my 1971 351 Boss restoration
hi folks,

this is going to be a lot of work because i have a restoration thread of my 351B in german so i have to translate evrything in english. i'll be posting A LOT of pictures so i hope you're ok with that.

to my boss. this car was made for export to switzerland in 1970. according to my research around 9 cars were exported to CH but i haven't had the chance to contact kevin marti to be 100% sure. i know for a fact that this is the only one in austria.

-) 3,91:1 rear axle
-) staggered shocks
-) 351 cleveland 4 bolt high output engine 11,7:1 = 330PS
-) 4 gang toaploader
-) fold down group
-) rear defrost
-) center console
-) power steering

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p.s. this is how the car will look like when it's done:
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here a picture of my vert:
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here are a few impressions of the car when i bought it.

beautiful :-)
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deluxe interior
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the soda blasted bolt on parts
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a few pictures of the problem areas
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the front part is all solid!
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here we have a few images when i picked the car up from CH. since it was disassembled i had to stuff a lot of things into my VW bus.
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all the bolt on things were soda blasted and to tell you the truth I#ve never seen such perfect doors herein europe!

i started to disassemble the engine and was positvely surprised on which state it was in. the block was bored to 0.030 and everything was basically NEW. so all i had to do is reseal it and paint the engine :-).

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that's it for now. more to come.


i check the main bearings on the engine and as you can see everything is perfect. the crankshaft is in spotless condition. i guess i was very lucky.

even the engine mounts are ford NOS.

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on we go with the emminger invoice
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on we go with the restoration. my neighbor eddie is the one helping me with the welding work.

since this boss never had a radio the antenna hole has to go
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grinding the welding work down
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tinning paste
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heating it up
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applying the tinn
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let it cool off
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i don't know what this is called in english SORRY.
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closing a few little holes on the doors
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this is a puller in case you can't access the dent from the other side.
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you weld a spot onto the dent and then you pull it out.
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the rest is done with a hammer and tinn
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there were a few dents in the oil pan that had to be removed :-)

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on we go with a few more welding pichtures.
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here are a few pictures before and after.

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after the media blasting work
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hi guys,

here i have a few impressions while i was getting the engine ready..

i painted the engine with por15 engine enamel
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the soda blasted valve covers
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NOS oil pan seal :-D
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new timing chain
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almost done
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the original 4300D autolite carb
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original boss intake
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original ram air plenum painted
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more to come
i started closing up the engine and here are a few pictures.

timing chain is A-Ok so on goes the seal
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looking good
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on goes the intake
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getting the torque right 3/8 = 28-32 ft/lb
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i found the correct distributor for my boss engine. cost a fortune though.

NOS base plate
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more to come
we moved on to the door etc. all bare metal parts were epoxy primed

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after the primer was dry
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here a few close ups of the 4300D carb and of the "almost" finished engine:

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more to come
hallo folks,

the original crankshaft wasn't in the engine but i was told that the 4MA cranks are the same.
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one we go with the pre lubrication of the engine :-)

oil pan bolted onto the engine block
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out goes the distributor and in goes the bit that drives the oil pump
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counter clock wise and away we went as long as the battery lasted
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distributor back into the engine and we were ready for the fire up
here i have a few close ups of the distibutor

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as you can see i am using the pertronix ignition solution. i've been doing that with all my mustangs and never had any trouble.
as you can see not much rust is in this boss.
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this area was a little rusty bit nothing really serious.
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the seats are in great condition which means they don't need to be recovered
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the P/O gave me 4 door panels, so luckily i was able to refabricate 2 good ones out of the 4.
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lots of parts that i still have to go thru
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took the rear window out only to find "almost" no rust :-)
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the headliner will be replaced
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here's how i restored the 2 door panels.

the 73er deluxe panel
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the old beat up ones
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before cleaning
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after a good wash
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after cleaning the carpet area
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new glue
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original molding after using never dull :-)
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the original handel
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the original cup moldings
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put in the wood applications and carefully bend the catches back...try not to break them
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i used vaseline to preserve the panels. vaseline make the plastic softer.
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here are a few pictures of the rear seat. as you can see the rear seat was used from 69-73
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here the seat tag from 1970
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my boss was built in 24 november 1970

yes LOTs of work!!

