloads)
Attachments '59SF convertible 006.JPG (160KB - 177 downloads)
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big m
Posted 2012-11-16 2:18 PM (#347415 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I made up a mating piece for the side of the drain channel, and welded them together. After dooing this, my repair piece was ready for fitting. I cleaned up the edges, and took a burr to a rust hole to get rid oof any weakened metal, and by then the hole was the size of a fifty cent piece. I made a piece to weld into it, butt welded, and ground it smooth.

Next, I placed the curved channel I had made intoo the body, and tacked it in place. Looked too be a good fit, so i welded it completely, and finished it off.



('59SF convertible 007.JPG)



('59SF convertible 008.JPG)



('59SF convertible 009.JPG)



('59SF convertible 011.JPG)



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Attachments '59SF convertible 007.JPG (148KB - 171 downloads)
Attachments '59SF convertible 008.JPG (150KB - 176 downloads)
Attachments '59SF convertible 009.JPG (153KB - 173 downloads)
Attachments '59SF convertible 011.JPG (167KB - 338 downloads)
Attachments '59SF convertible 013.JPG (161KB - 181 downloads)
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big m
Posted 2012-11-16 2:31 PM (#347417 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I wanted to put the swages into the replacement rocker panel drain holes, so afrter measuring and drilling, I made a tool basically consisting of a slide hammer and nut and bolt, and was able to knock a slight swage into the 12 gauge steel. The purpose of this was to not draw dirt up into the rockers when driving on dirt roads and such.

---John



('59SF convertible 015.JPG)



('59SF convertible 016.JPG)



('59SF convertible 017.JPG)



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Attachments '59SF convertible 015.JPG (149KB - 180 downloads)
Attachments '59SF convertible 016.JPG (159KB - 184 downloads)
Attachments '59SF convertible 017.JPG (152KB - 177 downloads)
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d500neil
Posted 2012-11-16 2:37 PM (#347418 - in reply to #347415)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Exner Expert 19,174 posts. Neil passed away 18 Sep 2015. You will be missed, Neil!

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Amazing work, as always!

To what do you ascribe all of the rust out that Rusty endured?

Merely driving in a wet salty environment, or being stored in a wet area, continually?

In other words, is there any particular pattern to the damage which would tell a story about how 'he' got to be so deteriorated?

Any unusual areas of rust out; like, on that drain channel, that you don't usually see in a hulk???



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big m
Posted 2012-11-16 2:50 PM (#347421 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Thanks, Neil,
This car was left in an abandoned wrecking yard in Upstate New York since about 1965. The trees grew up around the yard, and obscured its contents from view. The wet environment hastened the rust out, as the car slowly sank into the soil. It was sold new in Ithaca, according to Chrysler historical, so it had 'lived' nearby since I got it. All the rust could be attributed to these facts.

A good friend of mine discovered this yard, and bought a '49 and '51 Mercury convertible, as well as seven or eight ford woody wagons for his needs, and he shipped this Plymouth out to me to cover a storage bill he owed me. Sadly, he passed away from cancer complications before he could see progress on this car, so I guess you could say I'm doing the work in his honor.

---John
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1961plymouthfury
Posted 2012-12-29 11:58 PM (#353090 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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My Fathere told me that Chryler product vehicles back then had rust problems. Good luck with the restoration . How much more you need to do? I hope some year you bring it to the Cars on the Square in Athens, AL . I know they would love to have you come
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big m
Posted 2012-12-30 1:57 PM (#353153 - in reply to #353090)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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1961plymouthfury - 2012-12-29 8:58 PM

My Fathere told me that Chryler product vehicles back then had rust problems. Good luck with the restoration . How much more you need to do? I hope some year you bring it to the Cars on the Square in Athens, AL . I know they would love to have you come


Thanks.

I have plenty more to do, although the body itself is almost ready for primer.

I have been shrinking some high spots on the body, and re-leading some of the body seams, as well as making the convertible specific mounts. My camera broke, and M'lisa bought me a new one for Christmas, so hopefully I can get the photos small enough to post.

---John
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1961plymouthfury
Posted 2012-12-31 3:25 PM (#353318 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



Expert

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I told my father about your car and were it sold. He told me the car sold brand new at a Erie J Miller Plymouth Chrysler Plymouth at Elmira Rd in Ithaca , NY. The dealership is no longer in business . I heard they got bought out by another dealership in Trumansbug
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1961 fury
Posted 2013-01-04 8:21 PM (#353963 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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JOHN THIS IS ONE OF THE BEST THREADS I HAVE EVER SEEN , YOU HAVE QUITE THE TALLENT IN RESURRECTION !!!
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big m
Posted 2013-04-11 5:15 PM (#369078 - in reply to #353153)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I jacked up our '59 Desoto convertible to get a look at the special convertible body mounts, and made several measurements.
As the floors were from a closed car, the outriggers from the seat brace would need to be removed, as convertibles do not use them. After removing them, the surface for the new mount was cleaned.
I fabricated a new mount from the same gauge steel, using the measurements from the Desoto. Next, a 3/8" hole was drilled in the proper spot, and a nut was tack welded to the reverse side.

---John



('59 SF convertible 003.JPG)



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



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Attachments '59 SF convertible 003.JPG (386KB - 159 downloads)
Attachments '59 SF convertible 001.JPG (235KB - 179 downloads)
Attachments '59 SF convertible 002.JPG (456KB - 163 downloads)
Attachments '59 SF convertible 004.JPG (303KB - 170 downloads)
Attachments '59 SF convertible 005.JPG (257KB - 168 downloads)
Attachments '59 SF convertible 006.JPG (269KB - 155 downloads)
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big m
Posted 2013-04-11 5:23 PM (#369081 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Next, the new mount was welded in place, and the entire process was repeated for the opposite side.

---John



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



('59 SF convertible 009.JPG)



('59 SF convertible 010.JPG)



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Attachments '59 SF convertible 007.JPG (390KB - 152 downloads)
Attachments '59 SF convertible 008.JPG (417KB - 172 downloads)
Attachments '59 SF convertible 009.JPG (484KB - 163 downloads)
Attachments '59 SF convertible 010.JPG (411KB - 165 downloads)
Attachments '59 SF convertible 011.JPG (261KB - 171 downloads)
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big m
Posted 2013-04-11 5:29 PM (#369088 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Next was to repair the seam on the deck panel, when the right side was hit, it had buckled the seam, and rusted behind the lead. I melted the old lead out, repaired the metal beneath, and paddled lead into the seam to finish it. I also did a bit more lead work elsewhere on the body, it really didn't need much.

