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Classic Mustangs Tech Forum

Technical discussions specific to 1964-1967, 1968-1970, and 1971-1973 Classic Mustang. Discuss all tech related to in-line six cylinder and V8 powered Vintage Mustangs here.

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Unread 03-28-2010   #1 (permalink)
gbellca is offline Rookie


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Default 1966 Mustang Door rebuild

The driver side door on my 66 convertible was hit and I want to replace the door panel. In addition the door doesn't lock anymore so I'm think it may be good to go in and replace the parts inside the door as well. Is there a good manual or instructions out there to describe the process. I have the shop manual but looking to see if there is anything else to use along with that.

Thanks.
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Unread 03-28-2010   #2 (permalink)
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So, how bad was the door before you got hit?

And how bad is the damage?

The driver's door takes so much abuse. Mine was hit as well and repaired by the original owner, and I spent a lot of time dragging the door, kicking and screaming, back to life. If I had the money at the time, I would have bought a new door shell and been done with it already!

My door had cracks around the three screw holes for the latch mechanism, as well as cracks by the hinges, all of which needed repair. My door would not close very well, open very well, or lock very well. I pulled the latch mechanism out, gave it a good soak in paint thinner, and went after it with a toothbrush to really clean it up. Then I replaced all the little fittings on it for the control rods, bought that screw kit with the washers to reinstall, and greased the whole thing up before reinstalling. Now, it works like a charm. I am willing to bet your original mechanism is just dirty and/or out of alignment (due to the screw holes cracking) I also bought new door hinges. You can rebuild the hinges with new pins, and I just didn't think I could do it right so I bought new ones. As it turns out, I did hinge pins on my '90 Mustang and it was pretty straightforward and not as hard as I thought.

As for reskinning the door, I haven't done this, but it looks like a PITA. The pain part would be trying to get the look right in the door jamb, IMO. But I haven't tried it. If the door has been bashed in, it might have "tweaked" the rest of the door, pulled in the corners and what not, and you would need to straighten it out a bit, adding to the headache. I love Mustangs, but I wonder if Ford expected these cars to last longer than a few years? I heard 7 years was the lifespan, and the crappy, flimsy doors is good proof of that theory. Doors that fall apart, yet a drivetrain built to last. Go figure. But I digress.....

Can you post some pics?
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1990 GT 25th Anniversary 5.0 AOD Convertible. SOLD
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Unread 03-28-2010   #3 (permalink)
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Hey gbellca. :smilie Welcome back!

You say your driver's door got hit and you want to replace the door panel. I'm kind of confused on what you mean by door panel. Please explain or better yet, post a picture if possible.

You also say your door doesn't lock anymore. Do you mean you can't lock it with a key or it won't lock when you push the door button down? Or it won't latch properly because of the accident damage.

In any case, post back and let us know. I'm sure we can fill in the vague spots in the shop manual for you.
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Unread 03-28-2010   #4 (permalink)
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We installed a new skin on our 66 drivers door. I would rate it a 5 on a 1-10 scale. It took about 6 hours to remove the door, remove the skin, remove the vent window, grease the window mechanism, install the skin, mig weld the skin tot he frame and reinstall the vent assembly.
Helpful tips:
Measure the distance from the top "point" on the vent window to the back of the door by the handle. This will make it much easier to install and adjust the vent window
Install a new window felts BEFORE you install skin. It is much easier

Here are pictures from when we did the skin:
New Door Skin

Good Luck and BE Safe
Ron
Christophers 66 Mustang Restoration and Modification
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289 4v, Roller Rockers, Electric fan
Performer & 650 Edelbrock
MSD ignition, Crane Cam
Tri Y into 2.25 Shelby side exhaust
T5 conversion, Hydraulic Clutch and 3.55 Trac Lok
CSRP SN95 Discs
<=== CLICK on the "house" to visit my 66 website!
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Unread 03-28-2010   #5 (permalink)
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Here is a free online Ford Factory Shop Manual that may give you more information

api_user_11797_Edze's Documents | Scribd

Good Luck and BE Safe
Ron
Christophers 66 Mustang Restoration and Modification
__________________
A code 66 coupe, Father~Son Restoration
289 4v, Roller Rockers, Electric fan
Performer & 650 Edelbrock
MSD ignition, Crane Cam
Tri Y into 2.25 Shelby side exhaust
T5 conversion, Hydraulic Clutch and 3.55 Trac Lok
CSRP SN95 Discs
<=== CLICK on the "house" to visit my 66 website!
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