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Old 13-09-2011, 12:32 PM
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Project Maddy - The return of the Madden

Hi all, first time posting and havent found the area that you introduce your self but I thought I would share a build that Im doing for a fella in Melbourne.

Were Matt & Sheri from Shermatt International in Florida. Some of you may know us but those that dont, just want to say Gday

Cheers

Matt

_________________________________



The Green Machine

This story takes place in a dark lit building in Florida where a 68 S code laid on its side suspended to a rotisserie for over 15-20 years
As some of you may know, I had a 1968 S code convertible sitting down at Sunstate mustangs workshop that I had intended on finishing off where the previous owner left it.

The car was bought out of Ft Lauderdale (restored) and driven across Florida to Sherm’s workshop where it was decided that it could have been restored a lot better. Next thing you know, it’s a bare shell and slung up on the spinner
After the owner had given up on the exercise, it sat there until now. I knew of the car and checked it out every time I attended the building but never pulled the trigger until about 4 years ago. It then sat there for another 2 years until it was pried from my hands from a fella from Melbourne. AKA Chopper
A very convincing young lad he was and the force was strong in him but was also a very realistic jedi ninja on what I wanted to see done with the car. At the time I was helping build another car on a budget and told him that I wasn’t prepared to see it built the same way and told him that if you want me to restore it, that it would have to be done my way and in my time (1 year) and the main thing that sealed the deal was to be patient. Delivery time landed in Oz was estimated of September 2010
A price was laid out itemizing what he would be getting and what he wouldn’t along with a $6000 balloon that “could” be tapped into as we all know there’s always something not taken into account. I allowed $3000 of my time that I knew in advance wouldn’t cover the hours involved but at the time, I didn’t mind as it was still my car and I wanted it built a certain way.
With the work schedule I had, the old girl laid up for another 2 months until one day, I finally had a window of opportunity where we could get cracking on it. The car was moved from the dark abyss of Shermans workshop over to Oldsmar Florida (Oldsmar is named after Oldsmobile as it was the testing grounds for R.E. Olds and his cars)


The car was carefully loaded onto another rotisserie where it was decided to get it blasted in house and remove the entire floor pan and replace with new. A cost not expected but very well necessary.







The previous restoration mob had done a job that this car would never twist or buckle. That was the problem. Every seem to every panel that should have been spot welded had been welded with almost 1cm of what I call “spaghetti weld”. It was everywhere. One it looked horrible but two….It just looked horrible. It made the 1st day on the job very daunting as it wasn’t expected (like all projects) My $3000 quoted for labour was slowly being hacked into. Went through $100 of grinding wheels to attempt to clean it all up and 3 days of doiking around

Then it was back to me where it sat for another few weeks while I tried to find the time to get cracking on it. That just never happened. I had to finish off the Fatkids 500 and get it out of the way. Secondly, I wanted to get it ready for the Turkey Rod run up in Daytona. By the way, a 427 wins hands down over a 428. What a machine that thing was. Once finished, I only owned it for 2 days. Sold to a lawyer in Orlando.

With the new floor pan all done and all the spaghetti weld taken out of it, we now had a car with good bones to work with. There are still a few spots that I wish we could of rectified but they were of no real major concern. Whoever built the car, had used angle iron under the seam to the torque box rail and bent it into shape. That was cut out and linished back but still retains a 4mm space of redundant steel.
The exterior of the car was in fantastic shape and just needed to be re-assembled and get all the panels re- aligned so we could test fit all the panels before it went to paint. Something I had planned to do myself but good ol Chopper threw a spanner into the works and said the Fatkids most hated word…”metallic”. He had decided to that it should be painted to what the Marti report said along with the door tag. Lime green…blahhh!!!
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  #2  
Old 13-09-2011, 04:41 PM
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Frank351 Frank351 is offline
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Hi Matt and Sheri.

Glad you found this forum. There are a few of the Mustangers here. A good bunch and very laid back.