---John



('59 SF convertible 008.JPG)



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Attachments '59 SF convertible 008.JPG (319KB - 168 downloads)
Attachments '59 SF convertible 007.JPG (275KB - 167 downloads)
Attachments '59 SF convertible 005.JPG (362KB - 162 downloads)
Attachments '59 SF convertible 004.JPG (246KB - 164 downloads)
Attachments '59 SF convertible 003.JPG (286KB - 166 downloads)
Attachments '59 SF convertible 002.JPG (207KB - 174 downloads)
Attachments '59 SF convertible 001.JPG (257KB - 166 downloads)
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oldwood
Posted 2013-04-11 5:55 PM (#369101 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


Expert

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You have brought the term "Get the lead out" to a WHOLE NEW MEANING!!! Down here in the South your new name would be "Master John".
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moparsteve
Posted 2013-04-12 2:11 AM (#369172 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]


Elite Veteran

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sir - all i have to say is this - from what i saw 3 4 yrs ago this car or what was left was broken in two pieces - you are a genuine master at this trade. thank you for saving a fine example of the forward look.

steve
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ccpanel
Posted 2013-04-12 3:11 AM (#369174 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


Member

Posts: 9

Location: nor-cal
how about a photo of the car showing the whole thing?
You have done soo much in teh details it kinda hard to see a car in the pile of newly fabricated parts!
from all the pics and comments I bet you are replacing half of the original steel!
a task of huge proportions!
congrats!
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ccpanel
Posted 2013-04-12 3:11 AM (#369175 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


Member

Posts: 9

Location: nor-cal
how about a photo of the car showing the whole thing?
You have done soo much in teh details it kinda hard to see a car in the pile of newly fabricated parts!
from all the pics and comments I bet you are replacing half of the original steel!
a task of huge proportions!
congrats!
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big m
Posted 2013-04-13 11:49 AM (#369453 - in reply to #369175)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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ccpanel - 2013-04-12 12:11 AM

how about a photo of the car showing the whole thing?
You have done soo much in teh details it kinda hard to see a car in the pile of newly fabricated parts!
from all the pics and comments I bet you are replacing half of the original steel!
a task of huge proportions!
congrats!


I'll have a photo or two showing the entire body shortly. Just about done with the heavy welding and fab work.

---John
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big m
Posted 2013-04-13 11:56 AM (#369454 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I had saved the old quarter panel skins for a reason-The trim holes in the panels were for a base model Fury and not the Sport Fury. I thought the lower line of holes might be the same, but no such luck.
I measured the placement of the holes and spacing, and used a trim insert too determine their location on the quarter. Holes were then drilled with a 1/8" bit, then larger to the necessary size.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



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Attachments '59 SF convertible 001.JPG (126KB - 182 downloads)
Attachments '59 SF convertible 002.JPG (125KB - 179 downloads)
Attachments '59 SF convertible 003.JPG (125KB - 183 downloads)
Attachments '59 SF convertible 004.JPG (125KB - 189 downloads)
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big m
Posted 2013-04-13 12:00 PM (#369455 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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The driver side was then done the same way.
Afterwards, all the trim holes that were not going to be used were carefully welded up, and ground smooth both on the inside and outside.

---John



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



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Attachments '59 SF convertible 005.JPG (125KB - 189 downloads)
Attachments '59 SF convertible 006.JPG (125KB - 185 downloads)
Attachments '59 SF convertible 007.JPG (126KB - 195 downloads)
Attachments '59 SF convertible 008.JPG (126KB - 196 downloads)
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big m
Posted 2013-04-13 12:03 PM (#369456 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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The large medallions were interesting to get the placement for the holes to be drilled, as they were offset. These are specific for each side, due to the shape of the panel.

---John



('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



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Attachments '59 SF convertible 004.JPG (126KB - 183 downloads)
Attachments '59 SF convertible 005.JPG (126KB - 181 downloads)
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Resurrector
Posted 2013-04-13 7:58 PM (#369526 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


100010010025
She's coming along nicely John! That '59 body is going to look so good, especially in convertible form. I've often thought if GM had built that body, they would have hidden the gas filler behind that Fury Medallion, seeing as how they seemed to love hiding the filler in unique places
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big m
Posted 2013-04-15 8:17 PM (#369935 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Thanks, Jeff!
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big m
Posted 2013-04-16 12:57 PM (#370070 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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The convertible top cylinder mounts were eaten away badly, but these were all I had to work with.
I carefully removed what was left of them in order to determine what their mounting pieces looked like.
I blasted the loose rust off the mounts, and found they were badly pitted, and in places half their original thickness. I heated them up cherry red, and filled the low spots with brass, then removed the excess. These will work fine now.

---John



('59 SF convertible 001.JPG)



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('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 007.JPG)



Attachments
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Attachments '59 SF convertible 001.JPG (125KB - 190 downloads)
Attachments '59 SF convertible 002.JPG (125KB - 182 downloads)
Attachments '59 SF convertible 003.JPG (125KB - 190 downloads)
Attachments '59 SF convertible 004.JPG (126KB - 180 downloads)
Attachments '59 SF convertible 005.JPG (125KB - 186 downloads)
Attachments '59 SF convertible 006.JPG (125KB - 180 downloads)
Attachments '59 SF convertible 007.JPG (126KB - 174 downloads)
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big m
Posted 2013-04-16 5:01 PM (#370108 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I had enough of the remains to one of the underbody reinforcement brackets, that I was able to come up with a suitable replacement. The corner underdash brackets from a 1960 Thunderbird were identical, except for the missing captive nut, and the length. I cut the bracket down, and found a suitable threaded nut that was close to the original.
Thanks to the help from Matt Dorshug, as he supplied proper placement measurements from his own convertible, I was able to drill the three holes and line up the underbody brace.

---John



('59 SF convertible 008.JPG)



('59 SF convertible 009.JPG)



('59 SF convertible 010.JPG)



('59 SF convertible 011.JPG)



('59 SF Convertible 001.JPG)



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Attachments '59 SF convertible 008.JPG (126KB - 177 downloads)
Attachments '59 SF convertible 009.JPG (125KB - 184 downloads)
Attachments '59 SF convertible 010.JPG (133KB - 189 downloads)
Attachments '59 SF convertible 011.JPG (125KB - 183 downloads)
Attachments '59 SF Convertible 001.JPG (125KB - 183 downloads)
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big m
Posted 2013-04-18 12:37 PM (#370461 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Now that all the heavy welding is completed, time to have a blast! Sand blast, that is. One of my most dreaded messy jobs, but I refused to take the body somewhere to have it screwed up after spending all this labor on it.
I rolled the rotisserie outside the barn, and spent nearly a day and a half lightly blasting the inside and hidden areas, as well as the outside. After finishing, it took another two hours blowing sand from crevices and such.
Finally, I sprayed a good coat of etching primer throughout the body.

---John
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dukeboy
Posted 2013-04-18 12:57 PM (#370466 - in reply to #370461)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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John, Awesome work. Those '60 Thunderbird pieces are many times what I do as well. Find something close and use that. I am amzed at the amount of work involved here. Again, Keep messin' round and you'll have a driver.
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big m
Posted 2013-04-18 1:11 PM (#370469 - in reply to #370466)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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dukeboy - 2013-04-18 9:57 AM

John, Awesome work. Those '60 Thunderbird pieces are many times what I do as well. Find something close and use that. I am amzed at the amount of work involved here. Again, Keep messin' round and you'll have a driver.


Thanks, Chaney!
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big m
Posted 2013-04-18 1:12 PM (#370470 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Here are the photos I meant to attach, except the computer wigged out.

---John



('59 SF Convertible 002.JPG)



('59 SF Convertible 003.JPG)



('59 SF Convertible 004.JPG)



('59 SF Convertible 005.JPG)



('59 SF Convertible 006.JPG)



Attachments
----------------
Attachments '59 SF Convertible 002.JPG (125KB - 175 downloads)
Attachments '59 SF Convertible 003.JPG (126KB - 172 downloads)
Attachments '59 SF Convertible 004.JPG (126KB - 185 downloads)
Attachments '59 SF Convertible 005.JPG (126KB - 171 downloads)
Attachments '59 SF Convertible 006.JPG (126KB - 175 downloads)
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wizard
Posted 2013-04-18 1:20 PM (#370473 - in reply to #226386)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Some work you've done there John - like "Bring em back alive" That car sure is a Phoenix
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Windsor59
Posted 2013-04-18 1:45 PM (#370475 - in reply to #370473)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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Hi John
Found a pic at my Sport Fury I had before.
quarter panel skins holes



(P1010010.JPG)



Attachments
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Attachments P1010010.JPG (98KB - 170 downloads)
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BarnFind57
Posted 2013-04-18 4:48 PM (#370512 - in reply to #226386)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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Wow.