while disassembling the car i was amazed how good this car was. i took a lot of pictures not only to know where what goes but also to show how assembly was done back then...rather fast and sloppy.

here are a few impressions

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kick panel area driver side
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behind the dash...
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behind the steering wheel
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vent area driver side....not even surface rust
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here without the box
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original as if it came off the assembly line yesterday
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all original stamping
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rust area
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i moved on by removing the toploader, fuel tank, headliner, chrome molding, brake lines, fuel line, shock absorbers and so on. none of the bolts ore screws broke or were damaged. i was so amazed how good this 71 mustang was! a few rust problems did show up but nothing really serious. the rear panel and the wheel moldings needed some attention, but that was about it.

rust problem: the wheel area
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the original rear bumper
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brakes A-OK
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the toploader...only thing missing was the tag...found that thru the german forum :-)
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here's a picture of the torque box
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the front suspension area
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a few more pictures of the under carriage
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the rear axle that was on the car wasn't the original 3,91:1 axle but i found the original in switzerland
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these are the parts that need to be restored
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New rear panel
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a few more pictures of the interior
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this is really alot of work!!

rust issues:
both rear wheel houses and the rear panel...that it :-)

here a few more impressions of the disassembled boss.

getting the right color for the under carriage
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chocolate brown
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out goes the front suspension
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i've never seen this before on any of my mustangs. this spring was hooked onto the floor and was used to keep the parking brke cable straight. :-)
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this is the 3L25 (3,25:1) rear axle. the original 3L91 (3,91:1) is in stock now :-)
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untouched under carriage. never welded or molested :-)
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federal law in switzerland states that the entire VIN number hat to be visible within the engine bay.
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the swiss vin was located right next to the original ford VIN number under the right fender
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the naked boss
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I've been working on the boss for around 1 year now and the stuff i posted was the work of 2 there's more to come.

stay tuned
i work on my project using the chaos theory.
up next were smaller repairs because the weather was too cold to work in the garage.

the original collapsible tire repainted
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the drive shaft repainted...the correct marking are to fellow
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dash before
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sanded down
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repainted in matt black
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since the weather was so cold i started on smaller things that i could take home.

here's a step by step thread on how to overhaul a power steering pump

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reassembled and back on the engine
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a friend and i put the boss on a moveable rack

we used an engine crane to lift the rear of the car
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using a 4x4 works fine :-) as you can see
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coo huh
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the boss on mini wheels :-D
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my original flywheel was missing so i called up perogie and randy had one on his shelf :-)

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up next is the recovering of the fold down elements
it took me around 4 hours with a few beer breaks :-)

new carpets, the refurbished chrome molding and the painted fold down parts
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glue and the electric screw driver
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double sided tape works pretty good too
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i'm always looking for 71-73 parts.
as a matter of fact, i have a 75 dipstick in my boss and i'd love to have a 71 number in it. i mean it works perfectly fine but i'm trying to staying as original as possible.

up next were smaller parts like the hinges and latches. they were media blasted and painted in iron cast...that's a little darker than the original.

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the collapsible tire is nothing really new for you guys in the US, but here in austria NO ONE knows this. here i'm posting a few pictures of the tire inflation...had to know if it works or not.

without air
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half full here you can see how the tire wanders up :-)
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fully inflated
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didn't forget the warning decal
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last but not least the inflator
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it's always the little things that waist your time. well here's a perfect example:

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the hinge springs for the ram air hood were "square" :-)
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painted wiper arms and speaker grill
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this could be interesting for some. i wanted to keep the original gas tank and since it was busted anyway eddie and i tried saving it.

but before we started that i finished the dash

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after paint
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with gauges and clusters
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now to the fuel tank: DON'T try this if you haven't done this before. the fumes in the tank can blow up in your face!!

we welded big nails onto the dent and then pulled it out.
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after...looks like new :-)
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lets carry on with the rear axle
after the axle was media blasted i painted it with POR15
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out goes the old fishy smelling oil
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i painted the diff in primer red
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seal area nice and clean
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sealer before the paper seal goes on
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felpro seal
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that diff is soo heavy!
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new bearing seals
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i knocked them in with a big nut
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the new oil. if you have a locked axle don't forget the additive!!!
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reassembly of the rear brakes
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all new springs
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new SS brake lines and parking brake cable
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last but not least the original tag
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up next will be the welding work


before starting up with the actual welding work on the wheel housing we took out the front window.