Cheers,
Frank.
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  #3  
Old 13-09-2011, 04:49 PM
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Hey Matt & Sheri - I'm a customer of yours from last year (great car!). Nice build and welcome aboard
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Old 13-09-2011, 11:22 PM
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Quote:
Originally Posted by Frank351 View Post
Hi Matt and Sheri.

Glad you found this forum. There are a few of the Mustangers here. A good bunch and very laid back.

Cheers,
Frank.
Howdy Frank

Geez, your everywhere mate. Every forum I see...your on it!

I joined this one a few years back but lost my username and password and everynow and then, someone will post a link back to a thread on this site....think it was "moe" a cupla days ago.

Thought I would sign up again as its a pretty good site

---------- Post added at 11:16 PM ---------- Previous post was at 10:36 PM ----------

Quote:
Originally Posted by tezza101 View Post
Hey Matt & Sheri - I'm a customer of yours from last year (great car!). Nice build and welcome aboard
hey TS

I think I found a photo of you in front of your car on this site a few months back. Hope you dont mind but I stole the pic to change out the one on our website under the testimonials link.

Car looks awesome in the pics

Matt

---------- Post added at 11:22 PM ---------- Previous post was at 11:16 PM ----------

Part 2
We finally found some time to get the car all refitted and all the panels aligned ready for paint.






Now it was time to prep the under chassis and clean up the 9 inch and give it a quick service while it was out.











The entire boot are had seem sealer that was as thick as, so we decided to strip the entire area and clean it up so once painted, it looked as it does on the outside. What a task that was but well worth it. (2 days of prep)














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Quality Exporters of Classic Cars
Shipped Right, Done Right....WORLDWIDE
USA 0011-1-727 364 8707
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  #5  
Old 13-09-2011, 11:27 PM
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PART 3
The car was dropped to a fella that I knew years ago that actually helped me restore my first mustang when I moved here. He had opened up a shop 8 months back and as you know, I was looking for a decent painter. Something that I have found very hard to find. If there not asking drug dealer prices for their work, their all on drugs and do lousy work. He had called out of the blue one day and sort of fell in my lap.
Car was dropped down to him and I explained what I wanted as a finished product. Mr Madden had agreed to pay $500 towards the paint as I would have had to pay another painter $500 to shoot it as it was metallic but I payed the rest. Something that I offered to do. $3000 that I quoted for labour is almost depleted now.
The painter called me and says that he has done all the inside of the car and he was ready to prep and shoot the outside. Being a little hesitant after all my dealing with painters, I sent Sheri down to get me some pics of the car. She returned with these.



















---------- Post added at 11:27 PM ---------- Previous post was at 11:24 PM ----------

He went a little over board I thought but I suppose I did say “where ever you see red, I want Green” From the photos, I was quite happy to let him finish. He told me the whole thing would take 2-3 weeks and we were in week 2.
In the meantime, it was discussed to rebuild the engine and trans so Mike got started on that.












Before Mike started to re-assemble the engine I checked the engine over and noticed something inside the block that should have been clear and free. Inside the engine between 7 and 8 cylinders (up where the brake booster would sit and the hardest place to get to on these FE engines) there was something in there. After dinking around with it, I noticed that was a welsh plug/freeze plug…inside the block.

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USA 0011-1-727 364 8707
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  #6  
Old 13-09-2011, 11:28 PM
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Mike grabbed some pliers and pulled it out. There was still something in there. He dug around and found another welsh plug….but wait, yep…there’s another one. 3 welsh plugs in the block. Someone had odviosly tried to put new plugs in the engine while it was still in the car and was having a prick of a time doing it with everything in the way. Would have been great for water flow. With those pulled out Mike cleaned it all out and started the rebuild