Just wow...


Nice work, man.

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oldwood
Posted 2013-04-18 5:03 PM (#370514 - in reply to #370512)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]


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Well hell your almost finished!!! LOL Building the mtr. and drivetrain is the easy part.
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dukeboy
Posted 2013-04-18 7:27 PM (#370539 - in reply to #370514)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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I'll say it yet again, this thread should be ear marked for Anyone that thinks their car has too much rust to save it.
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big m
Posted 2013-04-19 12:37 PM (#370661 - in reply to #370473)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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wizard - 2013-04-18 10:20 AM

Some work you've done there John - like "Bring em back alive" That car sure is a Phoenix :)


Thanks, Sven!!
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big m
Posted 2013-04-19 12:38 PM (#370663 - in reply to #370512)
Subject: RE: The ressurection of 'Rusty' [the '59 Sport Fury]



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BarnFind57 - 2013-04-18 1:48 PM

Wow.

Just wow...


Nice work, man.



Thanks, Rick!
Nice to see you out enjoying your ride, lately!!

---John
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big m
Posted 2013-04-19 12:43 PM (#370664 - in reply to #370514)
Subject: Re: The ressurection of 'Rusty' [the '59 Sport Fury]



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oldwood - 2013-04-18 2:03 PM

Well hell your almost finished!!! LOL Building the mtr. and drivetrain is the easy part.


In reality, I had most of the mechanicals ready, but that was years ago, so hopefully most has no problems. I will be restoring and adding the convertible frame parts to a coupe frame next.

---John
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wizard
Posted 2013-04-19 2:18 PM (#370686 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Now to the big question John - would you ever be able to sell that car???? All the love, blood, sweat and pain you put into her will never balance - but you might have the car that you really wanted and eager for since many years.
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big m
Posted 2013-04-19 2:48 PM (#370695 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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That's right, Wiz. I'd better keep this one, as too much time will have been invested in it. It does have some sentimental value, as a good friend [Dammit Jim] found it, and my friend Roger helped me with it. Both have passed on now.

---John
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PlymouthFury
Posted 2013-04-20 9:58 AM (#370851 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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John your work is looking great... Won't be too much longer before she's starts becoming a car again!
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big m
Posted 2013-04-20 11:32 AM (#370867 - in reply to #370851)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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PlymouthFury - 2013-04-20 6:58 AM

John your work is looking great... Won't be too much longer before she's starts becoming a car again!


Thanks, Austin!!
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MOPAR-TO-YA
Posted 2013-04-20 5:04 PM (#370891 - in reply to #226386)
Subject: RE: The Resurrection of 'Rusty' [the '59 Sport Fury]


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John, with all the patience, mental determination, and time-- you must not have any kids at home--or maybe even none. How else could a person do all the work you have done to get to this point??? My up-most respect for your skills , and hope someday I will be seeing this car on your next roadtrip adventure! ...........................MO
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wbower3
Posted 2013-04-20 5:07 PM (#370892 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


Walter passed away on Jul 29, 2014. We will miss you, Walt!

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John, what's your completion date?
I need a quarter panel made for the right side of my CRL, and I want to ship it out for you to do it.
You do too good work.
Awesome even!.

Walt
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60 Plymouth
Posted 2013-04-20 8:22 PM (#370932 - in reply to #370892)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Gives me hope John!! Looks great
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big m
Posted 2013-04-22 2:06 PM (#371226 - in reply to #370932)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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60 Plymouth - 2013-04-20 5:22 PM

Gives me hope John!! Looks great


Thanks, Aaron!


---John
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1961plymouthfury
Posted 2013-04-22 2:34 PM (#371235 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Looks good I hope 1 of these years I see you at the Cars and bikes on the square in Athens, AL . The more fowardlook cars there the merrier. I know these folks would love to have you attend.
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mopardave
Posted 2013-04-22 7:23 PM (#371301 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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That is just WONDERFUL! You are magic!
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big m
Posted 2013-04-24 4:53 PM (#371714 - in reply to #370891)
Subject: RE: The Resurrection of 'Rusty' [the '59 Sport Fury]



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MOPAR-TO-YA - 2013-04-20 2:04 PM

John, with all the patience, mental determination, and time-- you must not have any kids at home--or maybe even none. How else could a person do all the work you have done to get to this point??? My up-most respect for your skills , and hope someday I will be seeing this car on your next roadtrip adventure! ...........................MO


We do plan on making a road trip [if we can still afford fuel] as we had a blast doing this with the '58 wagon, and you and Cheryl are on our list to visit again.

---John
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big m
Posted 2013-04-24 4:55 PM (#371715 - in reply to #370892)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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wbower3 - 2013-04-20 2:07 PM

John, what's your completion date?
I need a quarter panel made for the right side of my CRL, and I want to ship it out for you to do it.
You do too good work.
Awesome even!.

Walt


Thanks, Walt!

As to a completion date, it's hard to say, as I need to finish up a body work job on a Merc I was sucked into some time ago. I thought your bodywork was mostly done on your '55, or am I mistaken?

---Joohn
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big m
Posted 2013-05-03 1:09 PM (#373282 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Now moving on to the chassis. The original convertible frame was rusted through in places, not worth trying to save, although there were some convertible specific pieces that needed to be saved.
I had another chassis from a coupe that had been blasted and painted gloss black years ago, perfect choice for this. I set the two side by side, noting any differences, and measuring any found.



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



Attachments
----------------
Attachments '59 SF convertible 001.JPG (126KB - 180 downloads)
Attachments '59 SF convertible 002.JPG (126KB - 180 downloads)
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big m
Posted 2013-05-03 1:11 PM (#373283 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I used a die grinder to remove the special convertible body mounts on each side, and sandblasted them clean. The donor frame was measured and marked for placement of these mount ears after cleaning the black paint off. Then, they were welded on.

Convertibles also used their own specific torsion bars, longer to clear the X-frame, so I went ahead and snipped the torsion bar mounts from the frame.




('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 008.JPG)



('59 SF convertible 009.JPG)



Attachments
----------------
Attachments '59 SF convertible 003.JPG (125KB - 187 downloads)
Attachments '59 SF convertible 004.JPG (126KB - 136 downloads)
Attachments '59 SF convertible 005.JPG (126KB - 179 downloads)
Attachments '59 SF convertible 006.JPG (125KB - 189 downloads)
Attachments '59 SF convertible 008.JPG (125KB - 190 downloads)
Attachments '59 SF convertible 009.JPG (126KB - 172 downloads)
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big m
Posted 2013-05-03 1:18 PM (#373287 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I used a cutting torch to remove the X from the rusty frame, as well as the torsion bar mounts, as they nestle in the end of the X. I measured the torsion bar mounts I had cut out against the cleaner ones from the coupe frame, and found they were the same, so I welded these in place at the proper spots.
Then I completely sandblasted the X member to remove the rust from the deep pits. One end of the X on the top side was badly pitted, so I decided to fill these with brass to make it look a bit better. I also removed the remainder of the attaching pieces for the top, these were too far gone to reuse.

