Merch's Cyber Garage

Reassembly

The photo to the right shows a "rag" joint coupler for a 605 power steering box. If you don't use a "rag" joint the box will hiss so badly you can't stand it. Also, the 605 box is much larger than the original standard steering box, so you need to shorten the original steering rod. The photo shows the modifications you have to make to the shortened rod so it will marry up with the rag joint. It needs to be ground down to provide a flattened surface and a hole drilled for the pin that holds it in place. A relatively quick project that requires a bench grinder and drill.	I really need to take a shot of the old steering box alongside the new 605 box. The 605 box dwarfs the original!
.....OK, a quick reality check. Project '57 is a modified car not an original restoration. We are installing a modern wiper system, power steering, and power brakes. I believe these changes are all important for a safe vehicle that will be operated at highway speeds.  Unfortunately, all these changes require other changes.  For example, my old headers will not fit alongside the big 605 box.  So, I needed  new/different headers. Different headers will not work with the front pipes on my old exhaust system. So, I needed a new exhaust system. The brackets for the power steering pump will not work with my old side-mount motor mounts. So, I needed new side motor mounts.  Although none of the needed changes are too difficult, unplanned mods can become a source of aggravation, project delays, and increased costs. OK, you were warned!
Ready for gas...	The photo on the left shows the "repop" gas tank, painted with an original "tank tone" paint from Eastwood. The straps that hold the tank in place under the trunk have been cleaned and painted a gloss black. I used new bolts, a new sending unit, new filter, and orginal style clutch head screws to hold the sending unit in place. I blasted the original filler tubes and painted them the same "tank-tone" color. The original rubber was all replaced as well. I even picked up a "repop" stainless strap that holds the vent tube in place - just like the original. I had cleaned up the original filler box and repainted it a flat black. I also polished the door stainless and used new rubber bumpers. The finished project looks great.
Note the size difference between the brake master cylinders.  The small original master cylinder was used with standard drum brakes all around. The new master cylinder is much larger. It uses a vaccuum line from the engine and provides a power boost to operate the disk brakes up front and drums in the rear.  (Note the proportioning valve that regulates pressure between the front disks and rear drums.)	The next step requires bending new brake lines... ...yikes!
Installation was rather simple and required drilling a new hole in the brake pedal arm, one inch lower than the existing hole, to support the new push rod.
Work continues on Project '57.  Our immediate goals are to get the glass and engine/trans installed so we can move this summer.  The wiring, interior, and stainless will have to wait for now. ...Say, did you notice the background image on this page?  It is a shot of the rear of Project '57 during installation.  You can see the rear emblem has been installed but not the bumper, trunk lock/key, and rear area stainless.  Wild, eh?... (I was playing with the software again!)