He had some delemas along the way with the crank aswell as the rods were numbered all mismatched and one was bent. Few other problems with the build but all were overcome.
In the meantime, I had gone down to collect the car all finished (week 4). When I picked it up, I noticed a few things wrong with it and was very disappointed about all the over sparay all over what we had spent close to 3 weeks building. It was only when I got it back to the workshop in the shade that I found my worst nightmare. There was over spray over everything. Pin dents, swirls, no cover on the rocker panels or rear quarter lower parts….blah blah blah.
I was Pi55ed.
I went around the whole car with a water based POSKA and started to pick the pi55 out of the car. This is what I found. (pics where taken same day for John so you may not get the idea without a verbal description that I did as soon as it was morning in Oz) something that I didn’t really want to be the bearer of bad news.



















---------- Post added at 11:28 PM ---------- Previous post was at 11:28 PM ----------

Yes, you can say I was very disappointed. I took a chill pill and went home and slept on the problem before I arked up. Next day I rang him and came to the conclusion, that regardless….paint is everything.
I told him what I expected and what I was prepared to do. Even though its not my problem I offered to pay for “ALL” new materials for him to rectify the problems and get it done right. Yes, I ate that aswell. $3000 is now gone (and some)
Mike finally got the engine to a stage of 90% whilst I was sorting all this BS out.








Im sorry this is such a long post but I haven’t had a chance to post and upload all this coz Im just too busy but this is where we are at up until a month ago and I still have a little more story to go and most of the photos are on my camera. I have also done my back in so all I can do is stay home and stuff around on the computer so I figured I would get the 15 pages of photobucket and this story closer to where it actually is.
Actually, I might just dump em to photobucket now and finish it off now.
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Shipped Right, Done Right....WORLDWIDE
USA 0011-1-727 364 8707
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  #7  
Old 13-09-2011, 11:30 PM
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Part 4 Shermatt strikes back

With the Deathstar almost nearing completion, Evil lord madden was counting the days before he could unleash the fury onto Australian roads and fire off his deadly load causing greif and peril to all those that encountered the evil sith lord. (AKA chopper)

Car came back from paint after 7-8 weeks and we ready to strip the old girl down again. Still very pi55ed off about the whole situation but we had a few weeks to chill out about it. The 2nd time round came out a lot better but Im still not happy with it. Im having him sort the rest out in our workshop so I can over see it before he touches it again. The one car that I wanted looking awesome first time round is just biting me on the #### not to mention Im now having to pay Mike to work on the car for the next few weeks to get it finished. Sometime it hurts but its all worth it. Lord madden owes the fatkid a beers or 1000

Mike got cracking on stripping the entire under chassis down and all the suspension for a repaint. Needed that like a whole in the head as it took a total of 4 days. Only finished it yesterday (Mon the 28th 2011). Part of the respray was to also address 3 parts of the car that needed attention before it was assembled and none of it got done. Go figure. Thought while I was at it I would respray the engine bay again along with the entire under chassis, wheel wells and front inner fendor aprons.



















While we were inside stripping down the mustang, Shelby thought he would get cracking on stripping down a tree branch to get into the groove of things and maybe help out in his own way. That got Sheri motivated to start cleaning up some of the new interior and stripping down the seats ready for upholstery.



















---------- Post added at 11:30 PM ---------- Previous post was at 11:29 PM ----------

Mike started to spend the next days blasting everything ready for primer while Shelby decided to guard all the parts laid out. Shelby protected parts going in this unit. Sheri got stuck into sorting the doors and Mike took a breather to dink around while she was on her back LOL 























This is whats left of the 94 Lexus LS400 that we picked up for $600 for the Mercanstein project. Makes a great hanging rack for painting parts. Rest off the car is all cut up and donated to a friend that recycles steel. Im keeping the floorpan for the pick up points of where the old running gear was just incase I need some donar steel. Definitely want the transmission tunnel so were going to lay it up on the outside of the workshop until I have some spare time



---------- Post added at 11:30 PM ---------- Previous post was at 11:30 PM ----------

In between Mike rebuilding the heater box, he gave me a hand starting on the engine bay and suspension. Got it to a stage yesterday where the diff was all back in. Rebuilt the rear brakes and lines and had the Evil sith lords car on the ground where it will sit for 4 days so we can finish up another job being shipped on Friday. Having a dodgy back doesn’t help none either.











