In my last post (two weeks ago, sorry about that) I’d started out replacing the front suspension ,and ended up stripping the front end completely off. The new plan was to check over, derust & repaint all the inner structure, while leaving the exterior looking just as ratty as before. I’m sure some of you are wondering why I don’t just paint over all the worn out paint & surface rust, but I both rather like the patina on the car, and would prefer consistently ratty to a mismatch of ratty & repainted.

First up was assessing what I found. And I was surprised to find just how good everything was. There was surface rust in several places, like the edges of the cowl, the torque boxes, the bottoms of the fenders & inner fenders & under the battery tray. However there was absolutely zero rot anywhere. Not one rot hole to be found. When I pulled apart the “better” of the two ’62 Comets I had, it had been a very different story.

This was all the more surprising considering the piles of pine needles & mulch hidden at the bottom of both fenders and packed into the cowl drains. I can only guess that that stuff dated from the last few years(and in particular the eight months the car sat in the woods before I bought it), rather than the previous decades it sat in a barn. So the moist plant matter didn’t have time to really encourage rot.

The next step (after I spent 45 minutes with a pressure washer removing a garden’s worth of plant debris from inside the cowl) Was to start grinding down all of the rust in preparation for paint. It may not look it in shots like this, but every spot of rust has been diligently gone over with a wire wheel and/or angle grinder. Ford used a rust-colored primer though, so exposing that ended up making the car look more rusty, not less.

I also ground off what I initially though was a layer of undercoating, but eventually realized was actually a sort of clay-heavy dirt that was caked onto every surface of the wheelwell and had been there so long it had taken on the appearance of being part of the original car. I eventually was able to get everything looking as shiny new as I could, and was able to start putting paint on, instead of grinding it off.

Lets hear it for Masterseries paint, This is my absolute favorite rust-sealing paint, and I’ve been through at least 3-4 quarts so far on various projects (and have two more I just bought sitting in the garage for later on this car). I put a nice thorough coat onto everywhere I’d found rust, making sure to get it into and gaps or cracks where rust might fester. As much as I wanted to just coat everything, I had to prioritize as I was low at the time and didn’t have time to wait for more to be delivered. So stuff ended up looking a bit odd, with seemingly random silver painted bits over the worn old paint. And, of course, because the universe likes to mess with me, it started to drizzle the moment I was done paints, necessitating an emergency solution.

Next up, painting and more painting.