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Horse Heaven's elite staff begins the careful disassembly and documentation process...
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A reasonably good car to start with. We located this car in Visalia, California in 1983, and stored it until 2004.
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As always, the process continues with high pressure, high temperature washing.
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Document, measure, photograph. Then disassemble. At this phase, we're assessing damage, and deciding what is saved and what is removed.
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Ultimately, the left quarter panel is replaced, and the right one is saved.
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The body is sanded to metal, and the right-side quarter panel gets a lower patch welded in.
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Fresh sheet metal is carefully fitted and then welded in place.
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Templates help us correctly locate each of the emblems before paint is applied.
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The painted unibody rolls out.
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Painted in the same order it was in 1966, interior surfaces first, then the Springtime Yellow exterior.
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The body is moved into the finishing room, where we begin by assembling the doors and suspension.
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In a miniature way, we try to duplicate the factory process, by having all the sub-assemblies, wiring, and fasteners grouped in order of assembly.
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The suspension used during the body and paint process is replaced with the properly detailed, original components.
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The 289 Challenger Special was painted Ford corporate blue for the first time in 1966, then, again, in June, 2005.
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Carefully hidden under the blue paint, this time, is a 303 horsepower, dyno-tested 289. The manifold is a cosmetically re-sculpted Edelbrock Per'FORD'er RPM. Look closely!
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There's a sound system hidden in there, too, with high-end speakers set in our own tuned capsules behind the stock kick panels.
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To allow the higher frequency sounds to pass, the stock kick-panels are perfed with a unique, if not original, design.
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The finished engine looks as good as it runs.
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The parchment deluxe interior with black carpets and woodgrain details looks just like it did forty years earlier.
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The cathedral-bowled Holley and polished valve covers produce one of the best looking engines ever.
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