Topic: 1968 Mustang S Code San Jose Assembly Sequence

[bullitt68]

I have started installing under dash, firewall, and engine bay parts. I am curious what is the best sequence to follow. I am going to install as many parts as I can on the firewall and under dash to prep for the motor install (separate thread post for that). Just curious what the sequence for headliner, front & rear glass, gas tank, or anything else I should be aware to not install before something else. I assume that headliner before glass. Any reason to hold off on the gas tank, ie fold down back sets assembly? Also wonder about kick panels and if I should hold off on anything that could make it difficult on the drivers side.

I have installed the heater vents in the dash, but not the dash speaker or heater box. Should that go in before motor install?

Should I install anything that may be challenging before the steering column?

[J_Speegle]

Since we're discussing general restoration assembly and not factory assembly sequence your going to get allot of suggestions as to what worked better or preferred order from each person. IN addition, since there are so many parts we're not going to get them all. Also, often the order of reassembly, especially what area to start with often depends on what is available and ready. The order changes for many depending on their out sourcing of tasks or even the order parts are received. Given the pictures you provided and assuming that everything is ready to go I would do the dash completely so that everything that is going to stick through the firewall is there and in place. Of course the steering column would be one of the last things to install other than dash pad (don't forget to position the VIN tag  during the process.

Often some will leave the gas tanks out till after interior as it allows you to crawl into the trunk from below and access some of the rear interior parts during installation.

Yes headliner (marking or placing locators for visor, shoulder belt, roof console brackets -in place if equipped - coat hooks and so on before the headliner is buttoned up. 

Leave the seats out till last - in fact just about the very last part to install other than maybe the hubcaps   I know they are big and a pain to store but they, at the same time can get really in the way in the car.

Are you putting fully assembled doors on or are you going to weight them down to get them adjusted in place?

Guess that is a start and I anticipate your going to get a fair amount of suggestions.

[jwc66k]

Being my "suggestions" have already been discounted, I'll defer to some "quirks" that I found in the Osborn produced Mustang Assembly Manuals. If you have a set, take notice of the Ford document numbers on each page located in the lower right hand corner (examples - E8-8140-1 in electrical, N8-8210-1 in body, T8-8310 in interior). Don't use the Osborn assigned page numbers. Those document numbers seem to correspond to sequential assembly line "steps", and those steps bounce back and fourth between body, electrical and interior manuals (engines were assembled away from the line, and chassis stuff was - well - the exception). To add "clarity" to my discovered "quirk", the item numbers listed on each page "seem" to correspond to assembly line steps, item 1 is installed first, then item 2, etc. Hardware items use letters associated with each numbered item for assembly. This is not an absolute. It is what I noticed on certain assembly drawings from 64 thru 68 (1969 thru 1973 have a slightly different format number but "seem" to be the same.
As for me, I installed what I had in hand, and took it out when it got in the way of something else. It's called "learning by error". It's how you get experience - make a lot (yes, it is two words) of errors.
Jim

[bullitt68]

Since we're discussing general restoration assembly and not factory assembly sequence your going to get allot of suggestions as to what worked better or preferred order from each person. IN addition, since there are so many parts we're not going to get them all. Also, often the order of reassembly, especially what area to start with often depends on what is available and ready. The order changes for many depending on their out sourcing of tasks or even the order parts are received. Given the pictures you provided and assuming that everything is ready to go I would do the dash completely so that everything that is going to stick through the firewall is there and in place. Of course the steering column would be one of the last things to install other than dash pad (don't forget to position the VIN tag  during the process.

Often some will leave the gas tanks out till after interior as it allows you to crawl into the trunk from below and access some of the rear interior parts during installation.

Yes headliner (marking or placing locators for visor, shoulder belt, roof console brackets -in place if equipped - coat hooks and so on before the headliner is buttoned up. 

Leave the seats out till last - in fact just about the very last part to install other than maybe the hubcaps   I know they are big and a pain to store but they, at the same time can get really in the way in the car.