we fiddled a wire between the fame and the window and cut it out by moving the wire back and forth
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simply push the window forward and out goes the windschield
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easy does it
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up next was the center console. it's amazing how many parts you have to refurbish when you restore a car.
center console before:
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clock before
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cleaned and lubed
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reassembly of the center console

new paint job
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after that i put the boss balancer back onto the engine
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rebuilt the air cleaner

original filter
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ready for the engine....
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finding that heat shield and heater riser tube was really hard.
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up next was the toploader

hurst shifter beautiful
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just hat to clean the linkage
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the hurt shifter handle
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the top loader before
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more to come soon
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now to the top loader

cleaning took around 4 hours what a pain in the ass
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original seal kit
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the tail housing had a leak and this is why
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grinding the bad welding work down
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this is liquid metal that is heat and pressure resistant
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from the outside
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and inside
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let it dry for 30 minutes
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and on goes the sanding
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almost done
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and painted in iron cast
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the bell housing should have been blue i know. i liked it better in cast iron
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no i didn't forget that :-)
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the 40 year old paper seal :-)
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this seal was rock hard
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in goes the new one
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the front paper seal with silicone
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back in place
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tail housing
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new paper seal with silicone to be on the safe side
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tail housing with the new real seal
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one last look into the tranny
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before paint
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with hurst shifter "bone" and the dust boot. btw you can use the dust boot from the 70 top loaders as well
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the boss linkage is gold from what i have researched :-)
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pre lubed gears
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detailing the engine
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i hope that's enough for now :-D
let the welding begin

i'll let the pictures speak for themselves

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this is the most tedious work i can image
[Image: 3acC0.jpg]

it's a dirty job but someone's got to do it
[Image: MdNR9.jpg]

[Image: iNvJi.jpg]

[Image: iFeQ9.jpg]

[Image: MdVkA.jpg]

bye bye rust :-)
[Image: iNAIA.jpg]

as you can see we had some fun too :-)
[Image: iNKH9.jpg]

let the tinning begin
[Image: iNNbi.jpg]

[Image: 3ak5r.jpg]

tinning ingredients
[Image: Me1P0.jpg]

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looks good huh
[Image: MeqLr.jpg]

et voilà ....
[Image: MevKJ.jpg]

here are a few more pictures of the welding and tinning work.

before tinning
[Image: NZl10.jpg]

[Image: kr_gi.jpg]

[Image: NZu_A.jpg]

[Image: kpI0J.jpg]

don't be greedy with the tin
[Image: ksocJ.jpg]

[Image: ksvH9.jpg]

[Image: ksybi.jpg]

the side panel tinning
[Image: kqaXr.jpg]

[Image: NZYWi.jpg]

[Image: 4SxKi.jpg]

sanding with 80 paper
[Image: N_2VA.jpg]

[Image: 4SCJA.jpg]

now the car can go and get sand blasted
[Image: ksPEi.jpg]

more pics to come

WOW!! Now thats what I call a post!! SSig_Kewlpics Goodpost Winner
Thanks for all the detailed pictures. Looks like your doing a great job. Bow I like the picture of you peeping through the side marker light hole.
thnaks for the feedback guys.

after the welding work was done it was time to remove the rest of the remaining paint.

packed and ready to go
[Image: noJPi.jpg]

[Image: AWm29.jpg]

[Image: noRiJ.jpg]

[Image: noWi0.jpg]

while the boss was away i got a few tags from marti :-)

[Image: Olv1A.jpg]

[Image: 6mniS.jpg]

the buck tag
[Image: 6mpO0.jpg]

the 351 BOSS engine tag
[Image: OlCw0.jpg]

the owner card
[Image: OlHvi.jpg]

hi folks,

here are a few pictures of the boss after media blasting and 2K epoxy primer.