I did manage to get the entire interior sanded, primed and painted but ran out of charge in my camera so I am going to get some more snaps as soon as I fing the charging cable. But the best picture I can give John right now is these ones. Love finding the build sheets in a car for any of our clients. Im just as exited as they would be. Need to get some moisture next to it to soften the brittle paper but that’s something that takes a huge amount of time so I will get to that when I have 3-4 hours free.



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Shipped Right, Done Right....WORLDWIDE
USA 0011-1-727 364 8707
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  #8  
Old 13-09-2011, 11:33 PM
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PART 5
By request of Sheri, I was forced to stay home today so I decided to try and unfold the build sheet without breaking it. Ive done this before but it is very nerve racking and you need to be extremely patient when separating all the pages as there glued together and brittle. Not all of them are, I pulled one out of a 1 owner 67 fastback last week and it unfolded easy as. This one seems extremely brittle.

I boiled up some water in the microwave, laid down a Tea towel to absorb the condensation from the pan I was going to cover over the boiling water with the build sheet under there aswell. Left it for 4 hours, came back and managed to get one fold open but that was a little pain in the a55. But alteast now the outer pages are not as brittle.







I know its no biggy to some about finding your build sheet and having a pictorial about how to salvage one without breaking it, but Im stuck home all day laid up on the couch and wanted to do it anyway. I hope it may benefit some.

I boiled some more water and started the process again. I forgot to metion, you have to leave a gap at the base of the pan or you will soke your document and turn it soggy. The rest of the pics are taken through out the day. Leaving the sheet under the pan on each UNFOLD if that’s what you call it



















---------- Post added at 11:32 PM ---------- Previous post was at 11:31 PM ----------

Now if you cant read that, that must be something wrong with you….LOL 
I managed to save 99.9%. I partially lost a page number but nothing relevant to the specs on the car. Before I went to lay the sheet flat, I quickly hit it with some steam from an iron, let it sit for a few minutes then gave it one good burst of steam from the iron then applied some pressure from the iron to get all the wrinkles out. Came out a treat. Believe it not, the hardest part was putting it in the clear folder

---------- Post added at 11:32 PM ---------- Previous post was at 11:32 PM ----------

Part 6 “Walk of the Shebangie”
Been pretty busy since the last post so I haven’t had a chance to post any updates. We got the new brake booster and master cylinder painted up, ran all the fuel and brake lines, Mike repaired the engine bay loom and re-wrapped it. Got the dash all painted along with the doors. All the internals of the door where blasted and primed. Rebuilt the entire heater box balsting all the little bits that where steel.

















Got the brake booster and steering column blasted and fitted (had to repaint it twice as I scratched the bugger) Damn rag joint was a pain in the A55, was late on Friday and I had already opened the bag with all the rag joint bolts and the pie shaped washers from the old one so I zip locked them into a bag and taped them to the steering colomn…do you think I find them yesterday…tottaly forgot where I had put them…walked around for 3 hours looking for them….Sheri finally found them.









---------- Post added at 11:33 PM ---------- Previous post was at 11:32 PM ----------

Finally got the new electric motor fitted and ran all the lines. I had come in on a Sunday several months back and blasted the convertible top frame, primed it, then painted it a nice satin flat black. Was very happy with how it came up actually. There wasn’t any pitting in the frame anywhere. Came up really nice.



















