Howdy! So my most recent work on the Cougar has been the rear frame rail sections that I picked up from NPD here in Ocala. I’ve also received the trunk pans, rear trunk crossmember and drop offs from John’s Classic Cougars which will be installed once my frame rail repairs are complete.
So I’ve leveled out the car and cut out the area of the rail that I plan to replace, lining up the spring shackle bushing properly to my previously recorded measurements. I haven’t cut both sides of the replacement piece to fit yet because I want to be very meticulous about getting it to fit right when I’m done but I’m noticing the height of the rail may not be quite right.
I’ve, unfortunately, had to stop working on it for a while due to some long work travel but I was hoping maybe some folks here could give some insight into the challenges they’ve faced in making the same repair. There is a guy who has a partial video of the repair on his 69 Cougar but that’s it and there’s no way to message on YouTube from what I can tell. So yeah, any help or tips would be appreciated! Thanks!
-Tom
Thanks Don. I commented. Do you know if there are multiple manufacturers out there for these rail sections? I’d be willing to spend the money on a second one to see if it fits any better.
Can anyone any advice on how they’ve made repairs to rear frame sections before? Maybe a specific part they’ve used that grafted in nicely? Would really appreciate it!
I’ve replaced all the panels in the trunk area on a Cougar. But, I have never had to do a frame rail. Might want to contact KTL restorations for advise. https://www.ktlrestorations.com/
Can always check the Mustang boards as the process for a Mustang would generally be the same.
So, a frame rail patch was too easy. I ended up sectioning-in box steel tubing from the wheel well rearward to allow me to widen the wheel tubs a little bit as well as square off the frame to make mounting the 99 Cobra IRS “easier”, ha…ha…ha! I’m a glutton for punishment apparently. This has been a pretty daunting task and I’m not even close to done yet.
I also picked up a 2003 cobra engine/trans and all related necessities as well as the rod and custom front end and crossmember kit. I decided to shift my attention to the front end so I could get that installed and then I’ll be able to ensure the IRS is square to the front end before finalizing my brackets to the new rear frame. I also still have to make some fish plates for where I tied into the stock frame to strengthen the area but that’ll come after I get the IRS subframe in place.
If anyone has the sloped trunk sheet metal from the axle hump down to the forward edge of the fuel tank or a good condition steering column, let me know. I’m in NY/NJ for a couple weeks and then back to Florida, so either location works for me right now to pick up.
Tom,
It would be helpful to know what year your Cougar is. I have a pile of OEM steering columns here. I am located in PA (near Hershey) so it might not be too far out of your way if you are in the NY/NJ area.
I should be around. Let me know your schedule and what all parts you are looking for. I can then gather everything together in one place and meet up with you.