[Image: 5c7QJ.jpg]

epoxy inside and out
[Image: r5v2i.jpg]

[Image: 5ccQ0.jpg]

the under carriage was painted in (RAL8007)
which was the closest color i found that was hidden under the fuel tank.
[Image: 5cakS.jpg]

[Image: 5cfk9.jpg]

[Image: r5q30.jpg]

[Image: r5sy9.jpg]

[Image: r5xxr.jpg]

[Image: 5c5lA.jpg]

extensions fit SUPER
[Image: 5cYdJ.jpg]

mocked up the fenders real fast
[Image: 5c_IS.jpg]

[Image: 5d2d0.jpg]

more to come soon

after i got the car back from the media shop i had to put it back on it's "feet" suspension.

painted the engine bay in matt black
[Image: EuLY0.jpg]

upper arms
[Image: EuOs9.jpg]

[Image: EuQXi.jpg]

brake and fuel lines back on
[Image: EuTrr.jpg]

wiper motor and linkage
[Image: EuVWA.jpg]

i use mike sanders wax to preserve the cavities as well as the bolts
[Image: 2enj0.jpg]

[Image: 2epO9.jpg]

the canister back in place
[Image: 2esii.jpg]

steering back in place
[Image: 2euNr.jpg]

brake lines passenger side
[Image: 2exhA.jpg]

had to lift the rear with the engine crane
[Image: bNCA0.jpg]

bringing the leaf springs in place
[Image: bNF49.jpg]

[Image: bNHzi.jpg]

lifting the leaf springs and the rear axle back in place was tough.
installed the new staggered shocks
[Image: bNK3r.jpg]

the shock absorbers and the fuel tank
[Image: bNMyA.jpg]

spindles finally back on the car
[Image: bNU20.jpg]

linkage bolted together with the spindles
[Image: bNWx9.jpg]

the rear mini sway bar :-)
[Image: bNZ1i.jpg]

the bigger front sway bar :-D
[Image: bO0wr.jpg]

engine bay on the 2.may.2010
[Image: bO30A.jpg]

the fire wall area
[Image: jqgLi.jpg]

brake booster and master cylinder back on the boss
[Image: jqlKA.jpg]

this is our self made engine stand
[Image: vjwh9.jpg]

up goes the boss engine and onto the test stand
[Image: UeXti.jpg]

the engine and the radiator ready to get fired up
[Image: jqydi.jpg]

BOSS flywheel & FMX housing of a 351W to bolt on the starter.
[Image: vjIKS.jpg]

the engine fired up at the first turn over. and smokey it was
[Image: vk9br.jpg]

rumble in the jungle...
[Image: jqNb9.jpg]

oil pressure after 20 minutes
[Image: vkS50.jpg]

temperature after 20 min. 170F
[Image: UfiVA.jpg]

not a drop of oil or water was under the engine. i was very happy about that :-)
[Image: Ufqp0.jpg]

here's the initial fire up of the boss engine

what more is there to say....very happy

hi guys,

here's a quick update on the boss progress. the following parts were put back onto the car:
-) Speedometer cable
-) engine bay harness
-) horns
-) starter relay
-) voltage regulator
-) windshield washer bottle
-) seals in the engine bay
-) pedals and heater box
-) fire wall seal
-) floor panel plugs
-) headliner
-) interior lights
-) battery tray

prepared all seals with mike sanders wax
[Image: oGql9.jpg]

hood to cowl seal
[Image: oGvkr.jpg]

Original REV limiter, NOS voltage regulator, NOS starter relay, NOS junction block
[Image: oGxPA.jpg]

engine bay harness
[Image: 9twii.jpg]

washer bottle
[Image: 9tyNr.jpg]

[Image: 9tBhA.jpg]

[Image: 9tDMJ.jpg]

[Image: 9tGgS.jpg]

[Image: AG7ri.jpg]

boss engine fire no. 2


it was time to put the boss back on his feet.

self made coil spring compressor :-)
[Image: xLHp0.jpg]

wax to avoid the nasty noises
[Image: xLJU9.jpg]

[Image: xLMoi.jpg]

in it goes
[Image: xLOTr.jpg]

done after 20 min of hard work
[Image: xLRnA.jpg]

i'm using the whites KYBs. i kept the original swiss konis that were on the car when i bought it.
[Image: eqWDS.jpg]

[Image: eqZ80.jpg]

[Image: er0D9.jpg]

[Image: er37i.jpg]

[Image: er5Cr.jpg]

one more test run of the engine.

up next is the sanding of the car....i hate this part :-(

here are a few more pictures of the exhaust system

[Image: SIPGJ.jpg]

