Raw material.JPG
142 hits | 54.14 KB | Posted: 10/24/15
One block of 1" x 6" 6061 aluminum. Raw material. There's an adapter in there somewhere.
(Posted in: Carb intake to throttle body elbow adapter)

roughed in2.JPG
143 hits | 43.05 KB | Posted: 10/24/15
Die grinder with carbide bit got the ports roughed in pretty well. Need to do finishing work on the outer profile and sand the ports smooth. That takes most of the time.
(Posted in: Carb intake to throttle body elbow adapter)

finished elbow bottom.JPG
144 hits | 51.93 KB | Posted: 10/24/15
Plenum bolted to adapter. Just a little step here and there. Won't hurt anything.
(Posted in: Carb intake to throttle body elbow adapter)

6666.JPG
144 hits | 44.73 KB | Posted: 5/20/16
New and old. Takes a lot of trimming to get a good butt weld.
(Posted in: Floor pans and carpet)

finished elbow.JPG
145 hits | 47.52 KB | Posted: 10/24/15
The way it'll look on the car. Not too shabby for a guy in a garage with a drill press and die grinder.
(Posted in: Carb intake to throttle body elbow adapter)

on engine rough holes.JPG
150 hits | 68.18 KB | Posted: 10/24/15
Starting to cut out the ports. Cut out a pair of circles with a hole saw to get a bunch of material out at once. The adapter fits the studs like a glove. I swapped out these old studs for ARP versions later.
(Posted in: Carb intake to throttle body elbow adapter)

router1.JPG
150 hits | 74.5 KB | Posted: 10/24/15
Used my router with a plunge cuttting straight bit to rough in the first 1/8" of each side. Just easier and faster than the die grinder.
(Posted in: Carb intake to throttle body elbow adapter)

image.jpg
151 hits | 43.99 KB | Posted: 4/13/14
Another shot of the manifold. You can see the hose routing better here. The fan sensors are on the bottom. I spray painted the wires: blue for low temp; red for high temp.
(Posted in: Fan switch manifold)

IMG_1461.JPG
151 hits | 54.43 KB | Posted: 4/28/14
Kinda blurry picture of the heat shield I put over the passenger side header. It's 22 gauge mild steel so it won't melt and hopefully it will keep a lot of heat away from the fuel lines. They already have heat sleeve on them but there's no kill like ...
(Posted in: Details)

3333.JPG
151 hits | 46.32 KB | Posted: 5/20/16
Bad on on side, new on the other. Just cut out of 20-gauge sheet.
(Posted in: Floor pans and carpet)

12185352_10205241990834285_1927709287611782961.jpg
151 hits | 61.98 KB | Posted: 8/10/16
(Posted in: 1965 galxie LTD)

Front inlet.JPG
152 hits | 85.34 KB | Posted: 10/24/15
Would have looked nicer like this but it fits best facing the passenger side. Oh well.
(Posted in: Carb intake to throttle body elbow adapter)

IMG_2760.JPG
152 hits | 59.91 KB | Posted: 3/10/16
Assembling the Megasquirt. Lots of soldering.
(Posted in: Megasquirt fuel injection)

router2.JPG
153 hits | 77.9 KB | Posted: 10/24/15
More router work on this side.
(Posted in: Carb intake to throttle body elbow adapter)

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_2559.JPG
154 hits | 74.95 KB | Posted: 5/20/16
Crimp fitting, solder to cover the open end, marine heat shrink to seal and act as strain relief. That's how I do it at least.
(Posted in: Trunk mounted battery)

12195007_10205241988114217_3390308272293978733.jpg
154 hits | 62.13 KB | Posted: 8/10/16
(Posted in: 1965 galxie LTD)

IMG_2761.JPG
155 hits | 84.85 KB | Posted: 3/10/16
Mostly done. Had a bit of trouble getting the laptop to talk to the ECM but I got it figured out.
(Posted in: Megasquirt fuel injection)

finished2.JPG
156 hits | 51.61 KB | Posted: 10/24/15
A little work with sanding rolls really cleaned up the ports. Not too shabby. I also ran the router down the center divider to clean and straighten it. The outer profile was a bunch of drilled holes, angle grinder, router, and sanding rolls. I had to...
(Posted in: Carb intake to throttle body elbow adapter)

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_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)

