Enginebuild 005.jpg
356 hits | 66.3 KB | Posted: 5/5/08
The first of eight pistons in their home. I only took one picture because eight pictures would be boring.
(Posted in: engine build 08')

enginebuild 6.jpg
318 hits | 77.42 KB | Posted: 5/5/08
I'm cleaning all the head bolts before relubing them with ARP moly lube. Cleaning old stuff is most of refreshing an engine. It takes a lot of lacquer thinner and time with a wire wheel. The engine is living in a bag while this goes on because wire w...
(Posted in: engine build 08')

enginebuild 7.jpg
407 hits | 85.11 KB | Posted: 5/5/08
First head on. You can see the generous use of ARP moly lube on the heads. Limiting friction is critical to getting accurate torques. You can also see the Redline assembly lube on the fuel pump eccentric. Proper lube for every application. At this po...
(Posted in: engine build 08')

enginebuild 8.jpg
410 hits | 86.43 KB | Posted: 5/5/08
Both heads in place. Fel-Pro 9333pt1 head gaskets. Cylinder sealing is not an issue with iron headed 351ws. You can also see the Harland Sharp roller rockers and the Trick Flow custom length one piece moly pushrods, for the guide plates.
(Posted in: engine build 08')

DSCF2683.JPG
409 hits | 78.86 KB | Posted: 5/13/08
Alright! It's almost done. Oil pump and pan are on as are the timing cover and water pump. The water pump is a police version and cast iron. It weighs more but it has a larger impeller and shaft plus it has a scrolled housing. I'll give up a couple p...
(Posted in: engine build 08')

DSCF2684.JPG
387 hits | 75.85 KB | Posted: 5/13/08
Same state as the previous pic but from a low angle so you can see the oil drains for the turbos and the neat blue line from the silicone oil pan gasket. Hopefully it won't leak.
(Posted in: engine build 08')

DSCF2685.JPG
438 hits | 78.65 KB | Posted: 5/13/08
That's my intake! A Weiand stealth, gasket matched and cleaned up at this point. The rear water port have been drilled and tapped 1/4 NPT so I could add these 90 degree fittings and run 3/8 hose to the water cooled turbos. Don't run too much water to...
(Posted in: engine build 08')

DSCF2686.JPG
363 hits | 67.17 KB | Posted: 5/13/08
A better shot of the fittings installed. The hard part was holding the manifold steady in the drill press. I don't trust any human to be able to drill a hole perpendicular to anything, not even myself. Drilled 1/4" pilot. Cut to 7/16 with step bit. D...
(Posted in: engine build 08')

paintedmotor.jpg
415 hits | 73.67 KB | Posted: 8/23/08
This the motor painted and ready to go in the car. I still need to find an oil cooler o-ring and some little things, and fix the power brake booster first but I'm almost ready. I painted the whole thing semi flat black, for that stealthy look. It sti...
(Posted in: engine build 08')

third pedal 002.jpg
387 hits | 75.09 KB | Posted: 12/3/08
On the left a stock Mustang GT pedal assembly. On the right a stock full size LTD/Crown Vic assembly. Notice that the lower row of bolts is exactly the same. The top row of bolts is the same width but the LTD assembly is 1 3/4" taller. A couple sheet...
(Posted in: The third pedal)

third pedal 003.jpg
376 hits | 72.54 KB | Posted: 12/3/08
The Mustang uses a different power booster mounting flange. But notice that the LTD flange is a big flat piece of steel. It's held on with four spot welds. Drill them out, weld it on the Mustang part, and redrill, easy. Or do what I'm doing, just cut...
(Posted in: The third pedal)

third pedal 004.jpg
367 hits | 104 KB | Posted: 12/19/08
Here I've already cut and welded a Crown Vic bolt pattern flange onto the Mustang pedal assembly. I had to heat and bend the Mustang flange out a bit to get the correct bolt spacing but it was a minor issue. It doesn't show up well in the pics but th...
(Posted in: The third pedal)

third pedal 005.jpg
397 hits | 99.74 KB | Posted: 12/19/08
Here you can see the piece of sheet metal I bent up to extend the bolt pattern 1 5/8" to match the Crown Vic pattern. I could have just made tabs but I wanted the extra strength of a fully welded piece. The piece was bent and fit to match the contour...
(Posted in: The third pedal)