[Image: SISaS.jpg]

[Image: SIUG0.jpg]

the boss is starting to look like a car now. fenders are back on now :-)

[Image: ztnmi.jpg]

[Image: ztpRr.jpg]

hi folks,

this is the part that i hate most when restoring a car. the BLOCK SANDING!!

all parts aligned
[Image: PJIHi.jpg]

[Image: PJGc9.jpg]

stage 1 of the trunk
[Image: PJLbr.jpg]

the engine with mufflers
[Image: PJNGA.jpg]

[Image: PJQaJ.jpg]

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my friend roland putting on the primer
[Image: l7cPi.jpg]

we primed the entire car to be on the safe side.
[Image: l7fjr.jpg]

looking good to finally have one color on the car
[Image: l7hOA.jpg]

ready for transport to the paint shop.
[Image: l7kiJ.jpg]

after wrapping and loading up the the boss we were finally on our way to the paint shop.

06:00 my garage
06:26 loaded and ready to go
[Image: CmbUr.jpg]

[Image: CmeoA.jpg]

[Image: CmjnS.jpg]

07:01 take off to styria
08:12 coffee break
[Image: CmlT0.jpg]

09:08 checking the cover
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10:28 arrival in styria
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[Image: CmvRA.jpg]

[Image: CmylJ.jpg]

[Image: CmAQS.jpg]

[Image: CmDl0.jpg]

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the car is at the paint shop since august 2010. here are a few pictures of the progress.

the hood scoops
[Image: tApfr.jpg]

[Image: tAEdi.jpg]

[Image: tAGIr.jpg]

[Image: tAJcA.jpg]

die hinteren gußecken
[Image: tAQH0.jpg]

[Image: tATb9.jpg]

front and rear valance
[Image: SWEm0.jpg]

[Image: SWGR9.jpg]

[Image: SWJli.jpg]

more to come later :-)

the most important part in doing the paint job is to take your time. you've got to let everything dry properly.
a good paint job takes around 4 - 8 months. my painter has the car now 5 months and the progress is slow but the final product is amazing.

[Image: ZSojS.jpg]

[Image: ZSqP0.jpg]

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the black hood turned out amazingly good
[Image: g1AW0.jpg]

hi people,

while the car was at the paint shop we reunited the engine and the top loader.

before on the home made engine tester
[Image: qED4S.jpg]

mufflers off
[Image: qEN3r.jpg]

[Image: qEPyA.jpg]

carefully taking off the original carburetor
[Image: qES2J.jpg]

[Image: qEUxS.jpg]

the 2nd stage of the intake always blows me away :-D
[Image: qEX20.jpg]

lifter plate
[Image: qFpYJ.jpg]

off goes the h-pipe
[Image: qFssS.jpg]

draining the water
[Image: qFuY0.jpg]

now where did i put the engine crane
[Image: qFxs9.jpg]

the farmer who owns the place where i have the garage has a pretty big lifter :-)
[Image: qFzXi.jpg]

up! this thing lifts around 10 tons
[Image: qFRpi.jpg]

a different angle
[Image: qFWoA.jpg]

cleaning the flywheel
[Image: qFYTJ.jpg]

[Image: qG0nS.jpg]

new bushing clutch pilot
[Image: qG2T0.jpg]

[Image: 1oSqr.jpg]

[Image: 1oUVA.jpg]

[Image: 1oXpJ.jpg]

[Image: 1oZUS.jpg]

[Image: 1p1p0.jpg]

don't know the english word for this stuff. it secures the bolts.
[Image: 1pHOr.jpg]

centerforce in place. i still have the original one though.
[Image: 1pKiA.jpg]

[Image: 1pMNJ.jpg]

it took us a while to get the fork in place
[Image: 1pPhS.jpg]

fork seal...wrong way around now that i think of it
[Image: 1pRN0.jpg]

back together again
[Image: 1r7BA.jpg]

finally engine and top loader reunited
[Image: 1ra5J.jpg]

now all i need this the car
[Image: 1rcAS.jpg]

now you guys are pretty much up to date. it took me long enough. this is the fun part. putting everything back together again :-)

[Image: 59BI0.jpg]

[Image: 59Ec9.jpg]

[Image: 59GHi.jpg]

[Image: 59Jbr.jpg]

[Image: 59LGA.jpg]

[Image: 59OaJ.jpg]

[Image: 59QFS.jpg]

[Image: d2zy9.jpg]

[Image: d2C2i.jpg]

patrick, my painter, sent me a few more pictures of the fenders. he decided to sand everything back down again since he wasn't too happy about the priming stuff we did. all that work for nothing.