2222.JPG
160 hits | 70.65 KB | Posted: 5/20/16
Rotten floor pan. Need to fix this.
(Posted in: Floor pans and carpet)

IMG_20160326_191220301.jpg
161 hits | 36.7 KB | Posted: 8/10/16
(Posted in: 1965 galxie LTD)

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_1375.JPG
162 hits | 52.37 KB | Posted: 3/2/14
I rerouted the fuel line through the front crossmember but it turned out that the new route was closer to the exhaust than I like so i made this quick aluminum heat shield / bracket.
(Posted in: Details)

IMG_2831.JPG
162 hits | 67.53 KB | Posted: 3/10/16
Eight holes all drilled. Just need to make a quick fixture to hold the bungs properly.
(Posted in: Megasquirt fuel injection)

IMG_20160326_191340970.jpg
162 hits | 31.64 KB | Posted: 8/10/16
(Posted in: 1965 galxie LTD)

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_1478.JPG
163 hits | 71.57 KB | Posted: 5/6/14
Driver's side air intake. MIG welder makes adding bits of steel easy. Barbecue paint dries very fast and is a nice flat black.
(Posted in: Details)

IMG_2885 (Edited).JPG
163 hits | 59.46 KB | Posted: 5/20/16
Trim ring and gauges set in place.
(Posted in: Center console )

IMG_2825.JPG
164 hits | 62.52 KB | Posted: 3/10/16
Welded lug supports the intake port. I bored a hole under this so the bit wouldn't ride down the flange and screw up the hole.
(Posted in: Megasquirt fuel injection)

finished studs.JPG
165 hits | 50.07 KB | Posted: 10/24/15
Studs installed. The upper plenum fits it perfectly. I need to cut a gasket for it because Ford used an o-ring and I changed the port just a bit.
(Posted in: Carb intake to throttle body elbow adapter)

IMG_2901.JPG
165 hits | 51.86 KB | Posted: 5/20/16
Drawer and lid installed all open.
(Posted in: Center console )

IMG_20160326_191354738.jpg
165 hits | 24.86 KB | Posted: 8/10/16
(Posted in: 1965 galxie LTD)

IMG_1507.JPG
166 hits | 48.99 KB | Posted: 6/7/14
The top piece of steel is now cut out so I can hold the reservoir steady while I mark and trim the cardboard for the lower bracket. The steel is on top in this picture but the final bracket has the steel under the plastic. Tack welded it and couldn't...
(Posted in: Remote power steering reservoir)

IMG_2875.JPG
167 hits | 73.81 KB | Posted: 5/20/16
Console mock up with lid and drawer.
(Posted in: Center console )

IMG_2830.JPG
169 hits | 72.5 KB | Posted: 3/10/16
The more angled holes rode a little so I had to ream them later but it wasn't much of an issue.
(Posted in: Megasquirt fuel injection)

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_1348.JPG
170 hits | 37.56 KB | Posted: 2/8/14
I needed a place to put two radiator fan switches and the return water from the water-cooled turbos. I had some 1.25 in x 1.5 in aluminum stock lying around and I have the right tools. Here I'm just laying out the design.
(Posted in: Fan switch manifold)

IMG_2826.JPG
170 hits | 74.07 KB | Posted: 3/10/16
Boring the injector bung holes. I used normal water to lubricate the bit so there wasn't any oil to soak into the aluminum and contaminate the weld. I had to constantly spray water but it worked fine. I already spent a lot of time boiling this intake...
(Posted in: Megasquirt fuel injection)

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_2824.JPG
173 hits | 72.17 KB | Posted: 3/10/16
Made a bracket to hold the intake flat for boring the injector holes. Simple 45 degree plate bolts to the intake flange and bolts to the drill press.
(Posted in: Megasquirt fuel injection)

IMG_2827.JPG
173 hits | 68.23 KB | Posted: 3/10/16
Boring another hole. Setup worked just fine.
(Posted in: Megasquirt fuel injection)

bt7.JPG
173 hits | 45.33 KB | Posted: 3/8/16
Battery box vent. Hose plastic epoxied into the 90 degree bulkhead fitting and into the trunk sheet metal.
(Posted in: Trunk mounted battery)

IMG_20160326_191204162.jpg
173 hits | 18.19 KB | Posted: 8/10/16
(Posted in: 1965 galxie LTD)