Extreme Makeover Phase 2:
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Extreme Makeover Phase 2:
 
The primary focus of this project is to see how an average guy installs these beautiful parts in his garage with normal hand tools. We all know that professionals can build these cars but how about the average guy. Follow along and see how I do it. The platform is StreetRodding.com's phantom 36 Ford sedan delivery... already unique (because Ford never made this car). We will make it even more so by installing new components from our family of advertisers. I will deal with the paint in another phase. So come along and watch the old dog learn some new tricks.


Sheetmetal Alignment (body, doors and front cap)
  • Loosen the body from the chassis
  • degrease, clean and finish painting the chassis (need a lift to finish)
  • Bolt gas tank to chassis
  • Build and install console
  • Align body holes to chassis
  • Bolt body to chassis
  • Reinstall engine and transmission
  • Fit doors and shim as required
  • Modify firewall for bulkhead connectors (for a/c and heat)
  • Install the new US Radiator and fan/shroud)
  • Repair toeboard to firewall
  • Fill miscelaneous holes in the floor and firewal
  • soundproof and seal the floor and firewall
  • Clean and paint the front floor and firewall
  • Build and install new dash using 1956 Plymouth front
  • Install the Flaming River column and hook up steering
  • remove weather stripping and fit the rear door
  • clean and paint the rear floor underneath the wooden deck
Exterior
  • Repair spots in body and paint
  • Replace running boards with rubber covered boards
  • Repair front fenders/grill and paint
  • Repair hood top and paint (possibly build a three piece hood)
  • Repair hood panels and paint
  • Paint wheels
Do graphics (maybe ghost flames) and pinstripping


PHASE 2 IS OVER....

What started as an update to various components on the 36 Delivery turned into a major undertaking lasting two years. Fortunately I had the time and I have a family of advertisers willing to step up and help with their great products. Without them the Extreme Makeover Project would not have been possible. Watch for the car at show's over the next year or two and be sure to ask any questions you might have. I know the answers because I did it all with the help of a friend or two.

Following are parts used, suppliers and basically the high points of the project....


A1Electric supplied power windows and the looms that connect the door to the "A" pillar for routing wires

American Autowire supplied the kill switch, battery cables and all connectors

Coker supplied the wide white wall radial tires

Flaming River supplied the "variable ratio" power rack, pump, polished steering column, and all connectors

Lokar supplied the tranny dipstick, carb and ATV brackets, pedals, ebrake and shift linkage

Painless Performance supplied the instrumentation wiring harness, trunk light, and wire covers

Phoenix Transmission supplied the 2004R tranny and torque convertor

Ron Francis supplied the wiring harness

Rust Bullet supplied their rust resistant paint

Stainless Works supplied the full length headers and complete exhaust system

The Driveshaft Shop supplied the beautiful aluminum driveshaft and Ujoints

US Radiator supplied the triple flow "Dessert Cooler" radiator and the tranny cooler

Vintage Air supplied the complete Gen II Maxi Cooler A/C system


In addition I built a one off dash using a 1956 Plymouth face. I designed and made a console to house instruments, tach, window switches, power mirror switch, two radio speakers and cup holders. The console also houses the wiring panel and misc other goodies. For the first time in 20 years of owning the car I had part of the upholstery done (doors, dash, console, kick panels and carpet. Getting in the car feels like a Ferarri.... driving it is great... the a/c blows cold and has defrost and heat. I picked up a refurbished 1956 Plymouth radio with IPOD plug and all new electronics inside. I used Mercedes arm rest from the junk yard and had Larry Darling stich the Ultraleather. The seats are dyed to match. The car is making it's semi completed debut at the Southeast Nationals in Tampa. I hope you will stop by, take a look and say hi.....


PHASE 3 will encompass paint touchup and roadrash/paint repair
 
 
September 14, 2007 07:47 AM
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View from the rear door..... more work to do in the back :) 
 
 
All the creature comforts 
September 14, 2007 07:46 AM
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Flaming River tilt column with shifter, LeCarra banjo wheel, Vintage Air, homemade dash using 1956 Plymouth front, 1998 Chrysler Sebring convertible seats, homemade console, power windows from A1-Electric, CB, 56 Plymouth radio with new electronics and IPOD capable, Autometer instruments.... all the creature comforts...still to come rear view camera with screen in the rear view mirror 
 
 
 
September 14, 2007 07:39 AM
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Mercedes 300D arm rest.... no idea what year... 
 