third pedal 006.JPG
397 hits | 79.01 KB | Posted: 12/26/08
It took awhile to get to this point but the pedals are bolted down and the right height and spaced out for my big feet.
(Posted in: The third pedal)

third pedal 007.JPG
455 hits | 72.08 KB | Posted: 12/26/08
The view the driver sees. The gas and brake are the same height now after I bent to brake pedal up three inches. The clutch is up about three inches more. If I can I'm going to find a way to lower the clutch pedal so they are all the same height. I t...
(Posted in: The third pedal)

third pedal 008.JPG
486 hits | 66.07 KB | Posted: 12/26/08
The Mustang and LTD pedals have the same stock curve but the Mustang brake rod lug is 1/2" higher. The right is the stock LTD and the left is the bent Mustang part. The weird dark spot that looks like a wrinkle is some relic of the digital camera. It...
(Posted in: The third pedal)

third pedal 009.JPG
420 hits | 66.94 KB | Posted: 12/26/08
A better view of the bent pedal. This assembly is finished. Its been extended, reflanged, brake pedal bent, clutch pedal shortened and painted. I might try and adjust the clutch pedal lower if I can do it and still get good clutch function.
(Posted in: The third pedal)

brake plate1.JPG
345 hits | 55.84 KB | Posted: 9/20/09
I whittled a new brake power booster spacer out of a chunk of 1/2" aluminum. The stock one was cheap plastic.
(Posted in: The third pedal)

brake plate2.JPG
358 hits | 37.4 KB | Posted: 9/20/09
I roughed out the shape with saws, cut-off wheels, and drill bits. Then I trimmed it with a 1/4" carbide bit in a router. It worked for me but I cannot guarantee that it won't explode and slice you to bits so beware.
(Posted in: The third pedal)

brake plate3.JPG
370 hits | 47.48 KB | Posted: 9/20/09
If it's carved out of one piece of metal, it's billet. My car has custom billet parts.
(Posted in: The third pedal)

brake plate4.JPG
340 hits | 40.77 KB | Posted: 9/20/09
Just another view, it took awhile to make so I took a lot of pictures.
(Posted in: The third pedal)

IMG_1293.JPG
163 hits | 45 KB | Posted: 2/1/14
Indexing the bellhousing. This is the second try; the first try with the stock dowels had it about 9 thousandths out of alignment. Tremec's spec is less than 5 thousandths so I ordered a set of 7 thousandths offset dowels. Now it's only 1.5 thousandt...
(Posted in: The third pedal)

IMG_1295.JPG
180 hits | 63.93 KB | Posted: 2/1/14
Flywheel, pilot bearing, clutch disc, and pressure plate all installed. That's a Spec pressure plate and Centerforce Dual-Friction disc. I ordered them from promotionpowertrain.com
(Posted in: The third pedal)

IMG_1296.JPG
178 hits | 85.91 KB | Posted: 2/1/14
Tremec TKO II, used but fresh of a rebuild from Liberty Gear.
(Posted in: The third pedal)

IMG_1298.JPG
154 hits | 64.77 KB | Posted: 2/1/14
Hole cut in the trans tunnel. It got cut out a little more after this and I need to find a shifter boot but it comes out in a good place. Shifter doesn't hit the seats!
(Posted in: The third pedal)

IMG_1305.JPG
178 hits | 49.46 KB | Posted: 2/1/14
I put a level line on the engine before taking out the AOD shell I had bolted to the trans. The TKO uses the same bolt pattern for the mount as the AOD but the mounting pad is about 5/8" higher. I made a spacer out of 5/8" aluminum. It's ju...
(Posted in: The third pedal)

IMG_1306.JPG
194 hits | 49.58 KB | Posted: 2/1/14
Trans bolted down with the spacer installed. The top of the trans just touched the floor pan. I later pulled the trans and hammered a couple divots for clearance.
(Posted in: The third pedal)

IMG_1319.JPG
188 hits | 45.1 KB | Posted: 2/1/14
The stock driveshaft was a little too long for the TKO but it turns out that the later model police Crown Vics used an aluminum shaft that was a bit shorter. It took a couple conversion u-joints to adapt the bigger joints on the aluminum shaft to my ...
(Posted in: The third pedal)