Are you putting fully assembled doors on or are you going to weight them down to get them adjusted in place?

Guess that is a start and I anticipate your going to get a fair amount of suggestions.

Thanks Jeff that is great information. I am not sure how I am going to do the doors yet, but normally I install the doors first and then install the linkage/hardware/glass and adjust etc. Not sure if there is a different way or preferred way. Speaking of sequence, is it standard practice to install as per the assembly line or as suggested based on various factors. Yes all of the sub assemblies and parts done and are ready to install. I am glad I checked because originally I was going to instal the motor first, but great to know to complete the dash first. I was also gong to do the steering column first.

Suggestions are great, but too many can be confusing indeed. Since I am new to Mustangs its all a great learning process and all the help is greatly appreciated.

[bullitt68]

Being my "suggestions" have already been discounted, I'll defer to some "quirks" that I found in the Osborn produced Mustang Assembly Manuals. If you have a set, take notice of the Ford document numbers on each page located in the lower right hand corner (examples - E8-8140-1 in electrical, N8-8210-1 in body, T8-8310 in interior). Don't use the Osborn assigned page numbers. Those document numbers seem to correspond to sequential assembly line "steps", and those steps bounce back and fourth between body, electrical and interior manuals (engines were assembled away from the line, and chassis stuff was - well - the exception). To add "clarity" to my discovered "quirk", the item numbers listed on each page "seem" to correspond to assembly line steps, item 1 is installed first, then item 2, etc. Hardware items use letters associated with each numbered item for assembly. This is not an absolute. It is what I noticed on certain assembly drawings from 64 thru 68 (1969 thru 1973 have a slightly different format number but "seem" to be the same.
As for me, I installed what I had in hand, and took it out when it got in the way of something else. It's called "learning by error". It's how you get experience - make a lot (yes, it is two words) of errors.
Jim

Thanks Jim that is great information. I had no idea there was a sequence to the Ozbourne manuals. I have 4 of them.

I know what you mean about making errors, it seems that is all I do. I have had to redo almost everything at least once and have also been doing the "what is in hand" sequence as well. This website is so invaluable, I can't even imagine what a mess I would have made of my car without it. I am learning slower than most I am sure, but as long as the end result is good, it will have been worth it.

[67gtasanjose]

Check with Jeff about sound deadener and sealant "timing of application" but many of these steps are performed after a certain list of components are in place (timing can vary pending time and location of your individual car's assembly date). For example, I see items in fender well locations that are in their "restored condition ", which look good but these are items that often get covered by sealants or deadener.

[bullitt68]

Check with Jeff about sound deadener and sealant "timing of application" but many of these steps are performed after a certain list of components are in place (timing can vary pending time and location of your individual car's assembly date). For example, I see items in fender well locations that are in their "restored condition ", which look good but these are items that often get covered by sealants or deadener.

Thanks Richard. I am planning to apply seam sealer on the firewall once all the components are installed and to the wheel wells after the fenders are installed

[J_Speegle]

.............................. Speaking of sequence, is it standard practice to install as per the assembly line or as suggested based on various factors. Yes all of the sub assemblies and parts done and are ready to install. I am glad I checked because originally I was going to install the motor first, but great to know to complete the dash first. I was also gong to do the steering column first.

It really depends. I will normally default to as they did on the line, it worked for them, so why not use in most cases, but as mentioned it really depends on the situation and area.  Of course you choose to do things like paint parts off the unibody already, like many though this just creates more work later. Its almost always about choices. Sometimes/often the original way is the easiest

Thanks Richard. I am planning to apply seam sealer on the firewall once all the components are installed and to the wheel wells after the fenders are installed

Might want to hold off until everything is installed - pretty much - you can leave the front wheels off in this case, before you apply the sound deadener. If you leave some things till last and they are in the spray pattern or even the overspray area it will stand out to those that understand the process and steps used originally. This includes items installed in the engine compartment and ends of bolts, wire retainers, screws whose ends stick through the the wheel well side