DIY Network

1962 Fort T-Bird: Audio-System Upgrade From "Classic Car Restoration" episode DCR-309

	Car-audio expert Johnny Ray of Custom Autosound.
	One option for easy installation of new stereo speakers is to install replacement kick-panels, with speakers already mounted in them, on both sides of the passenger compartment.

In this final episode in DIY's Classic Car Restoration series on the 1962 Ford Thunderbird sports roadster, our project car gets some finishing touches -- including an audio system upgrade, a new steering wheel and a new set of Kelsey-Hays wire wheels and new tires. Finally, we give a summary recap of the entire project.

In this first segment, the sound system in the car gets a serious upgrade when the original stock 6-volt mono radio gets replaced with a new AM/FM receiver (made to look like a vintage radio from the 1960s era) connected to concealed speakers and a trunk-mounted multi-disc CD-changer. The new multi-feature sound system can be operated via a remote control unit. Car-stereo expert Johnny Ray, of Custom Autosound® assists us in the installation.

Materials:

Car-stereo kit (receiver, speakers, CD-changer)
Standard automotive tools (socket wrenches, extensions, combination wrenches, screwdrivers, nut-drivers, etc.)
Cordless drill with screwdriver attachment
Air compressor and impact wrenches (optional)

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 on 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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According to automotive sound-system expert Johnny Ray, car-audio specialists like his company Custom Autosound® offer a variety of custom in-dash sound systems designed to fit in the existing dash-openings of classic vehicles, and which emulate the look of the vintage radios (figure A).

Some of these modern replacements feature a faceplate that looks like the original AM radios installed in earlier automobiles, but which also features FM stereo and a digital tuner that appears beneath the "AM dial" when the unit's power is turned on (figure B).

Figure A

Figure B

Since our desire was to keep the original radio in the car, the system we installed was a "hidden" sound system (figure C) with a receiver that mounted inside the dash on top of the original unit. Other components included stereo speakers concealed under the seats and a CD-changer that can be mounted in the trunk. According to Johnny, the "hideaway" audio system can be concealed in a variety of locations in the vehicle -- including behind the dash, under a seat or in the trunk.

The system can operated using a remote control (figure D) from inside the car or from a distance up to 50 feet away.

Figure C

Figure D

The Thunderbird's existing stock dash-mounted mono speaker is replaced with a modern dual-cone stereo speaker featuring a larger cone area (figure E). The new speaker fits in the same sized opening as the original mono speaker.

Concealed stereo speakers (figure F) are also mounted beneath the seats. These speakers can be surface mounted, so no additional cutting will be necessary for installing them in the Thunderbird. They are 120-watt powered speakers, and each features a woofer that faces up and dual tweeters facing front and rear. Matched with the new receiver, the combination should be effective in filling the passenger compartment with sound.

Figure E

Figure F

Following is a summary of the major steps in the sound-system installation as shown in the episode. If you're not comfortable working with electrical and sound-system wiring, most custom car-audio shops offer installation services at a reasonable rate.

• The first step in the installation is to remove the dashboard grill and the old paper-cone speaker (figure G).

  Johnny then fishes the new speaker wires through the dash opening for both of the speakers that will be mounted under the front seats.

  He then begins installing the new sound system. He first plugs the original antenna lead into the new unit. Then he hooks up the power wires, the ground and the speaker wires. With everything wired according to the manufacturer's instructions, the new stereo unit can be installed through the speaker opening (figure H). In our case, we mounted the new unit on top of the existing radio. It's held in place using velcro.

  Figure G

  Figure H

  
  

  Figure I

  Johnny then fishes the CD-changer wire through the dash and out the driver's side.

  The door-sill plate gets removed sin order to run our wires under the carpeting (figure I). The wire for the CD changer is run back to the trunk through this path. As with all car sound-system installations, a big part of the job consists of concealing the wires as best as possible.
  With the wires in place, we can install the CD-changer on the side of the trunk (figures J and K). It is simply secured to the floor of the trunk with screws.

  Figure J

  Figure K

  
  Loading the CD player is simply a matter of ejecting the multi-CD magazine, loading it with CDs and inserting it back into the player (figure L).

  Johnny puts the new dash speaker back in place (figure M), secures it with screws and replaces the grill.

  The other speakers simply get mounted underneath the seats, and then the seats are put back in the car. The last step is to make sure that all of the speaker wires are connected properly to the speaker terminals.

  Figure L

  Figure M

  
  Once the system is installed, it's controlled by a slim control module that can be hand-held or mounted in a concealed location, or it can be operated by the wireless remote control.
  

  
  

  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.

  
  Vintage Thunderbird Club International
  www.vintagethunderbirdclub.org
  The Vintage Thunderbird Club International (VTCI) is an organization dedicated to the restoration of Thunderbirds and is an excellent resource for many aspects of restorations. The organization establishes juding rules and offers technical advice and production data.
  

  
  

  GUESTS :
  
  Johnny Ray, Custom Auto Sound
  Fullerton, CA
  Website: www.casmfg.com
  Automotive sound systems, including those designed with the look of original systems for classic and collector cars.

  ALSO IN THIS EPISODE:
  	1962 Fort T-Bird: Audio-System Upgrade
  	1962 Fort T-Bird: Steering Wheel Replacement
  	1962 Ford T-Bird: Wheels and Tires
  	1962 Fort T-Bird: Restoration Recap and Final Thoughts