FC: A '65 Comes Alive! | In Lisa Miller's Automotive Technology Classes Tamalpais High School Fall 2010 - Spring 2014
1: Our project started with one tired and partially beat up Mustang. Over the course of 4 years 300+ students participated in repairing several hundred vehicles and joined in the restoration of one '65 Mustang convertible. Here is our story so far...
2: On a typical day in the shop students learn to work on modern cars. A few common repairs taught are shown below. | Pulling a trouble code, installing a tire, and performing a disc brake job
3: Left - Rejoicing in the success of a wheel balance | Right - Finding vehicle specifications on our shop management program | Left - Performing run-out compensation in preparation for a wheel alignment
4: Tool Room Management | Lubricating a rusty exhaust prior to removal | Removal of an Audi engine
5: Learning to identify that drip in your driveway!
6: A couple more typical repairs... Replacing a timing belt and changing oil
7: Tire rotation | Instruction on setting a torque wrench | Brake rotor inspection
8: After seeing the 1955 Chevy Ms. Miller restored, students pleaded with her to teach them to restore an old car.
9: The Tam High Foundation generously provided the initial funds for the purchase of a project car. Students accompanied Ms. Miller to a car show to search for possible project cars.
10: Among a sea of hundreds of cars, students were guided to select a car worthy of a restoration project.
11: After evaluating many cars, we found one that fit our project needs, but it was $6,500 over our budget. Students were then taught the art of making a deal. After negotiations, we came away with a perfect project car that was right on budget!
12: Don't be fooled by the "resale red paint". The car was ripe with learning opportunity! It was completely intact but all vehicle systems needed restoration. | The leaky fuel tank, broken ball joint, and engine damage shown were just a few of the many learning opportunities!
13: Ms Miller teaches students to assess all vehicle systems.
15: Ms Miller organizes jobs by skill level; pink for advanced, green for intermediate, and blue for introductory. Below we are receiving our first shipment of parts!
16: Students organize a dedicated Mustang project only space in the shop and begin to learn disassembly.
17: Disassembly continues...
18: Ms. Miller instructs students how to safely remove the engine and transmission as one piece.
20: Preparing the engine bay for cleaning
21: Cleaning and scrubbing the engine bay in preparation for paint
22: Ms Miller is proud of the great work her students did painting the engine bay.
23: Easy access for pivot shaft and coil spring installation
24: All old fuel and brake lines were removed and students were taught to custom fit new lines. | Ms. Miller directs traffic in our busy shop.
25: Restoration of brake, suspension, and steering components. | Students learn to replace ball joints, pivot shafts, coil springs, and shocks. Ms. Miller does a demonstration.
26: Students complete suspension and steering work and are ready to learn a disc brake conversion.
27: Last minute engine bay preparation for our rebuilt long block and transmission installation. | Ms. Miller instructs and students work as a team to hoist the assembly up and into position.
30: SUCCESSFUL INSTALL!
31: One of many learning opportunities presents itself as students discover mounts do not line up properly.
32: Ms.Miller reached out to Mustang expert, Chris at Mustangs Muscles and Classics and learned that '68 Bronco mounts can be modified and used to provide a little more lift. In our case, we used one on the passenger side to bring our block into place with proper alignment.
33: Students learn about ignition systems in preparation for installing one on our Mustang.
34: Finishing touches on our differential prior to installation | Fabrication of an unavailable part | Installation of a new heater core and ventilation system
35: Rebuilding our transmission shifter | Installation of the driveshaft | Students are creative in overcoming the challenge of a timing mark that was not easily visible. Pink nail polish illuminates the mark beautifully!
36: STUDENT TEAMWORK | Ms. Miller inspects student work.
37: Exterior paint and body work was done by Milani's Autocraft. Our car returns to the Tam shop with a fresh paint job!
38: Our car did not come with wheels (rims & tires) that were a good fit. To correct rubbing in the fender well, students receive instruction on calculating the overall diameter of a wheel. We calculated the diameter for 3 different tire size options and selected the best fit.
39: Malugani Tire Center in Mill Valley donated all four tires for our Mustang! | Removal of our old wheels and installation of new tires
40: Students perform a front wheel alignment. Caster, camber, and toe are set to factory specifications.
41: Instrument panel and gauge restoration | Installation of new carpet
42: Celebration of successful wiring under the dash. | Here students are adding a mechanical temperature gauge for improved accuracy
43: Ms. Miller gets help from Chris Machado of Mustangs, Muscles and Classics on one stubborn export brace installation
44: Since Ms Miller is not an expert on interiors, she teaches students how to write a persuasive letter. They wrote to Franzini Brothers Upholstery. Mike Franzini responded and generously served as a guest expert in our shop teaching students to replace the interior. | As more and more of the Mustang is restored, it becomes obvious the interior needs work as well... | Sammy and Kari Hagar and The Hagar Family Foundation kindly provided funds for the interior project.
45: Mike teaches students how to apply new upholstery to the door panels | The new black interior is beautiful and just about complete. Ms Miller guides a student to thread a hole for the new seatbelt mount
46: Project list is down to one page! | The interior is complete! The red steering wheel is in honor of the TAM Red Tailed Hawks.
47: Over 300 students have had a hand in the restoration of this car. Some have gone on to become auto technicians. Some have entered automotive engineering programs, and ALL have gained confidence. They have become problem solvers, critical thinkers, team players, and are better prepared for many of life's challenges.
48: Although this first restoration is complete, the car remains loaded with educational value. As environmentally friendly technology for hot rods advances we may modify this car. In the mean time, future students will be tuning the Mustang for performance and learning about modern automotive technology on the many other cars that roll in and out of our shop.
49: Our Pony car is ready to run!
50: STUDENT REFLECTIONS | The skills I learned got me a job! | Inspired me to challenge myself academically & take more math and physics courses | Auto shop is my reason to come to school. | Inspired me! | Built my confidence! | Life changing! | Best class ever! | I'm more confident in the world as a result of this class. | I've learned how to be in a professional environment. | This class made me more confident about what to do when I have my own car. | This is part of who I am now. | I learned life lessons in this class. | Now I'm good with tools and do repairs on my own. | I'm not afraid of being stuck with a flat on the side of the road. I can take care of it myself!
51: Special THANKS for the generosity of the following sponsors: The Tam High Foundation Grant from the State of California Milani's Autocraft, Novato Sammy Hagar and The Hagar Family Foundation Mike Franzini of Franzini Bros Upholstery Vintage Wheel Works Horgan's Transmissions, San Rafael Johnny Franklin's Mufflers, San Rafael Covercraft Car Covers Malugani Tire Center, Mill Valley Jerry Piland and Hunter Engineering Mustangs, Muscles, & Classics, Santa Rosa Durkin Signs & Graphics, Novato Woodland/Napa Auto Supply, San Rafael Many thanks to the Tamalpais Union High School District and The Marin County Office of Education Regional Occupation Program (MCOE/ROP) for their support of Automotive Technology education.