---John




('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



('59 SF convertible 011.JPG)



Attachments
----------------
Attachments '59 SF convertible 002.JPG (126KB - 177 downloads)
Attachments '59 SF convertible 003.JPG (126KB - 191 downloads)
Attachments '59 SF convertible 004.JPG (125KB - 177 downloads)
Attachments '59 SF convertible 005.JPG (125KB - 182 downloads)
Attachments '59 SF convertible 007.JPG (125KB - 171 downloads)
Attachments '59 SF convertible 008.JPG (125KB - 177 downloads)
Attachments '59 SF convertible 011.JPG (125KB - 175 downloads)
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Doctor DeSoto
Posted 2013-05-03 11:48 PM (#373390 - in reply to #373287)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I did all this work on my Adventurer years ago. Few realize both the depth one can "drown" in
a project like this, AND the satisfaction of mastering it to a point where nothing "scares" you any more !

John, ... you ARE aware than when all this work is done, it's going to be a 59 Plymouth, right ?
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big m
Posted 2013-05-04 12:02 PM (#373434 - in reply to #373390)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Doctor DeSoto - 2013-05-03 8:48 PM

I did all this work on my Adventurer years ago. Few realize both the depth one can "drown" in
a project like this, AND the satisfaction of mastering it to a point where nothing "scares" you any more !

John, ... you ARE aware than when all this work is done, it's going to be a 59 Plymouth, right ?


There's not too many projects that I wouldn't consider as long as they are mostly complete. After this one, the '59 Desoto convertible will be easy, as it has little rust, and the '58 Fury which is also solid. The wrecked 300 D fuelie will be a bit more involved, but nothing like this. Hopefully I live long enough to complete a few of them LOL!

---John

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Lisa P
Posted 2013-05-05 8:19 PM (#373657 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Wow John, it looks awesome! Thanks again for all the photos and explanations of your restoration processes. I hope to use some of your techniques if I ever rescue another one!
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big m
Posted 2013-05-06 1:16 PM (#373777 - in reply to #373657)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Lisa P - 2013-05-05 5:19 PM

Wow John, it looks awesome! Thanks again for all the photos and explanations of your restoration processes. I hope to use some of your techniques if I ever rescue another one!


Thanks, Lisa!!
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ronbo97
Posted 2013-05-06 9:58 PM (#373836 - in reply to #373777)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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John -

An alternative idea to filling in the x-member pitting with brass is to crank up the settings on the MIG welder and puddle some weld bead in the rusted out areas, moving the nozzle in a circular motion. Then grind to smooth out. This would restore strength to the rusted out areas, where brass is a softer metal, not yielding as much strength.

Ron

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big m
Posted 2013-05-07 8:26 PM (#374042 - in reply to #373836)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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ronbo97 - 2013-05-06 6:58 PM

John -

An alternative idea to filling in the x-member pitting with brass is to crank up the settings on the MIG welder and puddle some weld bead in the rusted out areas, moving the nozzle in a circular motion. Then grind to smooth out. This would restore strength to the rusted out areas, where brass is a softer metal, not yielding as much strength.

Ron



I considered using that method, but I was waiting on a replacement liner for the welder, as it was not feeding correctly. The metal was not compromised enough to be any concern in using the brass, and I was able to keep moving along.

---John
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60 dart
Posted 2013-05-08 12:10 AM (#374073 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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i used that brass method quite a few times , works like a charm . i figured you were good Big John but you're way past good ------------------------------------------------------------later
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Doctor DeSoto
Posted 2013-05-08 2:53 AM (#374097 - in reply to #374073)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Watch out, John ! Sounds like Chuck is fixin' to give you a kiss here pretty quick !
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60 dart
Posted 2013-05-08 12:49 PM (#374163 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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and a hug----------------------------------------------------------later
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Fins/413
Posted 2013-05-08 1:16 PM (#374171 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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John I find this thread inspirational thanks for sharing.
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big m
Posted 2013-05-13 4:14 PM (#375022 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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The X is then primered to prevent flash rusting.
Mating the convertible X to the frame-These are installed from the bottom of the frame at the factory, as the ends of the bars overlap the frame rails. After setting this in place, I mounted a lower A-arm to each side, and test fit each torsion bar. Looks good, so each weld was completed.




('59 SF convertible 001.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



Attachments
----------------
Attachments '59 SF convertible 001.JPG (125KB - 173 downloads)
Attachments '59 SF convertible 003.JPG (126KB - 179 downloads)
Attachments '59 SF convertible 004.JPG (125KB - 207 downloads)
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big m
Posted 2013-05-13 4:16 PM (#375023 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I had a couple friends help flip the frame over, as now it's getting heavy! It has been in the 90's here for daily high temps, and welding in the heat is not the most fun you can have, but I wanted to press on.
As I stated earlier, the bottom of the X overlaps the frame, and the top has gaps on each corner for installation at the factory. Apparently, the factory just used nondescript pieces of scrap to join the X to the frame, there was no real common size or shape. I cut four eliptical pieces from a piece of steel the same thickness, and used them to join the frame to the X support. After tacking all four corners in place and making sure the fit was good, the pieces were welded completely. Voila! A convertible frame!

---John



('59 SF convertible 002.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 009.JPG)



Attachments
----------------
Attachments '59 SF convertible 002.JPG (125KB - 195 downloads)
Attachments '59 SF convertible 004.JPG (124KB - 180 downloads)
Attachments '59 SF convertible 007.JPG (126KB - 134 downloads)
Attachments '59 SF convertible 009.JPG (125KB - 135 downloads)
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big m
Posted 2013-05-13 4:20 PM (#375024 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Big Al's son, Damian, wanted to earn a few bucks, so I put him to work scuffing and preparing the frame for paint, then I suspended it for painting, semi-gloss black.

---John



('59 SF convertible 011.JPG)



('59 SF convertible 012.JPG)



('59 SF convertible 013.JPG)



Attachments
----------------
Attachments '59 SF convertible 011.JPG (126KB - 187 downloads)
Attachments '59 SF convertible 012.JPG (125KB - 181 downloads)
Attachments '59 SF convertible 013.JPG (126KB - 179 downloads)
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MOPAR-TO-YA
Posted 2013-05-14 1:46 AM (#375121 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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John, by any chance, have you kept track of how many spools of welding wire you have used on this project?.........................MO
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hemidenis
Posted 2013-05-14 8:09 AM (#375144 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Amazing job John, great craftsmanship I love to see this car getting back to life.
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oldwood
Posted 2013-05-14 1:06 PM (#375177 - in reply to #375144)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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I'm glad to see you hired a younger "Foward Looker" as we all are here for just a short time and this trade needs to be passed on. Here is an old saying: Doctor, I think we have a pulse. Good work Big John!!!
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big m
Posted 2013-05-14 1:56 PM (#375183 - in reply to #375121)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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MOPAR-TO-YA - 2013-05-13 10:46 PM

John, by any chance, have you kept track of how many spools of welding wire you have used on this project?.........................MO

After working on this for so long, as well as other welding projects inbetween, I have no idea how much wire I have used. It would have been interesting to know, though.

---John
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big m
Posted 2013-05-14 1:57 PM (#375184 - in reply to #375144)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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hemidenis - 2013-05-14 5:09 AM

Amazing job John, great craftsmanship I love to see this car getting back to life.


Thanks, Denis, I'm watching your projects come to life as well!!
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big m
Posted 2013-05-14 2:08 PM (#375189 - in reply to #375177)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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oldwood - 2013-05-14 10:06 AM

I'm glad to see you hired a younger "Foward Looker" as we all are here for just a short time and this trade needs to be passed on. Here is an old saying: Doctor, I think we have a pulse. Good work Big John!!!


