Automotive Experience
In the summer of 2018 I purchased a 1978 mustang in desperate need of repair. Almost too far gone but it was within my project budget. There was a considerable amount of rust on several parts of the car along with missing floor and trunk pans.
Along with my prior electronics experience, I learned to weld and research how to tackle problems that needed solved. I gutted the interior and repaired what I could;
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Interior
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Fiberglass dash repair​
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Sheet metal replacement
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Added gauges and controls
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Exterior
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Welding
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Fabrication
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Electronics
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Soldering​
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Design
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Engine
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Cleaning​
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Complete rebuild
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Cooling System
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Upgraded radiator​
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Converted to electric fan
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Suspension
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Replacement​
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Brake System
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Replaced entire system​
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Fuel System
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Tuning
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Replaced entire system​
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Retrofitted gas tank
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Patches were welded in to repair existing rust damage, as well as accommodate the relocated gas cap. Rear bumper was upgraded and a new support was fabricated. A rear spoiler was installed, as well as a new set of wheels and tires.
Every bulb and socket was replaced. The alternator was upgraded and the supporting wiring was modified. I also updated the cooling system with a temperature sensor and a switch for the radiator fan. Finally, I installed an electric fuel pump switch and usb charging ports.
I removed the engine for a complete rebuild and cleaning. I repaired and repainted the engine bay, and modified the wiring harness in order to accommodate all of the upgrades made to other systems. The engine rebuild required finding discontinued parts, mechanical knowledge, and interpreting outdated instructions and specifications.
The existing dash was repaired with fiberglass and repainted. Trim panels and seats were replaced and repaired. The driver side window regulator was replaced and adjusted. Other missing parts were sourced and replaced.
Left: The hole left in the driver side floor pan from rust.
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Right: The retrofitted gas tank from a 67 Mustang
Original to do list
After a while I switched to using a marker and cardboard for the ease of simplicity, but this was the original list when the car was originally laid out
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-Get engine running
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change oil ✔
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fill coolant ✔
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wire ✔
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battery✔
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starter solenoid ✔
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tune
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figure out fuel starvation - rewire pump and remove kinked line ✔
✔-brakes
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rear rebuild kit✔
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front rebuild kit ✔
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lines✔
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check master cylinder✔
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refill fluid✔
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bleed ✔
✔-fuel system
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check tank/fuel pump✔
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change lines✔
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remove stale gas/tank✔
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replace tank✔
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install tank✔
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get new gas✔✔
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check electric pump for psi rating✔
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replace carb and tune ✔
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repair kinked like ✔
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rewire fuel pump ✔
-dash
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get instruments to work and replace circuit board
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get turn signal lever✔
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wire key/new ignition switch✔
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clean and repair dash and dash pad
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check turn signal - replace sockets and bulbs
-tail lights
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check wiring/bulbs ✔
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check turn signals - replace sockets and bulbs
✔-headlights
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check wiring/bulbs ✔
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check turn signals - ✔
✔-wheels/tires
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find wheels✔
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get tires mounted✔
-suspension
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check front/rear suspension
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new leaf springs and mounts - no ✔
✔-hood/trunk latches
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repair hood latch ✔
-sheet metal
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new floor pans and fill holes
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new quarter
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repair panels
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door
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quarters
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fenders
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frame
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battery tray - relocate battery?
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-driveshaft
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measure and order - wait for martin
-transmission
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make sure clutch is connected - figure out why it wont disengage
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make sure trans is connected - ✔
A section from the excel file where I keep track of the car, this gives me part numbers for parts that are not original to the car, or hard to find parts. In case anything needs replaced, I reference this section.
Another section from the same file, that keeps track of the budget of the car. I save every receipt in a box, but the excel keeps track of the total cost of tools, parts, and anything else that gets put into the car. I started dating later into the project to also keep track of the timeline on the car. For example, I installed a new air filter on 6/1/2020 and it cost $10.74 with tax.