DIY Network

1962 Fort T-Bird: Restoration Recap and Final Thoughts From "Classic Car Restoration" episode DCR-309

	The final, final touch: a new Thunderbird emblem

With the new wheels and tires installed, our Thunderbird restoration is essentially complete. In this segment, we recap our restoration of this distinctive American classic.

Note: The summary of steps included in the automotive restoration procedures shown throughout this series of Classic Car Restoration 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.

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	Figure A

Our restored Thunderbird sports roadster is one of only 1,182 produced, and these were only made in the years 1962 and '63.

The sports roadster models featured the unique styling of a molded fiberglass tonneau cover that transformed the 4-seat sedan into a sporty 2-seater. Another impressive feature was the power convertible top, which folded up and stored in the trunk compartment eliminating the bulky canvas storage on the deck (figure A). The result was a sleek and modern body style that still turns heads today.

The car also featured many state-of-the-art components such as power steering, power windows, and a swing-away steering wheel. inspired by the modern styling of the 1962 and 1963 models, ford produced the sports roadster concept car in 2002. The car featured the molded fiberglass tonneau cover that made the original models so unique and sporty.

	Figure B
	Figure C
	Figure D
	Figure E
	Figure F
	Figure G
	Figure H
	Figure I

We started the restoration of our authentic sports roadster by taking it out of long-term storage. It was dirty and missing some trim, but basically whole and a good candidate for a "daily driver" restoration. Because the gasoline in the car had gone bad, we created a dedicated fuel supply -- a gas can and line attached directly to the carburetor -- to supply fresh gas to the engine so we could start the car and evaluate the systems. It's important never to start a car that has bad gas in it or you could risk damaging the engine. After some general maintenance work, we reconditioned the fuel tank and some of the fuel lines, upgraded to gas shock absorbers, upgraded to a limited slip differential (figure B) and installed a new exhaust system with larger 2-1/4" pipes to allow for better air-flow and performance.

We then did some major upgrades to the top of the engine. we installed new aluminum cylinder heads (figure C) with stainless steel valves and more efficient ports. our new aluminum intake manifold is much lighter then the old cast iron one. we installed a high-performance 600 cfm 4-barrel carburetor (figure D). We topped it all off with shiny chrome valve covers and a chrome air cleaner (figure E).

the upgrades to our '62 thunderbird 390 v8 increased performance from the stock 300 horsepower rating up to about 350. With the engine in good working order, it was time to turn our attention to the exterior of the car.

Paint and body expert Kevin Tetz helped me color-sand and buff the exterior and we were able to restore the finish to a beautiful shine - saving thousands of dollars had we needed to repaint the car. then our restoration expert, Keller Wallace, buffed out some of the chrome and metal trim, and we also installed new trim including reconditioned front and rear bumpers (figure F).

The exterior work really made our thunderbird sports roadster pop -- and we turned an important corner in our restoration process.

We also made sure to replace any missing or damaged emblems and sports roadster trim (figure G) which will add great value to the car. when doing a restoration, it's important to remember that the little things are just as important as the major improvements.

Although the interior of our car was worn and dirty, it was structurally sound and we could simply clean and polish it. we also used carpet and vinyl dye to restore worn areas. then automotive upholsterer Lynn Goins helped us replace our old and battered convertible top canvas (figure H).

we brought the car into the 21st century when Johnny Ray from Custom Autosound ® helped us install a state-of-the-art sound system -- without having to remove the original radio.

Finally, we were able to locate the beautiful Kelsey Hayes wire wheels that our 1962 thunderbird was missing (figure I). The chrome spoke-wheels and new tires complete the sports roadster features and help make our restored car an eye-catching classic.

	Figure J

One final tip: We made certain to keep all of the working original parts that were removed from the car (figure J) -- such as the cylinder heads, intake manifold, carburetor and valve covers. Future owners want to restore this driver-level car back to original condition -- which is important for show quality restorations.

RESOURCES :

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.

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.

Edelbrock Performance Products
Website: www.edelbrock.com

Larry's Thunderbird and Mustang Parts
Fullerton, CA
Thunderbird and Mustang specialty parts. Suppliers for the convertible-top canvas-kit installed on our Thunderbird.
www.larrystbird.com

The Eastwood Company

The Eastwood Company is a supplier of automotive-restoration parts, tools and supplies.

The Easthill Group, Inc.
The Eastwood Company
Website: www.eastwoodco.com

The Coker Tire Company
www.coker.com
The Coker Tire Company is a supplier for radial and bias-ply tires for classic, show and specialty vehicles. They make specialized "restoration-correct" reproduction tires -- accurate reproductions of vintage tires that are no longer available through conventional sources.

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.

Motorbooks International
www.motorbooks.com
Motorbooks International is a enthusiast's source for automotive books and information. At their website, they carry more than 6,000 book titles, making them one the largest and most comprehensive auto-related bookstores online. Among the books they offer are many popular and hard-to-find automotive-related titles -- car manuals and books on auto history, auto restoration and repair.

Ford Motor Company
www.ford.com

T-Bird Sanctuary
Supplier of Thunderbird parts and supplies. www.tbirdsanctuary.com

Classic Car Restoration 300 Series also thanks:

Ford Motor Company
www.ford.com

Advance Auto Parts
www.advanceautoparts.com

Krause Publications
www.krause.com

3M Corporation
www.3m.com


Bend-Pak / Ranger Inc.
www.bendpak.com


G S Distributing Company
Knoxville, TN

GUESTS :

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

Keller Wallace
Keller Wallace Street Rods
Volunteer Street Rod Association
Knoxville, TN

Walter Vaughn, Steele Rubber Products
Steele Rubber Products
6180 Hwy 150 East
Denver NC, 28037
www.steelerubber.com

Rob Duddy
T-Birds.com

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.