Now for the final fitment of the convertible top.
Just for shi7s and giggles we through it on for a larf









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USA 0011-1-727 364 8707
www.shermatt.com

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  #9  
Old 13-09-2011, 11:34 PM
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Here is a quick tip if your fitting new front bar brackets that are those Taiwanese jobbies, you have to grind down the tips at the front where there rolled and the bumper fits too. I hope you can the difference in the photo below. Im pretty sure the one on the left I have already grinded down and rounded the edges.



Apart from that, this is where we are at today. A lot more blasting and painting. Get all the brakes bled today before the engine goes in incase of any leaks or what ever. Going to use DOT 5 silicone brake fluid. Kinda pricey but won’t eat your paint if there is a leak. Piant the handbrake components and get that all plumed up aswell. Really don’t want to have mess with anything once the engine goes in.

Will try and get some more pics today (when I can post them is a different story though but I will do my best)

Matt

---------- Post added at 11:34 PM ---------- Previous post was at 11:33 PM ----------

PART 7 – No days at the beach

Well thought it was time to update the build. Been extremely busy trying to get the old girl finished

We started on the brakes and stocked up on all the fluids we will need for re-assembly. Went with DOT 5 Silicone brake fluid so if there’s any leaks, it’s not going to harm any paint in the engine bay or anywhere else for that matter.











Made sure all the lines were tight before we got cranking and sure enough, one line was tight but leaking from the proportioning valve and there was a huge leak from the rear line> Always pays to get the brakes sorted before the engine goes in…especially a big block. Getting your hands down under the proportioning valve afterwards is a bitch

FRONT LEAK



REAR LEAK



Masked up the inside of the boot with tape along with the rear wheel wells ready for Rhino liner. While I was at it, thoughts it would be good to clean out the inner doors with a pressure washer and wire brush, mask up any holes and shoot that at the same time. Going from a restoration to overkill at this stage but it looks great. Nothing you will ever see once the door panels are on but John will know.













---------- Post added at 11:34 PM ---------- Previous post was at 11:34 PM ----------

Mike was still dinkin with the engine so I got crackin on the inside floor of the car. Fitting Dyna mat most of the rest of the day was kinda fun. This is as far as I got with the dyna mat.















We dug out the old speedo cable to get all the engine bay sorted so we could drop the 390 in but noticed that it was trashed on a spot where a clamp was compressed against it. Considering I don’t want to replace that after the engine is in, we opted for a brand new one. Why not?...everything else is new, why stop now.



Pulled down the old seats and decided to restore the seats rather than just re-upholster them. Bought some burlap the same colour as the interior just to be different. Its meant to be a brown colour. Sandblasted the seat frames and painted in red oxide primer. Blasting took for ever as they are so intricate with all the springs.







Got sucked in by Sheri as she knew I was going to be blasting…ended up doing a table while I was at it. Didn’t bother me, I just laid the parts on top of the table and by the time I got to the table it was pretty well done. Had a bash at his original grille as well







With the engine and trans all done I thought I would spend a couple of hours rebuilding the dash fascia. Originally we were going with the black camera case style dash but like builds, things change. John decided on the ally look which I kinda like. I don’t care about it not being year model correct with tiny stuff like this. It can always be changed easily enough if you’re a purist.

I did this a week before the table was blasted. You can see the table in the picture below.



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USA 0011-1-727 364 8707
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  #10  
Old 13-09-2011, 11:36 PM
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Few days later we had Sheri polish all the original window chrome ready for the next day as we had the glass guys coming to do a few other restorations front windows. Sheri is the master of chrome.









We had to do something about the finish on the paint as I was just devastated with its finish after the 2nd attempt. More orange peel than you could imagine. Tim spent 3 days on the car and now Im very happy with it. Still, very disappointing after waiting 8-10 weeks. While Tim chipped away at that, I pre-fit the dash pad before the glass went. So much easier when theres no glass in the way. I also fitted all the chrome trim tabs around the frame as it’s a pain in the X wifeto get em in after.









































And just when the old shelf gets down to a few boxes, we walked around to all the differtent sections of the shop (trim section, engine section and parts section) we gathered all Johns bits and put them all back on his shelf so we could see that we had everything prepared for the next phase. It basically filled the shelf again.



