Hey y`all , the torque boxes (or lack there of) are purdy rusty and badly need replaced. Could I cut them (whats left of them) out with a grinder and cut off wheel without too much trouble or it there a better way ? Will 18 gauge mettal be good enough to replace them with ? How thick is the mettal the frame is made from ? I just got my front suspention rebuild kit (polly bushings) , 7/8s sway bar and slotted front rotors . I can`t wait to get it back on the road !!!
You ask good questions Elliot. I think removing with a cutoff wheel and grinder should work. I do not know the gauge of metal used in the frame. Once you remove the old metal you could measure to get an idea. I am going to have to fab up some torque boxes for that other stallion when I get to it. I was thinking of using maybe 14 gauge metal. You could actually build the torque boxes and then weld them in, or you could piece them together in the car. Probably get a better result from piecing in if you dont have much experience in doing this kind of stuff. I am looking forward to seeing your progress on this. Should prove to be valuable info for all of us. Dan
The torque box is the squareish hunk that tie the frame rails to the rocker panels. You have one in each cornor. Just look behind your front wheel and follow the frame rail back. Where it dead ends is the torque box.
I've done torque boxes in Mustangs and Cougars already. I have always used the pre-made replacements. Not sure what year would cross over into the Maverick, but I would try to use one of these pre-made ones. Make sure that the rest of the car is supported all over the place, even if you use a rotisserie, as once you start cutting it out, the car is gonna want to start sagging from lack of support. Enjoy, Eric J Here is a good "how to" on a torque box. http://www.mustangmonthly.com/howto/34419/
Elliot, sounds ambitous, but you can do it!! Jean had posted some pics a while back of the torque box repair that her and Dale had done, you might want to do a search on that post.