 
Wiring Panel moved 
September 03, 2007 10:52 PM
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I decided to put the Ron Francis "Bare Bones" Panel inside the console instead of under the rear sub floor....almost everything is rewired and working now... more pictures tomorrow 
 
 
 
August 14, 2007 09:56 PM
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Notice that the radio is installed also.... 
 
 
 
August 14, 2007 09:54 PM
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Glovebox door open.... door will get inside treatment...probably same as dash and console with ultra leather 
 
 
 
August 11, 2007 11:02 PM
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1956 Plymouth radio with modern printed circuitry inside.... I can play my IPOD through this radio, plus "search", AM/FM and CD changer... I won't need the CD changer since I have an IPOD with over 300 original artist oldies and other songs :) 
 
 
 
August 11, 2007 10:59 PM
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Front radial tire, wheel, trim ring and hubcap from Coker... notice how the front whitewall is proportionately smaller than the rear 
 
 
 
August 11, 2007 10:57 PM
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Rear wheel with wide white radials, trim rings and hub caps from Coker.... 
 
 
 
August 11, 2007 10:55 PM
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Rear wheel painted and cleared.... 
 
 
 
August 11, 2007 10:54 PM
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Console with instruments and CB installed.... 
 
 
New console.... 
August 09, 2007 09:25 PM
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Here's what I was working on for so long.... 
 
 
 
July 29, 2007 01:16 PM
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July 29, 2007 01:15 PM
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Flaming River Steering Shaft and Universals 
July 13, 2007 03:05 PM
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The Flaming River Stainless "DD" steering shaft and polished nickle plated universal joints make the job a breeze. The heim joint is a must for a two piece (three joint) installation. 
 
 
LeCarra Steering Wheel 
June 21, 2007 06:00 PM
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Here is the column and LeCarra wheel installed... 
 
 
Flaming River Column and Floor Mount 
June 21, 2007 05:58 PM
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Here is the Flaming River floor mount..... 
 
 
Flaming River Column Drop 
June 21, 2007 05:57 PM
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Here is the Flaming River column and drop.... mounted to the dash 
 
 
36 hood 
May 21, 2007 09:37 PM
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The hood was fitted to the grille and the radiator adjusted for gap's... everything will need a good cleaning once back together... 
 
 
front clip 
May 21, 2007 09:35 PM
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It is much easier to assemble the fenders and grille and inner grille support before installing onto the car.... 
 
 
US Radiator mount 
May 21, 2007 09:32 PM
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Here is the radiator suspended from the bottom of the mount to get the sheet metal to align....I plan to add a support from side to side that will both support and prevent any movement fore or aft.... 
 
 
Console coming together 
March 11, 2007 01:42 PM
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Here's the first views of the console with cardboard sides :) there are two cup holders (one is hidden)...the piece on the right hides the ac hoses and wiring.... the only problem is not much leg room... may have to relocate the gas pedal.... 
 
 
Dash back from the upholsterer 
February 28, 2007 09:02 PM
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Vintage Air Compressor 
January 28, 2007 05:45 PM
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Phoenix Transmission 2004R 
January 16, 2007 03:32 PM
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Engine and original 350 painted 
January 16, 2007 03:29 PM
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January 16, 2007 03:27 PM
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Phoenix Transmission 2004R 
November 30, 2006 09:17 PM
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Coker Tires 
October 05, 2006 08:56 PM
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October 05, 2006 08:51 PM
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October 05, 2006 08:44 PM
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September 13, 2006 06:22 PM
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Full shot... note no buffing, sanding or anything has taken place yet.... it's going to the upholsterer next to have the top covered.... then it's back into the car and hook everything up.... 
 
 
 
September 13, 2006 06:20 PM
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right side of the dash.... 
 
 
 
September 13, 2006 06:18 PM
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left side of the dash... dust and all 
 
 
 
September 13, 2006 06:17 PM
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Here are the glove box door, ash tray, and radio face plate... 
 
 
 
September 10, 2006 12:45 AM
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New 600 CFM Holley installed... notice that things are beginning to get a little dirty and tarnished :(  
 
 
 
July 22, 2006 10:06 PM
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July 22, 2006 10:05 PM
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July 22, 2006 10:04 PM
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June 28, 2006 10:18 PM
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June 28, 2006 10:15 PM
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June 28, 2006 10:09 PM
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June 28, 2006 10:06 PM
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June 28, 2006 10:03 PM
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US Radiator triple flow "Dessert Cooler" and Vintage Air condender 
 
 
 
June 28, 2006 10:00 PM
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June 28, 2006 09:57 PM
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May 13, 2006 12:52 PM
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May 13, 2006 12:51 PM
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Dash is taking shape.... 
 