[Image: mustang_205.jpg]

[Image: mustang_207.jpg]

[Image: mustang_208.jpg]

[Image: mustang_210.jpg]

[Image: mustang_211.jpg]

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[Image: mustang_299.jpg]

[Image: mustang_300.jpg]

[Image: mustang_301.jpg]

[Image: mustang_302.jpg]

[Image: mustang_303.jpg]

enjoy :-)

[Image: P1050065.jpg]

[Image: P1050066.jpg]

[Image: P1050068.jpg]

[Image: P1050072.jpg]

[Image: P1050073.jpg]

[Image: P1050076.jpg]

[Image: P1050077.jpg]

[Image: P1050078.jpg]

that was it. from now on it's real time :-)

best regards
hi folks,

i wanted to update you guys on the boss restoration. so far all parts except the body are done. the body is masked and ready for the first coat of filler. this will take another month or so and then HOPEFULLY i'll finall yhave some color on the body. can't wait!!

as you can see my painter even masked the undercarriage. there is still a lot of work that needs to be done but i hope to be done by the end of this year.


[Image: mustang_709.jpg]

[Image: mustang_710.jpg]

[Image: mustang_711.jpg]

[Image: mustang_712.jpg]

[Image: mustang_713.jpg]

[Image: mustang_714.jpg]

[Image: mustang_715.jpg]

[Image: mustang_716.jpg]

[Image: mustang_717.jpg]
Sweet work
Very impressive.I like what im seeing
Thanks Abudi,

That's what we need - I would call that documentation!
(06-10-2011, 11:42 AM)Steven Harris Wrote: Thanks Abudi,

That's what we need - I would call that documentation!

thanks for the positive feedback :-)

best regards from vienna
(06-10-2011, 11:42 AM)Steven Harris Wrote: Thanks Abudi,

That's what we need - I would call that documentation!

hi folks,

finally there is a little progress. the car last bit of the car is finally sanded down. the first coat of epoxy filler is on the car and should be done drying up in around a week. all in all i am hoping to get the 351B back by the end of august.

as usual the picture of the progress:

[Image: mustang_1511.jpg]

[Image: mustang_1520.jpg]

[Image: mustang_1524.jpg]

[Image: mustang_1525.jpg]

[Image: mustang_1526.jpg]

[Image: mustang_1527.jpg]

[Image: mustang_1528.jpg]

[Image: mustang_1530.jpg]

[Image: P1060528.jpg]

[Image: P1060529.jpg]

[Image: P1060532.jpg]

[Image: P1060534.jpg]

[Image: P1060536.jpg]

hi guys,

i got a few pictures from the paint shop that i'd like to share with you guys.

first coat of polyester filler
[Image: mustang_1541.jpg]

[Image: mustang_1544.jpg]

[Image: mustang_1547.jpg]

[Image: mustang_1548.jpg]

[Image: mustang_1554.jpg]

[Image: mustang_1556.jpg]

[Image: mustang_1557.jpg]

[Image: mustang_1558.jpg]

[Image: mustang_1559.jpg]

[Image: mustang_1560.jpg]

[Image: mustang_1561.jpg]

after everything was sanded down and degreased ... on went the second layer of polyester filler
[Image: mustang_1562.jpg]

2 coat
[Image: mustang_1563.jpg]

[Image: mustang_1564.jpg]

[Image: mustang_1565.jpg]

[Image: mustang_1573.jpg]

[Image: mustang_1572.jpg]

[Image: mustang_1571.jpg]

[Image: mustang_1570.jpg]

[Image: mustang_1569.jpg]

[Image: mustang_1568.jpg]

[Image: mustang_1567.jpg]

after the second layer is carefully block sanded the fine filler goes on the car. all in all, we might go into the booth in around a week. pls keep your fingers crossed that all goes well.

It looks like your making great progress! Keep the pictures and progress reports coming! Sign0175

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