IMG_1325.JPG
160 hits | 64.69 KB | Posted: 2/1/14
I needed to space the clutch cable out from the firewall a bit and adjust the angle to eliminate wear on the cable sheath. I started by cutting and shaping a couple plates of 1/4" steel to sandwich the firewall. Paper design, cardboard cut out, ...
(Posted in: The third pedal)

IMG_1326.JPG
159 hits | 63.95 KB | Posted: 2/1/14
Bare blank plates mocked up to the firewall. Had to shape them to fit over a flat spot but it all worked out.
(Posted in: The third pedal)

IMG_1327.JPG
171 hits | 62.14 KB | Posted: 2/1/14
It's a compound angle to get the flange flat and straight along the centerline of the opening in the firewall and the top of the quadrant. I made a wood block with the right angle. Drilling the 1/4" pilot was no problem. I drilled the hole on th...
(Posted in: The third pedal)

IMG_1328.JPG
162 hits | 66.57 KB | Posted: 2/1/14
Boring the larger hole. Keeping the saw cutting without too much chatter or sticking was a challenge. It took some serious clamps to keep the plate still.
(Posted in: The third pedal)

IMG_1329.JPG
174 hits | 53.64 KB | Posted: 2/1/14
Finished piece. Welded nuts to the inside plate. Welded nuts to the pipe to hold down the firewall adjuster. I like it.
(Posted in: The third pedal)

IMG_1330.JPG
180 hits | 38.64 KB | Posted: 2/1/14
Blurry but the wire goes straight through the center of the firewall adjuster and to the top of the adjuster.
(Posted in: The third pedal)

IMG_1331.JPG
170 hits | 48.23 KB | Posted: 2/1/14
Cable installed. Blurry. It was cold and dark at this point.
(Posted in: The third pedal)

IMG_1332.JPG
174 hits | 49.11 KB | Posted: 2/1/14
Everything installed. It works fine.
(Posted in: The third pedal)

IMG_1333.JPG
177 hits | 64.58 KB | Posted: 2/1/14
Better shot.
(Posted in: The third pedal)

IMG_1339.JPG
184 hits | 49.97 KB | Posted: 2/1/14
Had to hammer a divot in the crossmember to clear the cast torque arm mounts on the extension housing. The crossmember is 1/8" thick so it took a bit of heat and a big hammer to get that much deformation. I painted it to keep out the rust.
(Posted in: The third pedal)

DSCF2960.JPG
481 hits | 91.55 KB | Posted: 2/20/10
One piece of 1/2" x 2 1/2" flat stock long enough for two new header flanges.
(Posted in: Header flanges)

DSCF2961.JPG
376 hits | 88.34 KB | Posted: 2/20/10
Fel-Pro 1415 exhaust gasket on top of the stock. I'll be cutting the ports to match the gasket but drilling the wider World Products 3" bolt pattern. This gasket is recommended by World Products for the 2" bolt pattern and it matches the ports well. ...
(Posted in: Header flanges)

DSCF2962.JPG
400 hits | 80.61 KB | Posted: 2/20/10
Gasket taped down with the center line of the ports aligned with the center line of the flat stock. Just have to trace the ports.
(Posted in: Header flanges)

DSCF2963.JPG
407 hits | 92.5 KB | Posted: 2/20/10
Port outlines squared and scribed.
(Posted in: Header flanges)

DSCF2964.JPG
397 hits | 79.91 KB | Posted: 2/20/10
Taped the gasket back down to the port outlines and punched the corners. That's a piece of 1/2" tube with a transfer punch in the center. This accurately locates the center of the 1/2" drill that forms the corner of the port.
(Posted in: Header flanges)

DSCF2965.JPG
344 hits | 104.25 KB | Posted: 2/20/10
I drilled a 1/8" pilot hole first with a step bit. Then finished it with a 1/8" twist bit. Next I ran a 3/8" bit down the pilot hole and used a second step bit to expand the 3/8" hole to 1/2". In this picture you can see that some of the holes are fi...
(Posted in: Header flanges)

DSCF2966.JPG
392 hits | 88.63 KB | Posted: 2/20/10
After all the holes were drilled I scored the lines with a cut-off wheel on my angle grinder. Then I finished the scored areas with a body saw. Yes, it took awhile.
(Posted in: Header flanges)