Fitment and Alignment: Problems and Solutions 1. Filler Panel Finagle One of the more problematic pieces to fit was the filler panel that covers this support piece that connects the quarters to the wheelhouses.One of the more problematic pieces to fit was the filler panel that covers this support pi Right out of the box, this filler panel didn't match the quarters. The gap was way off on both sides.Right out of the box, this filler panel didn't match the quarters. The gap was way off on Aguayo had to grind down the mounting tab that didn't fit the support brace. He also had to hammer the edges of the filler panel and quarter-panels to make them align more closely.He also had to hammer the edges of the filler panel and quarter-panels to make them align Ultimately, Aguayo had to position a jack at the rear of the floor, raising it enough to twist all the components just right so everything lined up. Villarroel quickly jammed in some sheetmetal screws to hold it all together. Again, it helps to think of the whole car as a three-dimensional jigsaw puzzle. To get the horizontal trunk filler panel to line up with the quarters correctly, they had to twist up the floor in a counterclockwise direction. The best approach is to make the whole car fit together as a unit, not to force a single panel to fit its immediate neighbor. This also reinforces why it's best to screw together the car-you need to keep everything flexible while fitting all the panels.Ultimately, Aguayo had to position a jack at the rear of the floor, raising it enough to t 2. Need Longer Doors Once the Dynacorn quarters were in place, no amount of pushing, grinding, or swearing would close the gap between the quarter-panel and the passenger door to an acceptable distance. Carmody advised not freaking out if things don't line up exactly right, even though reproduction parts are stamped to fit OE dimensions: "I've seen original, unmolested, from-the-factory cars as much as 1/4 inch off in certain dimensions. Plus, mixing 44-year-old Ford parts with new stampings creates a whole new set of variables." Compounding this problem was the fact that this door came off of a different car on Recon's lot. To solve this, Aguayo added some extra length to the door by stitch-welding a length of welding rod to the edge of the door. After the welds were ground down, you couldn't tell a repair had been done looking at it from the outside. With all the fastback exterior sheetmetal in place, Aguayo and Villarroel measured the window and trunk openings with a tram gauge, checking it against a complete fastback they had in the shop.With all the fastback exterior sheetmetal in place, Aguayo and Villarroel measured the win Villarroel said that even though the measurements may all be in spec, the best check is a visual one. Notice that the taillight panel, trunk opening, and rear window openings are all aligned with the top of the dashboard. He said they often stand back during the assembly phase to verify that these surfaces are all parallel.Villarroel said that even though the measurements may all be in spec, the best check is a After all the measurements checked out, Villarroel and Aguayo began welding in the panels. Note the friction jack holding the shape of the trunk opening in place. After working so hard to get all the gaps just right, you don't want to warp them with a welder.After all the measurements checked out, Villarroel and Aguayo began welding in the panels. So far, this fastback conversion is basically just a new roof, quarters, and decklid, and that's stuff a competent bodyman can do without too much stress. But it's the inner supports that you can't find anywhere. Recon makes its own, and they're filled with cool dimple-die holes, a nod to Carmody's former life as a professional off-road truck racer. These panels offer much-needed support to this superflimsy Mustang chassis and are stronger than the support pieces a factory fastback came with.So far, this fastback conversion is basically just a new roof, quarters, and decklid, and Other parts not available in the aftermarket are the trim and upholstery mounting tabs. Recon also makes these and test-fits them with a full interior before shipping out a body.Other parts not available in the aftermarket are the trim and upholstery mounting tabs. Re With the back half of the car looking good, the guys began fitting the front subframe. The only parts salvaged from our car were the shock towers (in red primer). Everything else was new. Note that the subframe is supported by four jackstands, a friction jack across the top of the shock towers, and a piece of angle iron temporarily tack-welded in place near the firewall. It is absolutely crucial that these dimensions be correct-the motor mounts and suspension parts all bolt to the shock towers. If the towers are out of whack, the driveline angles and suspension geometry will be a big mess. Villarroel double-checked everything by measuring across the shock towers and from the firewall to the core support, top and bottom.With the back half of the car looking good, the guys began fitting the front subframe. The « | 1 | 2 | 3 | » | View Full Article By John McGann Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!