I try to get some of the younger generation to enjoy these cars, whether it be going to car shows, poker runs, etc. I totally support the younger folks entering the hobby, it would be nice to see more, rather than the gaming generation that we see quite often.

---John
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big m
Posted 2013-05-17 1:00 PM (#375702 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Starting the reassembly of the chassis-
I saved the original hardware and had it zinc plated, and I replaced all the ball joints, bushings, etc, and painted the components.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 005.JPG)



Attachments
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Attachments '59 SF convertible 001.JPG (126KB - 166 downloads)
Attachments '59 SF convertible 002.JPG (126KB - 169 downloads)
Attachments '59 SF convertible 003.JPG (127KB - 156 downloads)
Attachments '59 SF convertible 004.JPG (127KB - 152 downloads)
Attachments '59 SF convertible 005.JPG (125KB - 162 downloads)
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ronbo97
Posted 2013-05-17 6:38 PM (#375760 - in reply to #375702)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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Are those 12" brakes on the front ? Unless I'm mistaken, 57-9 Plymouths had lug bolts that went thru the wheel and screwed into the drums.

Ron

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big m
Posted 2013-05-17 8:23 PM (#375773 - in reply to #375760)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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ronbo97 - 2013-05-17 3:38 PM

Are those 12" brakes on the front ? Unless I'm mistaken, 57-9 Plymouths had lug bolts that went thru the wheel and screwed into the drums.

Ron



I'll have to call you eagle eyes, Ron!

The front and rear brakes were updated years ago, and fitted with later drum brakes. The car that had these drove and stopped well, so I figured I would stick with them, as long as they function well.

---John

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phurious
Posted 2013-05-20 12:20 PM (#376150 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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WOW!!!
John, I am always amazed with your work!
They say that "slow and steady wins the race", seems about right to me!
Hopefully she'll be done next year when I am able to come visit.
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big m
Posted 2013-05-21 12:35 PM (#376320 - in reply to #376150)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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phurious - 2013-05-20 9:20 AM

WOW!!!
John, I am always amazed with your work!
They say that "slow and steady wins the race", seems about right to me!
Hopefully she'll be done next year when I am able to come visit.


Thanks, Ron!!!
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carmikael
Posted 2013-05-21 5:14 PM (#376368 - in reply to #376320)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Awsome work John!

//Mikael

Edited by carmikael 2013-05-21 5:15 PM
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1961plymouthfury
Posted 2013-05-22 3:19 AM (#376443 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Its getting there . How much more you need to do ?
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big m
Posted 2013-05-22 1:29 PM (#376525 - in reply to #376443)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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1961plymouthfury - 2013-05-22 12:19 AM

Its getting there . How much more you need to do ?


I still have a ways to go. I hope to have the chassis mostly completed this week, but then have body work to do on a customer's car. Once I get back to it, I will have to mount the body on the chassis, and begin block sanding. The top frame assembly will be a major job, as most of it is rusted junk.

---John
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1961plymouthfury
Posted 2013-05-23 3:38 AM (#376653 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I read were the car sold when it was brand new. I told my father and he said the car 1st sold at Erie J Miller Chrysler Plymouth in Ithaca,NY. I know you have more to do and good luck with it.
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big m
Posted 2013-05-24 1:02 PM (#376913 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Next was the rear axle. One of the threaded ends was buggered up, so I decided to replace it rather than risk problems with it. I removed the inner and outer seals, removed the chunk, and cleaned out the axle housing. I painted it gloss black, and installed the new seals. The third member was in good shape, and the backlash was within tolerance, so after painting it, I bolted it back to the housing. After reinstalling the axles, I positioned it beneath the frame.
I then hung the leaf springs, and mounted the third member. Each night, I have to cover the chassis up, as the bat guano can make quite a mess.



('59 SF convertible 006.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



('59 SF convertible 009.JPG)



('59 SF convertible 010.JPG)



('59 SF convertible 011.JPG)



Attachments
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Attachments '59 SF convertible 006.JPG (126KB - 199 downloads)
Attachments '59 SF convertible 007.JPG (126KB - 160 downloads)
Attachments '59 SF convertible 008.JPG (126KB - 156 downloads)
Attachments '59 SF convertible 009.JPG (126KB - 156 downloads)
Attachments '59 SF convertible 010.JPG (126KB - 156 downloads)
Attachments '59 SF convertible 011.JPG (125KB - 154 downloads)
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big m
Posted 2013-05-24 1:05 PM (#376914 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I ran all the brake and fuel lines, and assembled the rear backing plates and drums, then a set of wheels [temporary, of course].




('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



Attachments
----------------
Attachments '59 SF convertible 001.JPG (127KB - 148 downloads)
Attachments '59 SF convertible 002.JPG (127KB - 155 downloads)
Attachments '59 SF convertible 003.JPG (125KB - 155 downloads)
Attachments '59 SF convertible 004.JPG (126KB - 152 downloads)
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big m
Posted 2013-05-28 1:38 PM (#377536 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I got the engine and trans painted and mated together, and installed it in the chassis. Then on to painting and installing small components.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



Attachments
----------------
Attachments '59 SF convertible 001.JPG (125KB - 153 downloads)
Attachments '59 SF convertible 002.JPG (126KB - 154 downloads)
Attachments '59 SF convertible 003.JPG (126KB - 156 downloads)
Attachments '59 SF convertible 004.JPG (126KB - 150 downloads)
Attachments '59 SF convertible 006.JPG (126KB - 152 downloads)
Attachments '59 SF convertible 007.JPG (126KB - 176 downloads)
Attachments '59 SF convertible 008.JPG (126KB - 167 downloads)
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ronbo97
Posted 2013-05-28 8:14 PM (#377609 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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Are you planning to paint the body and then lower it onto the frame ? I was kinda leery of that due to concern about paint scratches. What I ended up doing (with my Plymouth) was bolting the body to the frame, then installing the drive train after paint, but before the installation of the front clip. Going the same route with the convertible.

Ron
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d500neil
Posted 2013-05-28 9:08 PM (#377618 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



Exner Expert 19,174 posts. Neil passed away 18 Sep 2015. You will be missed, Neil!

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That chassis detail is PRIMO!


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VAN HELSING
Posted 2013-05-28 11:10 PM (#377637 - in reply to #377618)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



Elite Veteran

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.....


.....


John, these build photos are Gold !!. Keep 'em coming .

Very helpful for me when I get to my body-off-frame stage on my '59 Dodge, gives me great inspiration and ideas.

Time consuming though it is, everyone benefits from your time taken to upload photos so thanks for the pics .

Brilliant !!!

.......
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Fins/413
Posted 2013-05-29 5:57 AM (#377676 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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Covering it at night is a good idea bat poop is very strong. Beautiful
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Doctor DeSoto
Posted 2013-05-29 8:29 AM (#377702 - in reply to #375183)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Is bat poop a PPG product ? Where do you get it ?
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ttotired
Posted 2013-05-29 8:38 AM (#377705 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I believe it is readilly available in Transilvania

They have big bats there that really suck

So the story goes anyway

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big m
Posted 2013-05-29 12:32 PM (#377743 - in reply to #377609)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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ronbo97 - 2013-05-28 5:14 PM

Are you planning to paint the body and then lower it onto the frame ? I was kinda leery of that due to concern about paint scratches. What I ended up doing (with my Plymouth) was bolting the body to the frame, then installing the drive train after paint, but before the installation of the front clip. Going the same route with the convertible.

