We're off on another project now for a customer, who has 'convinced' us (to sway from the general concours theme that we tend to stick with!) to build him a Steve McQueen 'Bullitt' replica. He engaged us to find him a good car to start the project with, so the hunt began and eventually we turned up a really tidy, very complete (less the removal of engine and trans), original paint Acapulco blue/black trim '67 'S' code big block GT fastback. The great thing about this car is that nobody had messed with the wiring or any of the clips on the car from front to back - nothing had been tampered with! These are the dream resto cars. It also has all the right options to become a Bullitt replica, being originally fitted with a tach dash, a factory 390 big block like the original Bullitt car, along with a 9" diff ready for some 3.50:1 limited slip gears.
The engine and trans were long gone, but that everybody involved down to the ground, as we're installing a red hot, near big hp 302 Windsor, with aluminum Edelbrock heads, Shelby intake manifold and a 5 speed transmission.
The engine and trans were long gone, but that everybody involved down to the ground, as we're installing a red hot, near big hp 302 Windsor, with aluminum Edelbrock heads, Shelby intake manifold and a 5 speed transmission.
As you can see above, we started with a beautiful car and for that, it was worth the wait to search for such a vehicle, as in the end, the customer will save a bucket load of cash, restoring a good car, than a bad one.
The GT was pretty much stripped and then some of the more substantial required repairs, done. The only part not original paint, was the left rear quarter panel, where the two little fake side scoops are and it had been side swiped very lightly at some point. At a stretch, it could have been repaired, but it had damaged the secondary structure which holds the scoops and was simply 'ugly', so we opted to use a piece of original quarter panel that we had and graft it in. You'll note that we've done this so that you'd never pick it was done, once the car is painted, by not messing with the spot welds and edges down the B pillar, or the wheel arch.
The floors were very nice, but it was obvious that once blasted, it would be full of little pin holes here and there, and the tunnel had been hacked up for some monster HURST shifter at some point (they even cut the cross member under the floor), so we grafted a left over piece from a Shelby that we had, into this car to fix it. The floor sections were then replaced and came up very nicely. The underside will be dressed up once the car is blasted and on the rotisserie.
Other than that, this body really only needed some dents roughed out prior to blasting. It had NO rust in the usual Mustang places. The doors and guards/fenders are perfect, as is the trunk lid and hood.
The floors were very nice, but it was obvious that once blasted, it would be full of little pin holes here and there, and the tunnel had been hacked up for some monster HURST shifter at some point (they even cut the cross member under the floor), so we grafted a left over piece from a Shelby that we had, into this car to fix it. The floor sections were then replaced and came up very nicely. The underside will be dressed up once the car is blasted and on the rotisserie.
Other than that, this body really only needed some dents roughed out prior to blasting. It had NO rust in the usual Mustang places. The doors and guards/fenders are perfect, as is the trunk lid and hood.
Once the GT went up on the rotisserie, we found that some 'whacka', had beaten the hell out of the shock reinforcement cross member to accept the HUGE and at the time, 'trendy', air shocks. They were near as thick as your thighs, these shocks! Anyway, we had an original cross member that we'd removed from a Mustang in a wrecking yard in California, and trimmed a couple of replacement pieces out of that to repair this one. I'm sure you'd agree, that it's a lot more attractive than what was there previously!
The completely media blasted shell was then mounted on the rotisserie in the shop and a few pin holes that popped up in the original floors were given a spot of brass to fill them, some more body repairs completed, floor replacement sections dressed up, usual rust under the battery tray cut out and then hit with an acid etch primer. Next step will be replacing the battery tray section, finishing off some repairs and hole filling in the engine bay and then the car will be shot with epoxy primer to lock it down, before the blocking of the body panels begins.
Above, are a few pictures of the freshly built big hp 302 destined for the engine bay of this Bullitt replica. Should be a fun car to drive, backed up by a 5 speed and a 3.50:1LSD 9"!
