There's a fuzzy line in the sand when it comes to reviving a vintage vehicle. On one side, you replace shocks, suspension bushings, freshen up the engine, maybe an exhaust upgrade, a new carpet set after a paint job, a cool set of hoops and skins and you're stylin'. Not a thing in the world wrong with that route, but if you've crossed over into obsessive-compulsive land, like Editor Ford did long ago, you're probably going to skip the middle ground and D.I.Y or have a resto-shop totally disassemble and refurbish every component of your baby. Such is the case with the '66 Ranchero that landed on my doorstep a few weeks ago. This car will definitely be a driver in every sense of the word, but we're going ballistic and doing a number on it for a slick "form meets function" attitude. Instead of a mirror-shiny belly, we're using a factory-style, semigloss black urethane over a near bullet-proof coat of stoneguard that sits on a fat layer of black epoxy. It'll be durable and look great from every angle. My favorite philosophy when doing a car is "no excuses," regardless of its intended use.
That's why media blasting the stripped body was an easy decision to make. If you're sitting on the fence about going to the bone on your project, check out the final results of our coal-blasted floors. Even though the 'Chero is cherry, the result of blasting both sides of what we thought were solid floors, is the near flintstonian pans that obviously need replaced. This sounds bad, but we were lucky to discover the problem before paint, insulation, carpet, underlay, and wiring were installed on top of the diseased metal. Yes, it means more work and money, but the end result is a totally solid unibody--"no excuses." An interesting media was used in the process--a mix of crushed coal and slag--that's much less expensive and more aggressive than glass beads, but without the friction and warping factor of sand. Read on as we go "full-on meatloaf" with the Ranchero.

1 Here we're in the process...

1 Here we're in the process of mounting the 'chero on ourWhirly-Jig. Mounting a vehicle on any body handler is careful work andmust be balanced properly. It took about three hours to get ours set up.

2 A close inspection of our...

2 A close inspection of our floors revealed some surface rust,solid framerails, and layers of undercoat. Body handlers aresurprisingly affordable and make working on the dusty side easier.

3 Prep for media blasting...

3 Prep for media blasting includes removing as much of thefactory seam sealers as possible. It will be replaced with a modern,two-part sealer that will last forever.

4 Using a torch (with a fire...

4 Using a torch (with a fire extinguisher close by) and a gasketscraper, we turned loose about 10 pounds of old undercoat. This is animportant step because some types of media will just bounce off the softcoating and never penetrate to the metal.

5 After unloading the Ranchero...

5 After unloading the Ranchero from the rollback at S&SSandblasting, we talked strategy with Mike and asked a millionquestions. He listened to our needs and gave us exactly what we wanted.He was downright surgical with his aim.

6 Mike starts at the front...

6 Mike starts at the front and divides the car into sections,stopping to discuss our needs between sections. Finding someone with aprofessional attitude will assure a good level of communication.

7 The benefit of the Whirly-Jig...

7 The benefit of the Whirly-Jig is obvious and allows for a verythorough job. Mike uses an overlapping pattern, much like painting.

7 The benefit of the Whirly-Jig...

7 The benefit of the Whirly-Jig is obvious and allows for a verythorough job. Mike uses an overlapping pattern, much like painting.

8 Our left fender and trans....

8 Our left fender and trans. cross member showed severe nastinessand gets the same treatment as the car with dialed-down pressure.

9 We only stripped the driver-side...

9 We only stripped the driver-side quarter as the other side wasstraight and clean with no rust. Pressure is dropped and a circularpattern is used for exterior panels. Notice how far he is from thesheetmetal? That's experience. Mike says he's never warped a panel anddidn't even come close on our Ranchero.

10 Standing flat footed and...

10 Standing flat footed and stripping floors is a beautifulthing, as years of undercoat and grime came off in moments. Mike'shooded safety equipment gives him a constant feed of fresh air.

11 Smooth as the day it was...

11 Smooth as the day it was assembled--well, almost. We rotatedthe car to inspect, dump out coal from crevices, and touch up any missedspots before we load up and head back home.

12 Here's how we paraded...

12 Here's how we paraded to and from Paintucation studios on therollback. Notice the support stands under the jack points of the body.This is absolutely necessary for transporting a car on a body handler,otherwise you'll subject your car to stress that could affect bodyalignment and panel fit.

13 Back inside, we reinspect,...

13 Back inside, we reinspect, vacuum and blow, and vacuum andblow some more. like sand at the beach, the coal and slag hang aroundin the cracks.

14 Remember those "solid"...

14 Remember those "solid" floors? Here's the reality--nearFlintstonian metal. We definitely would have suffered moisture damage onour underlay and carpet from this.

15 I shot the naked metal...

15 I shot the naked metal with a fat coat of Sikkens epoxy assoon as we had the 'chero off the truck to keep it from flash rusting.There are metal treatments to use on bare steel if you have to leave ituncoated for extended periods of time, but get it covered ASAP. Metalthat's been blasted and rusts over needs to be reblasted to get the pitsclean, so it's very important to move quickly and efficiently at thisstage.

16 The sheetmetal is protected...

16 The sheetmetal is protected and ready for the next step.Epoxies come in a variety of colors. the red oxide color is a closematch to the primer that Ford used on their '60's underbellies, ifyou're after a factory look.

17 Having our body upside...

17 Having our body upside down will allow us to put a beautifulfinish on our undercarriage without worries of incomplete coverage orinsufficient film build.

18 I shot a grey epoxy in...

18 I shot a grey epoxy in the bed to accentuate the shadows ofdents and waves. We're going for a clean look, and I'll need all thehelp I can get with this well-used bed.

19 we've got a coating on...

19 we've got a coating on our Ranchero that will allow us thefreedom to work on one panel at a time. Now, about those floors....