Ron


Ron,
my plan is to paint the underside of the body while on the rotisserie, then have some big boys help me set it onto the chassis. Finish body work and paint on the exterior will be later, after I fit all the body panels.

---John
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big m
Posted 2013-05-29 12:33 PM (#377744 - in reply to #377618)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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d500neil - 2013-05-28 6:08 PM

That chassis detail is PRIMO!


Thanks, Neil, and I appreciate the info you had given me, it helped a lot!!

---John
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big m
Posted 2013-05-29 12:34 PM (#377746 - in reply to #377637)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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VAN HELSING - 2013-05-28 8:10 PM

.....


.....


John, these build photos are Gold !!. Keep 'em coming .

Very helpful for me when I get to my body-off-frame stage on my '59 Dodge, gives me great inspiration and ideas.

Time consuming though it is, everyone benefits from your time taken to upload photos so thanks for the pics .

Brilliant !!!

.......

Thanks for the good words!!

---John
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VAN HELSING
Posted 2013-05-29 8:09 PM (#377830 - in reply to #377705)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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ttotired - 2013-05-29 11:38 PM

I believe it is readilly available in Transilvania

They have big bats there that really suck

So the story goes anyway




........

...


Nup, Van Helsing got rid of the Transylvanian bats way back in 1888......... so the movie goes anyway !!! BOOM BOOM


.......


..
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big m
Posted 2013-05-30 1:07 PM (#377980 - in reply to #377702)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Doctor DeSoto - 2013-05-29 5:29 AM

Is bat poop a PPG product ? Where do you get it ?


It's 'Guano spot putty' tested on '87 Daihatsus.

---John
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60 dart
Posted 2013-05-30 5:54 PM (#378039 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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uh oh big john , does the wifey know you're usin her fitted sheets as car covers ----------------------------------------------------------later
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big m
Posted 2013-05-30 8:23 PM (#378078 - in reply to #378039)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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60 dart - 2013-05-30 2:54 PM

uh oh big john , does the wifey know you're usin her fitted sheets as car covers ----------------------------------------------------------later


LMAO, Chuck! I'd probably be in the doghouse if that was the case! A fellow I bought some cars from gave me a few sacks of household goods, and these were included.

---John
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big m
Posted 2013-07-14 1:27 PM (#385776 - in reply to #378078)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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While finishing up the bodywork on another car, I spent a few days gathering hardware from other cars in the yard. These I will have zinc plated, nearly 400 pieces.

I cleaned the entire bunch in acid to remove any rust, then neutralized them with a baking soda solution. Any with undercoat or paint I had to wire wheel, as the plating would not work properly with foreign matter. Afterwards, I washed the entire lot in lacquer thinner to remove any oil or undercoat residue.
One container will be yellow zinc [gold] and the other will be clear[silver]

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



Attachments
----------------
Attachments '59 SF convertible 001.JPG (125KB - 154 downloads)
Attachments '59 SF convertible 002.JPG (126KB - 151 downloads)
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big m
Posted 2013-07-29 1:08 PM (#388247 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Got the body mount parts and hardware back from A&A plating, everything came out nice!

---John



('59 SF hardware 001.JPG)



('59 SF hardware 002.JPG)



Attachments
----------------
Attachments '59 SF hardware 001.JPG (125KB - 156 downloads)
Attachments '59 SF hardware 002.JPG (125KB - 151 downloads)
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ronbo97
Posted 2013-07-29 2:29 PM (#388256 - in reply to #388247)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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John -

So what's your secret to remembering where each bolt, nut, screw and fastener goes on the car ?

Ron

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catman
Posted 2013-07-29 4:48 PM (#388269 - in reply to #226386)
Subject: RE: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Experience?

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big m
Posted 2013-07-29 4:54 PM (#388271 - in reply to #388256)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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ronbo97 - 2013-07-29 11:29 AM

John -

So what's your secret to remembering where each bolt, nut, screw and fastener goes on the car ?

Ron



Ron,
Even though I have taken an awful lot of these cars apart, often, I will have to go out back and check another car to see where something goes. I'd be a liar if I told you I knew where every one went to.

---John
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ttotired
Posted 2013-07-29 7:48 PM (#388296 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Pictures, lots and lots of pictures is how I do it and I still get stumped on some things

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ccpanel
Posted 2013-07-29 11:41 PM (#388349 - in reply to #388247)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


Member

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big m - 2013-07-29 10:08 AM

Got the body mount parts and hardware back from A&A plating, everything came out nice!

---John


where are they and are they reasonable cost?
I am in Chico and am looking at getting a bumper plated or chromed-not sure but I think plated would be very cool.
(its a 1950 2 ton chevy truck front bumper) and yes-i do have mopar too... pair of 55 imperials and a 55 savoy and a 48 chry royal and sold our 49 ply bus coupe few years ago... got rid of our set of 36 plymouths too(kinda regret that one)
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MOPAR-TO-YA
Posted 2013-07-30 1:57 AM (#388363 - in reply to #388271)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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big m - 2013-07-29 3:54 PM

ronbo97 - 2013-07-29 11:29 AM

John -

So what's your secret to remembering where each bolt, nut, screw and fastener goes on the car ?

Ron



Ron,
Even though I have taken an awful lot of these cars apart, often, I will have to go out back and check another car to see where something goes. I'd be a liar if I told you I knew where every one went to.

---John
This past weekend a friend came and was looking at my current project. He said' "you have taken every nut and bolt off this car and are putting them all back on" . I never thought about it before but that kinda puts things in perspective. That is a LOT of skinned knuckles and blood letting!.........................MO
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Doctor DeSoto
Posted 2013-07-30 1:35 PM (#388425 - in reply to #388363)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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You told him it is part of your religious expression, right ?
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big m
Posted 2013-07-31 12:15 PM (#388623 - in reply to #388349)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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ccpanel - 2013-07-29 8:41 PM

big m - 2013-07-29 10:08 AM

Got the body mount parts and hardware back from A&A plating, everything came out nice!

---John


where are they and are they reasonable cost?
I am in Chico and am looking at getting a bumper plated or chromed-not sure but I think plated would be very cool.
(its a 1950 2 ton chevy truck front bumper) and yes-i do have mopar too... pair of 55 imperials and a 55 savoy and a 48 chry royal and sold our 49 ply bus coupe few years ago... got rid of our set of 36 plymouths too(kinda regret that one)


A&A is located in Sacramento, look up Alta plating on the web. They could probably give you an estimate over the phone.

Stop by next time you are in the area!

---John
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big m
Posted 2013-09-24 7:16 PM (#399527 - in reply to #388623)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I finally completed the Turnpike Cruiser job for a customer, now my spare time goes back to this.

I installed the exhaust system this last weekend, it was a chore to get everything placed without touching the torsion bars or the X-frame. Last item on the chassis for now will be fitting the trans cooling lines. Easy to route them without the body being in the way.