---------- Post added at 11:36 PM ---------- Previous post was at 11:35 PM ----------

The new magnum 500’s rolled up the other day with all new centre caps and wheel nuts (14 x 7’s). I took a day off to go for a ride on the 48 with Sheri and a few friends down to our favourite Sunday breakfast joint in Safety Harbour then went on a ride around Sunny Florida. Was good to have a break.





Came in on the Saturday, did a ½ a day of panel beating/metal finishing the ute. Blasted it and got the under chassis in primer, painted the engine bay and rhino lined the wheel wells. Painted the engine bay so I could see if there were any other dents that I need to tend too….buts another build thread I think.



Im sorry there’s so many photos and they take a while to load but I would rather spend a few hours loading them in one sitting than trying to do it daily.

Hope your all enjoying the build so far
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  #11  
Old 13-09-2011, 11:39 PM
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Hopefully you can guess what’s going on. Cars coming along extremely well.



























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Old 13-09-2011, 11:40 PM
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Old 13-09-2011, 11:40 PM
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USA 0011-1-727 364 8707
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Old 13-09-2011, 11:41 PM
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Small scratch that I put into it….need to fix that























































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USA 0011-1-727 364 8707
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Old 13-09-2011, 11:43 PM
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Mike spent pretty well all day under the dash. It got to a stage that everytime I heard the word F#@K, I had to go and take a photo. Some slipped by as I couldn’t stop what I was doing.

Near the end of the day, I put my phone in the picture with the time on it. All of those pics and times were major “dummie spits”.
















Shelby decided to eat an apple




---------- Post added at 11:43 PM ---------- Previous post was at 11:42 PM ----------

Just thought I would share this as Mike and myself were very proud of what we had achieved over the weekend. There was the annual freedomfest held here on Saturday and Sunday for bikes and cars (very big event).We entered Sheri’s 64 falcon and decided to enter the green machine under a “works in progress” entry. In all there was 5 unfinished cars/restorations that were also at the event…maybe more as we shot off for most of the day after hanging around for an hour.

We also entered my 48 Sunbeam in the open bikes under “vintage” section. There was close to 1000 bikes at the event and probably over 3 million dollars entered under the bike show alone

Sheri took 3rd place with her pink 64 falcon
Mike and myself took 1st place for the 68 green machine
And to finish the day off, I took 1st place for the 48 Sunbeam. Not just winning a very cool American eagle trophy, but interviewed by some TV bike show, and a photo shoot for next issue of …ummm…some biker mag ….and offered to have a huge feature in next month’s iron and lace magazine with some chick on the bike…spose that’s why they call it iron and lace

The whole day, I thought I had left the camera at the office and when we got home, found it under NPD catalogue LOL. Kinda pi55ed about that as there were some really nice cars at the car show and for those that like bikes, well…its America…everything was off tap or naked. We continued to celebrate throughout the night to all hours of the morning. Was very pleased to get John a trophy for his baby before its even finished and while it still here in the states. A little bit of history already for John to take back home when he’s over here in August

Congrats John



---------- Post added at 11:43 PM ---------- Previous post was at 11:43 PM ----------

A lot of the small fidly bits have been blasted/painted/rebuilt…basically all the stuff that sucks during re-assembly. All the windows are now in with all new mechanisms. Rear windows still being worked on. Under dash is pretty well complete. Electric top all operational.

And after staring at that 390 forever, its finally in without even 1 nick on the engine bay paint

Should have the drive shaft, trans lines, exhaust, radiator, hood, and power steering all fitted up

Have “mwizz” from the forum coming over on Sunday to have a look at his 68 X code coupe so he will see the car before John does. Would be good to hear it run by the end of the day but we’ll see how we go. I have promised John a video of that moment should it occur















































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