As you can see from the pictures above, we've started applying the near identical sealers that the factory used (only a mile better in quality - but appearance wise, very close) and thrown it around like the guys on the line did. We use a very high quality marine grade red oxide style primer and it's 'bullitt' proof - no pun intended..! Now that the body of the car is blocked to within inches of its life, it's time to throw some green over spray onto the floor pans and paint inside both the trunk and car, so that when the paint is applied to the exterior, we can mask off the inside of the car from the outside, minimising the chances of contamination blowing from inside the car to the new exterior paint.
The body is blocked straight and ready for a final block before paint. Disregard the panel fit, as they're only on the car for transport to the booth (I hear you saying "thank god for that!")
Now the '67 has been blocked and hit with a gorgeous coat of Highland Green to bring it closer to Bullitt spec's, per the customers ultimate desire! Looks awesome. This is how a real, decent painter, paints a car - straight off the gun, no need for colour sanding, because it already has a beautiful consistent finish to it, over the entire job.
Again, as above, the panels are only refitted to the car for transport purposes. They've got to be removed again to paint the engine bay last, just as Ford did and then the car goes back onto the rotisserie again to have all of the undercarriage aspects completed, before being dropped to the ground for the final assembly.
Again, as above, the panels are only refitted to the car for transport purposes. They've got to be removed again to paint the engine bay last, just as Ford did and then the car goes back onto the rotisserie again to have all of the undercarriage aspects completed, before being dropped to the ground for the final assembly.
Below, we have some more updates to the '67. The brake booster has gone in, as has the wiring harness (after being stripped, connections cleaned and the loom retaped), washer lines, new front suspension, KONI shocks, etc. All of the time consuming dash construction is now completed, with the A/C unit, wipers, rebuilt wiring harness, detailed air vents and cabling, rebuilt park brake arrangement, steering column and pedal box, gauges restored and fitted to the dash, all in their respective places and tested for operation.
The front and rear screens went in without issue and look the part. All the stainless moldings for the car were polished to a high standard and snapped into place beautifully. The door glass was installed after replating all the removable items and regreasing the whole system. They motion up and down smoothly now. The tailights were also stripped down, the buckets replated and the rubber gaskets media blasted (yes, media blasted!) to remove the rust that had started to accumulate on them from prior to resto. They came up like new and are ready to throw in.
The front suspension is starting to take shape now. The original K/H rotors are blasted, painted and machined, ready to go on with the rebuilt original K/H calipers, which are also painted in a nice cast iron coloured clear over base 2 pack system. We figured it looked nice and matched up with the restomod style work going on with this car.
The front suspension is starting to take shape now. The original K/H rotors are blasted, painted and machined, ready to go on with the rebuilt original K/H calipers, which are also painted in a nice cast iron coloured clear over base 2 pack system. We figured it looked nice and matched up with the restomod style work going on with this car.
Fully stripped and rebuilt K/H brake calipers all come together on machined rotors with new bearings and lines, with all re-plated hardware. She'll be a pleasure to drive!
Getting down to the knitty gritty now, with the 'bling' going on and the beasty roller motor and 5 speed going into the engine bay. Soon, there'll be a 'fire in the hole'..!
Time for front end panels, hook up all the gadgets to the engine, plumb up the new Air Conditioning system and turn the key! It roured into life and certainly sounded the part, straight out of the extractors with no exhaust system fitted. The exhaust was fitted the next day and the car sounds really nice. We're very happy with it.
Today, most of the front end panels and bling went onto the car. This really starts to make it look done!
Here is it, idling away. Got a beautiful note to it with a hint of the cam that hides under the auspice of a roller cam!
Below, it sits on the lift at the exhaust shop where they fitted the system to it. This video was immediately after they fired it up to check for leaks etc. It's still blowing the oily residue out of the new pipe and all the gunk from welding it together, but sure sounds nice! Nearly time to go throw some miles on it and run the motor in properly, but not before a wheel alignment.