---John



('59 SF Convertible 001.JPG)



('59 SF Convertible 002.JPG)



Attachments
----------------
Attachments '59 SF Convertible 001.JPG (125KB - 136 downloads)
Attachments '59 SF Convertible 002.JPG (126KB - 134 downloads)
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wizard
Posted 2013-09-25 2:00 AM (#399590 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Nice work John - I see some really tight, narrow passages there
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hemidenis
Posted 2013-09-25 3:17 PM (#399683 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



Expert

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Amazing John!! and is very interesting how you keep all the cast iron parts of cast iron color, I never thought of that, mine was so rusted that I never could figure if they were factory painted or not, you may can tell us better.
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big m
Posted 2013-09-26 5:06 PM (#399864 - in reply to #399590)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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wizard - 2013-09-24 11:00 PM

Nice work John - I see some really tight, narrow passages there


Thanks, Sven!
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big m
Posted 2013-09-26 5:08 PM (#399865 - in reply to #399683)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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hemidenis - 2013-09-25 12:17 PM

Amazing John!! and is very interesting how you keep all the cast iron parts of cast iron color, I never thought of that, mine was so rusted that I never could figure if they were factory painted or not, you may can tell us better.


I used a POR 15 product called Metal Mask on those parts. Neil Vedder was a big help here as he had lots of factory brochures, assembly line pics, and those of his personal car. I was also able to check some of the lower mileage parts cars in the yard here to verify what was and was not painted.

---John
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hemidenis
Posted 2013-09-26 5:41 PM (#399870 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I have a feeling that the whole frame wasn't paint on my Imperial, I could find NO trace of paint in it, or the rear axle assy, except in those areas near to the engine, which would be visible with the hood opened.
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big m
Posted 2013-10-18 1:00 PM (#404529 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I wanted to replace the rear filler panel, as it had been bent when the bumper was pushed in, also, both ends were twisted. I figured it would take a good eight hours to get the metal satisfactorily straight. I had another option, which was to remove it and replace it with the NOS one I had found at a local swap meet for $40. I had to set the rear of the body down from the rotisserie, as it was in the way of accessing the back of it. By Using this piece rather than repairing the original, I was able to save about six hours of work.



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



Attachments
----------------
Attachments '59 SF convertible 002.JPG (126KB - 143 downloads)
Attachments '59 SF convertible 003.JPG (123KB - 133 downloads)
Attachments '59 SF convertible 004.JPG (126KB - 135 downloads)
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big m
Posted 2013-10-18 1:05 PM (#404531 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I had to use a carbide burr to remove the spot welds, as the angle would not allow drilling. After removing the bent panel, I cleaned and smoothed the body surface. Then I drilled holes in the panel for rosette welding later. Note the factory alignment [locator] holes in the panel, made for easy installation.



('59 SF convertible 005.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 009.JPG)



Attachments
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Attachments '59 SF convertible 005.JPG (128KB - 137 downloads)
Attachments '59 SF convertible 007.JPG (126KB - 165 downloads)
Attachments '59 SF convertible 009.JPG (126KB - 136 downloads)
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big m
Posted 2013-10-18 1:09 PM (#404534 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Panel is then clamped in place, and welded on. This entire process was completed in less than 2 hours.

---John



('59 SF convertible 010.JPG)



('59 SF convertible 011.JPG)



Attachments
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Attachments '59 SF convertible 010.JPG (126KB - 141 downloads)
Attachments '59 SF convertible 011.JPG (126KB - 136 downloads)
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plymouth
Posted 2013-10-18 1:10 PM (#404535 - in reply to #404531)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Excellent progress!!
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big m
Posted 2013-10-20 12:11 PM (#404924 - in reply to #404535)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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plymouth - 2013-10-18 10:10 AM

Excellent progress!!


Thanks, Christian!

---John
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FIN ME
Posted 2013-10-20 4:57 PM (#404946 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Wow, John, you are one hard working and patient dude!

You make it look easy...but I know it's NOT!



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big m
Posted 2013-10-21 1:56 PM (#405113 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Thanks, Rosy!!

Luckily, the weather held out for painting, I was concerned that it would either get windy, or cold, but was still with 80 degrees for the high. I reapplied seam sealer to all the necessary areas on the lower body, I didn't want to paint the bottom and then have seam sealer ooze out somewhere afterwards. Next was to paint the underside, in preparation of mounting the body back on its chassis for panel fitment. Came out pretty decent, after using a half gallon of single stage enamel.

---John



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 008.JPG)



Attachments
----------------
Attachments '59 SF convertible 002.JPG (126KB - 163 downloads)
Attachments '59 SF convertible 003.JPG (124KB - 181 downloads)
Attachments '59 SF convertible 004.JPG (125KB - 179 downloads)
Attachments '59 SF convertible 006.JPG (126KB - 156 downloads)
Attachments '59 SF convertible 008.JPG (124KB - 236 downloads)
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wizard
Posted 2013-10-21 2:01 PM (#405114 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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It's such a joy to see your progress after such a difficult project John - I read these posts with greatest interest.
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ttotired
Posted 2013-10-21 7:06 PM (#405161 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Its good to finally put paint on instead of taking it off

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FIN ME
Posted 2013-10-22 11:36 AM (#405262 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Oh, now that is pretty!

Great progress!


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bbrasse1
Posted 2013-10-22 4:05 PM (#405320 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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Looks great John! A lot of work there.
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oldwood
Posted 2013-10-22 4:22 PM (#405322 - in reply to #405320)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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Looking Gooooooood!!! Now what color is the car going to be? Please don't say R and W.
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ronbo97
Posted 2013-10-22 4:37 PM (#405324 - in reply to #405322)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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My vote would be Bittersweet (code ZZ). John's keeping that detail a secret, I guess.

Ron

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d500neil
Posted 2013-10-22 6:34 PM (#405346 - in reply to #226386)
Subject: RE: The Resurrection of 'Rusty' [the '59 Sport Fury]



Exner Expert 19,174 posts. Neil passed away 18 Sep 2015. You will be missed, Neil!

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I suppose, if you start with THIS, you could paint it any dayumm color(s) you want,
but, Rusty WAS a white car (right???) and he/she deserves to be "restored".

What color (codes) were its interior and top?







(RUSTY.jpg)



Attachments
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Attachments RUSTY.jpg (48KB - 182 downloads)
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big m
Posted 2013-10-22 7:16 PM (#405353 - in reply to #405114)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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wizard - 2013-10-21 11:01 AM

It's such a joy to see your progress after such a difficult project John - I read these posts with greatest interest.


Thanks, Sven!!
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big m
Posted 2013-10-22 7:20 PM (#405354 - in reply to #405346)
Subject: RE: The Resurrection of 'Rusty' [the '59 Sport Fury]



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d500neil - 2013-10-22 3:34 PM



I suppose, if you start with THIS, you could paint it any dayumm color(s) you want,
but, Rusty WAS a white car (right???) and he/she deserves to be "restored".

What color (codes) were its interior and top?




The original color was solid Tuxedo black, and the interior was red, with a white top. I will be going back to the same color and interior combos. The white on the car had been added sometime before 1965, when the car was crashed, and junked in the upstate New York yard where it languished all these years.

---John
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oldwood
Posted 2013-10-22 9:15 PM (#405372 - in reply to #405354)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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You know what they say,especially in CA, once ya go BLACK ya never go BACK. LOL All kidding aside, Black cars must be RAZOR straight and I'm sure this one will be. You know with black its easier to see the red. Thats the seats don't cha know. Get you mind out of the gutter.
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ToMopar
Posted 2013-10-23 3:07 AM (#405436 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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doesn't matter for me what color. I've respect of such a big project.
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big m
Posted 2013-10-24 8:02 PM (#405823 - in reply to #405372)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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oldwood - 2013-10-22 6:15 PM

You know what they say,especially in CA, once ya go BLACK ya never go BACK. LOL All kidding aside, Black cars must be RAZOR straight and I'm sure this one will be. You know with black its easier to see the red. Thats the seats don't cha know. Get you mind out of the gutter.


