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The Resurrection of 'Rusty' [the '59 Sport Fury]
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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)



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('50 Ford 011.JPG)



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Attachments '59 SF convertible 002.JPG (152KB - 209 downloads)
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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



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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]



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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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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]



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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]


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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)



Attachments
----------------
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!

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Location: bishop, ca
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]



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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)



Attachments
----------------
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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