Undoing the Effects of Time

The '63 Thunderbird sat for a long time and we're finding evidence of decay and signs of neglect in a past life - which, in many cases, is to be expected. We wonder what stories this old drop-top bird would tell, if it could. Kudos to the current owner for wanting to get her back on the road.

Though this is not a full restoration, we're going through the car system by system to make sure everything works as it should and is safe and reliable to drive and enjoy.

The drum brake system is rebuilt along with a new master cylinder. We were astonished to find several broken springs and other missing parts when the drums were removed.

Rebuilt drum brakes

Meanwhile we begin servicing everything in the engine compartment to both fix problems and improve reliability.

The power steering pump was leaking like the Exxon Valdez. The carburetor was gummy. Ignition wires were ancient. Belts tired. Hoses mushy. It all comes out for repair or replacement.

Engine thoroughly serviced

The Eaton style power steering pump is rebuilt. New gaskets will seal repainted valve covers.

The old, mechanical ignition points are replaced with a Pertronix electronic module and Flame Thrower coil. Of course, a new cap, rotor, wires, and spark plugs will complete the ignition system.

Detailed engine parts

The Ford 4 barrel carburetor sitting atop the 390 ci V8 is similar in appearance to the venerable Holley. It gets rebuilt to restore performance.

Rebuilt Ford 4V carb

Even the original copper/brass radiator showed evidence of leaking at a couple of solder joints where hoses connect. Such repairs are actually easy, unlike modern units made of plastic and aluminum. We pressure tested it to make sure.

Radiator leaks repaired

Meanwhile, much of the interior has been gutted. Seats were steam cleaned and repaired.

The heating and fresh air system was completely inoperable and the parking brake assembly seized with rust.

The engineers at Ford, back in the day, didn't necessarily design these cars with ease of service in mind. No, to get to just one likely-to-fail-part you may well have to take most of the dash apart.

Mostly gutted Thurnderbird dash

This is the heater core (which is like a little radiator) found inside the heater box. On the lower left corner is a cable operated water valve that opens and closes, allowing hot engine coolant to enter the core and provide heat to the passenger compartment.

The valve is seized with corrosion and needs to be replaced.  To do that the entire heater box has to be removed from behind the dash.

Heat core and water control valve

The heater box assembly: Inside is where the heater core lives. Our core was an original Ford part and didn't look like it had leaked but they usually do after many years so it will get replaced to be safe. The whole box has to be removed to replace it anyway. When these go, they make a mess inside your car.

Heater box assembly

On top of the heater box is a vacuum operated servo. You cannot easily get to this one while the box is in the car either. It opens or closes one of the doors inside the box, depending on your control settings. Since it no longer works, it'll get replaced while the box is out too.

Heater control vacuum servo

On the driver side, fresh air ductwork prevents full access to the parking brake (e-brake) pedal assembly, which was completely seized with rust - wouldn't budge.

After removing the ductwork the pedal could (just barely) be unbolted and removed. We soaked it in a vat of Evapo-Rust overnight (amazing stuff). It removed all rust and we were able to free-up the ratcheting pedal action once again.

De-rusted and painted parking brake assembly

When parts arrive from the Bird Nest in Oregon, we'll get much of this back in the car.