While the frame is good on my Merc, I have another project, a '66 Galaxie 7 Litre which uses the same frame as comparable Ford and Merc wagons, that has rust issues. I have been working at tackling them and thought I would share as it might help someone else save some money and trouble over replacing a repairable frame. This is what I started with, and when I have a few minutes over the next few days, I will post my work to date.
Yikes! Certainly a worthwhile project getting a 7-litre back on the road. Have you thought about using a modern frame? A Crown Vic or Mercury Grand Marquis would be a bit too short for the '66 wheelbase of 119", but a 2006 regular-length Lincoln Town C has a wb of 117.7", and the 'L' version is 123.7".
It's a project and I wanted to take on the challenge. If it wasn't a true 7-Litre car (convertible and 4-speed no less) I might not mind going down that road, but I wanted to keep a real convertible frame underneath.
Wow the frame on my 7Litre was no where near that bad, just the side rails which a friend at a metal shop made a new pair for me. I spent 6 years doing mine though I left the ford and Galaxie script off, (personal preference). Here are a couple shots of my car to help keep you interested in the job.
Nice car! The interior on mine is outstanding, especially given the fact that it's a convertible. The engine runs off of a can, and it will drive, but there are no brakes. The top looks newer and still works excellent. The body, on the other hand, needs some help. The frame I'm working on is actually a replacement frame. I was told the original looked a bit like a quilt, so I picked this one up as a donor car with the understanding it only needed limited work. There is pitting, which I expected, however the more serious rust is courtesy of mice nesting and rotting it from the inside out. The holes at the ends of the torque boxes actually allowed me to clean out the boxes as well as the frame rails, and there was a ton of stuff in there. I've now pressure washed it out twice, and after I finish cleaning it up, it will get one more bath before I seal it up. It is a factory red with black interior, and I will be making a couple of bolt-on additions, but nothing that can't be changed back if I ever decide to sell it at some point in the future. It's been a while since I owned a convertible, so I'm eager to get into this project!
I spent alot of time touring wreckers looking for good interior window trim as the anodizing on mine was pitted even found a spare grill from a LTD. That and http://www.dearbornclassics.com/ supplied quite a bit of repop parts. If you still have the Kelsey Hayes 4 piston calipers on yours most jobbers should be able to get replacement pistons and seals for them. I also went with a Wilwood adjustable biasing valve for the rear brakes.
Paul - there's a long wand-type spray head that will allow you to spray rustproofing inside the frame rails (if you aren't already aware of it) Body shop supply place should have it.
I will be using the Eastwood Products rust converter primer in the frame (internal frame coating)...no undercoating, at least not planning to at this time. I strongly suspect that, even if I put a fair number of miles on it each year, it will still outlast me. =-)
I have both the original rear antenna, and an NOS second "dummy" antenna for the dual antenna look. Thanks!