Dorsey, You're crazy, but I like it!! LOL!

Someday we'll get to meet up.

---John
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big m
Posted 2013-10-24 8:02 PM (#405824 - in reply to #405436)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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ToMopar - 2013-10-23 12:07 AM

doesn't matter for me what color. I've respect of such a big project.


Thanks, ToM!!
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big m
Posted 2013-10-29 12:16 PM (#406984 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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After sorting body mount hardware, I placed the pieces in the necessary spots. I had to look at some cars in the yard, as it was not fresh in my mind. I was hoping to have some friends over to assist with lifting the body onto the frame, but one had a sore back, and another did not show. After a bit of thought, I hooked up an engine hoist to the front, and used the back half of the rotisserie to support the rear. By then, Austin had gotten back from Yuba City, and we easily rolled the body over the chassis, and set it in place.

Afterwards, I threaded all the body mount bolts, and tightened them up. Finally, I removed the braces from the doors and quarters.

---John



('59 SF convertible 001.JPG)



('59 SF convertible 002.JPG)



('59 SF convertible 003.JPG)



('59 SF convertible 004.JPG)



('59 SF convertible 006.JPG)



('59 SF convertible 007.JPG)



('59 SF convertible 008.JPG)



('59 SF convertible 009.JPG)



Attachments
----------------
Attachments '59 SF convertible 001.JPG (126KB - 172 downloads)
Attachments '59 SF convertible 002.JPG (126KB - 153 downloads)
Attachments '59 SF convertible 003.JPG (126KB - 176 downloads)
Attachments '59 SF convertible 004.JPG (126KB - 152 downloads)
Attachments '59 SF convertible 006.JPG (127KB - 153 downloads)
Attachments '59 SF convertible 007.JPG (125KB - 177 downloads)
Attachments '59 SF convertible 008.JPG (126KB - 171 downloads)
Attachments '59 SF convertible 009.JPG (126KB - 173 downloads)
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Kenny J.
Posted 2013-10-29 12:45 PM (#406994 - in reply to #406984)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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It's coming along nicely, John.

But as you know, a car is original only once. So by restoring it, you are still ruining it...LOL!!!!!

Seriously, your accomplishment is amazing. And no, you can't have your 440 back for this one.

Tracie still talks about taking a family trip to Sacramento, so hopefully we'll be able to get together with you and M'Lisa then.

K.
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oldwood
Posted 2013-10-29 1:16 PM (#407002 - in reply to #406994)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


Expert

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I can just see you now driving down the CA coastline with dark sunglasses, cuban stogie,living the dream. I know what you mean when a helping hand is no where around. Close but NO cigar yet. Get back to work.
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big m
Posted 2013-10-29 2:44 PM (#407025 - in reply to #406994)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Kenny J. - 2013-10-29 9:45 AM

It's coming along nicely, John.

But as you know, a car is original only once. So by restoring it, you are still ruining it...LOL!!!!!

Seriously, your accomplishment is amazing. And no, you can't have your 440 back for this one.

Tracie still talks about taking a family trip to Sacramento, so hopefully we'll be able to get together with you and M'Lisa then.

K.


When you guys can make it, you know we'd love to see you!!

---John
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big m
Posted 2013-10-29 2:45 PM (#407026 - in reply to #407002)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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oldwood - 2013-10-29 10:16 AM

I can just see you now driving down the CA coastline with dark sunglasses, cuban stogie,living the dream. I know what you mean when a helping hand is no where around. Close but NO cigar yet. Get back to work.


Thanks, Dorsey, it's actually starting to resemble an automobile finally.

---John
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ronbo97
Posted 2013-10-29 4:17 PM (#407041 - in reply to #407026)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]


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John -

You 'wrote the book' on how to do this correctly. You should publish this thread in book form so future restorers can learn from you.

One minor thing: I noticed you were using some rubber body mounts. Unless I'm mistaken, I don't think any rubber mounts were used on the convert. There may have been a thread on this a while ago, but I can't be sure.

Ron

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Windsor59
Posted 2013-10-29 4:36 PM (#407042 - in reply to #407041)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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SUPER NICE WORK
Look like a car first time at many year
Thanks you show us how you built upp your Sport Fury
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56royaldodge
Posted 2013-10-29 4:39 PM (#407043 - in reply to #226386)
Subject: RE: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Looking good ... And Austin likes his Mickey's!!
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big m
Posted 2013-10-29 5:12 PM (#407046 - in reply to #407041)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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ronbo97 - 2013-10-29 1:17 PM

John -

You 'wrote the book' on how to do this correctly. You should publish this thread in book form so future restorers can learn from you.

One minor thing: I noticed you were using some rubber body mounts. Unless I'm mistaken, I don't think any rubber mounts were used on the convert. There may have been a thread on this a while ago, but I can't be sure.

Ron



Thanks Ron, and I'll have to check into the rubber mount pads. I did look under the '59 Firesweep convertible and it had them, but that car had been monkeyed with too.

---John
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Windsor59
Posted 2013-10-29 5:27 PM (#407052 - in reply to #407046)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I think Ron have right no rubber between the body and frame I just looking at my Windsor no rubber just metal copper

Edited by Windsor59 2013-10-29 5:28 PM
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christine-lover
Posted 2013-10-29 5:44 PM (#407057 - in reply to #407052)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Yes. They use 10 metal cups total. But trunk floor ones just in front of rear most may use something else. Haven't got to that. They look like it in my Plymouth.

Nice work John. I can't wait till I get to that stage. Now has solid body like all FL verts should have!
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d500neil
Posted 2013-10-29 6:23 PM (#407063 - in reply to #407057)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



Exner Expert 19,174 posts. Neil passed away 18 Sep 2015. You will be missed, Neil!

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I've got correspondence from Dodge to Carl Kiefaeker, in Re: his specially-ordered D501 hard top which was built onto
a convertible frame.

That letter states that that car had : "Solid Convertible Body Spacers" on it.

Dunno what the 'solid' spacers are/were, but they were not "rubber" ones, apparently.



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PlymouthFury
Posted 2013-10-30 1:33 AM (#407154 - in reply to #407043)
Subject: RE: The Resurrection of 'Rusty' [the '59 Sport Fury]



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56royaldodge - 2013-10-29 4:39 PM

Looking good ... And Austin likes his Mickey's!! :laugh:


Just gotta be careful not to get stung!!!
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big m
Posted 2013-10-30 8:03 PM (#407331 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I checked beneath an untouched '58 convertible, and yes, indeed, all the mounts are solid. I've found that some FL cars used the same steel 'cups' at the very front mounts, so I'll have to see if I can gather enough of them.

Thanks for everyone's input on this also.

---John
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1961plymouthfury
Posted 2013-11-01 2:47 AM (#407743 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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Its getting there.
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big m
Posted 2013-11-14 1:27 PM (#410675 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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It took about four hours of pulling body mounts, but I have finally gotten enough of the mount cups to replace the rubber mounts. after a thorough de-rusting, they are ready for installation.



('59 SF convertible 001.JPG)



Attachments
----------------
Attachments '59 SF convertible 001.JPG (126KB - 159 downloads)
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big m
Posted 2013-11-14 1:35 PM (#410679 - in reply to #226386)
Subject: Re: The Resurrection of 'Rusty' [the '59 Sport Fury]



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I stripped the two doors I had from a Fury, aside from several small dents and one poorly finished lead repair, they were pretty nice. After bumping and dinging the dents out, I sprayed metal etching primer on the bare steel.



('59 SF convertible 002.JPG)