 
 
April 02, 2006 08:02 PM
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Vintage Air Dryer and bulkhead fitting... there are different styles of bulkhead fittings 
 
 
 
April 02, 2006 07:31 PM
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March 19, 2006 09:26 PM
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March 19, 2006 09:23 PM
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March 19, 2006 09:21 PM
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Vintage Air evaporator with the motor cover off... notice the connections are easily accessed 
 
 
 
March 19, 2006 09:18 PM
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Vintage Air evaporator with cover... I added extra mounting straps.... and had to eliminate the cover for clearance 
 
 
 
March 19, 2006 09:15 PM
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Vintage Air polished dryer and bulkhead mounts 
 
 
 
March 18, 2006 07:58 PM
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March 18, 2006 07:56 PM
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March 18, 2006 07:53 PM
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March 09, 2006 02:13 PM
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March 09, 2006 01:59 PM
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The Driveshaft Shop aluminum driveshaft and Ujoints 
 
 
 
March 09, 2006 01:54 PM
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The Driveshaft Shop aluminum driveshaft 
 
 
 
March 03, 2006 10:10 PM
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February 14, 2006 10:02 PM
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February 14, 2006 09:57 PM
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February 14, 2006 09:54 PM
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Had to rework the hearer to exhaust connections when I switched from block huggers to full length Stainless Works headers and exhaust 
 
 
 
February 14, 2006 09:52 PM
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February 14, 2006 09:49 PM
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Flaming River's "variable ratio" power steering pump...I later changed the mount to a March to match the rest 
 
 
 
February 14, 2006 09:45 PM
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February 14, 2006 09:40 PM
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February 14, 2006 09:36 PM
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Full length headers from Stainless Works.... never have to worry about rust again :) 
 
 
 
February 08, 2006 08:03 PM
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February 08, 2006 07:58 PM
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A1-Electric door connectors.... very easy to use... just drill a hole through the door and "A" pillar and put them in :) 
 
 
 
February 08, 2006 07:53 PM
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February 08, 2006 07:50 PM
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made an access hole to get the door looms in... 
 
 
 
February 08, 2006 07:48 PM
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February 08, 2006 07:45 PM
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January 29, 2006 08:52 PM
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January 29, 2006 08:45 PM
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January 22, 2006 08:03 PM
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January 22, 2006 08:01 PM
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January 15, 2006 06:00 PM
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Clean and paint the engine and tranny.... too bad it won't stay this nice... 
 
 
 
January 15, 2006 05:57 PM
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January 15, 2006 05:53 PM
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January 04, 2006 10:18 AM
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January 04, 2006 10:15 AM
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January 04, 2006 10:10 AM
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January 03, 2006 11:20 AM
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January 03, 2006 11:11 AM
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January 03, 2006 11:08 AM
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factory power (armstrong) windows 
 
 
 
January 03, 2006 11:04 AM
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A1-Electric windows 
January 03, 2006 11:03 AM
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These were very easy to install 
 
 
 
January 03, 2006 11:01 AM
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A1 Electric windows come shrink wrapped in a single package 
 
 
 
December 04, 2005 01:09 PM
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December 04, 2005 01:08 PM
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December 04, 2005 01:06 PM
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November 20, 2005 05:19 PM
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November 20, 2005 05:19 PM
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November 20, 2005 05:18 PM
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Beginning of the dash construction using the 1956 Plymouth front 
 
 
 
November 02, 2005 11:42 PM
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November 02, 2005 11:41 PM
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November 02, 2005 11:40 PM
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October 30, 2005 08:36 PM
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October 30, 2005 08:35 PM
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October 30, 2005 08:34 PM
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October 30, 2005 08:33 PM
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October 30, 2005 08:30 PM
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October 30, 2005 08:29 PM
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When applying the Rust Bullet you need to wear gloves or plan on having paint on your hands for about a month... 
 
 
 
October 12, 2005 05:21 AM
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September 05, 2005 05:36 PM
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September 05, 2005 05:34 PM
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September 05, 2005 05:26 PM
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August 30, 2005 08:18 AM
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August 30, 2005 08:15 AM
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