DIY Network

1962 Fort T-Bird: Exterior Trim and Chrome Bumpers From "Classic Car Restoration" episode DCR-306

	Host Steve Magnante with the replacement chrome bumpers. In our case, it was cheaper and simpler to replace the bumpers than to try to recondition the rusty old ones.
	The chrome Thunderbird logo and Sports Roadster emblem.

In this segment, the Thunderbird's exterior chrome and trim pieces get repaired or replaced as needed.

Materials:

Standard automotive tools (socket wrenches, extensions, combination wrenches, screwdrivers, nut-drivers, etc.)
Air compressor and impact wrenches (optional)
Replacement trim pieces (as needed)
Buffing wheel
Jack and jack-stands

Safety Equipment:

Work gloves
Safety glasses or other eye protection

Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Car Restoration. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

Safety Alert: Always wear eye protection when working with power tools or pneumatic tools.

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When we bought our 1962 Thunderbird project car, it was in pretty good condition, but it had some obvious problems with the exterior chrome and trim (figure A). The front and the rear bumpers had a pretty severe case of rust. In some cases, there were actually holes (figure B). Generally speaking, the chrome was bleached out, flaking and pitted.

While it's possible to have bumpers like this re-built, welded again, ground and re-chromed, it is not cheap. To avoid all that trouble, we went out and we opted some reconditioned chrome bumpers from an online supplier specializing in vintage Thunderbird parts. This was a less costly option compared to what it would have cost to restore the bumpers that came on the car.

Figure A

Figure B

Figure C

When it came to the stainless-steel body parts on our Thunderbird, much of it was usable with a little bit of polishing. A bench grinder, cotton polishing wheel and some rouge was sufficient for polishing and some these pieces back into presentable condition (figure C). In some cases though, the stainless was bent or the cast pot-metal parts were too badly pitted for re-use. So again, we went onto the internet and found some reproduction parts as well as some good reconditioned original parts to bring our car back into shape.
Replacing the Fender-End Caps

One major eyesore that we had to deal with before changing the bumpers were the rubber fender-end caps. These fit between the car and the bumper, and the originals were badly dry-rotted. We replaced these with new ones from the reproduction after-market.

• Loosen and remove the headlight bolts (figure D).

• It's not necessary to disconnect the headlights completely. Simply lower them carefully (figure E) and allow them to hang so that you can reach the rubber caps.

  Figure D

  Figure E

  
  
• Remove the bolts that hold the rubber gasket in place, and peel off the old gasket (figure F).

• Install the new gasket (figure G), and secure it with the bolts.

• Reinstall the headlights.

• Repeat the steps to install the gaskets on the other corners of the vehicle (figure H), installing each new rubber cap.

  Figure F

  Figure G

  Figure H

  
  

  Figure I

Before attaching the fender molding, install the plastic fender bumpers (figure I) and metal retaining clips. These are attached by simply hammering them into place.

• Install the fender molding (figures J and K) by installing the tip-screw fastener into the front locking clip, then carefully pounding the molding onto the retaining clips along the fender by hand.

  Figure J

  Figure K

  
  
• We installed a new Thunderbird fender emblem as well as the Sports Roadster emblem. These simply snap into retaining holes (figure L). Details like these add significantly to the car's authenticity.

• Installing the new Thunderbird bumpers is not a one-person job. Keller Wallace and Kevin Tetz help Steve lift the bumpers into position (figure M). The bumpers are bolted to the frame from underneath the car.

  Figure L

  Figure M

  
  
• New vent trim was installed on the T-bird's quarter panels (figure N). These fit into pre-drilled holes and are secured from inside the trunk using locking nuts.

• The final detail with respect to the chrome and trim is the hood emblem that gets attached to the shiny, newly polished hood (figure O). The emblem is secured underneath the hood with locking nuts.

  Figure N

  Figure O

  
  

RESOURCES :

Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
Order this book from Amazon.com
Haynes Publishing

Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners and Restorers of Classic and Collectible Automobiles
1557881944
Jim Richardson
(November 1994)
To order this title from Amazon, click here.
H.P. Books

Thunderbird Restoration Guide, 1958-1966 (Motorbooks International Authentic Restoration Guides)
by William Wonder
Published by Motorbooks International, June 1997
ASIN: 0760303908
To order this book from Amazon.com, click here.

Illustrated Thunderbird Buyer's Guide (Motorbooks International Illustrated Buyer's Guide)
by Paul G. McLaughlin
Publisher: Motorbooks International (July 2000)
ASIN: 0879388706
To order this book from Amazon.com, click here.

T-birds.com
T-Birds.com
A website dedicated to the appreciation of 1961 through 1963 Ford Thunderbirds. Hard-to-find restoration parts and materials, including reconditioned original t-bird body parts, can be found through t-birds.com.

GUESTS :

Kevin Tetz
paintucation.com
Paintucation.com specialized in automotive body, paint and restoration services and instructional restoration videos.