IMG_2626.JPG
111 hits | 54.56 KB | Posted: 3/10/16
Working on the core.
(Posted in: Center console )

IMG_2627.JPG
114 hits | 59.35 KB | Posted: 3/10/16
Mostly roughed in. Lots of finish work to do though.
(Posted in: Center console )

IMG_2630.JPG
94 hits | 73.37 KB | Posted: 3/10/16
Holes for cup holders. These are 3 5/8 inch and I bought a 3 5/8 inch hole saw. They are a light interference fit. Perfect.
(Posted in: Center console )

IMG_2632.JPG
113 hits | 58.52 KB | Posted: 3/10/16
They are offset to one side to clear my arm angle to the shifter.
(Posted in: Center console )

IMG_2633.JPG
120 hits | 70.04 KB | Posted: 3/10/16
Mocked up with shifter boot and trim ring. I stitched that boot too.
(Posted in: Center console )

IMG_2680.JPG
121 hits | 41.76 KB | Posted: 3/10/16
Beginning to cover it in vinyl. I made the sides removable and bolted from inside so it would hide the seam.
(Posted in: Center console )

IMG_2681.JPG
107 hits | 59.92 KB | Posted: 3/10/16
Slowly working the vinyl down and around. Patience.
(Posted in: Center console )

IMG_2683.JPG
97 hits | 54.68 KB | Posted: 3/10/16
Covered in vinyl! Still need to make the pull out cup holders but coming along.
(Posted in: Center console )

IMG_2688.JPG
115 hits | 36.5 KB | Posted: 3/10/16
Checking the fit to the rear carpet. Perfect.
(Posted in: Center console )

IMG_2689.JPG
100 hits | 48.7 KB | Posted: 3/10/16
Pull out cup holders for the rear passengers. Not too shabby.
(Posted in: Center console )

IMG_2690.JPG
103 hits | 30.89 KB | Posted: 3/10/16
Nice aluminum drawer pull. I like.
(Posted in: Center console )

IMG_2470.JPG
188 hits | 58.2 KB | Posted: 3/10/16
Display for the Tech Edge wide band O2.
(Posted in: Megasquirt fuel injection)

IMG_2757.JPG
141 hits | 75.5 KB | Posted: 3/10/16
Big ol pile of fuel injection parts. This isn't all of it either. Takes a bunch of little bits to do things.
(Posted in: Megasquirt fuel injection)

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

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)

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_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)

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

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_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)

floor8.jpg
127 hits | 64.44 KB | Posted: 3/9/16
Front mount for the center console and the tower for the shifter boot. Made it flanged for rivets to match a lot of OEM designs. It got riveted down over a fat bead of seam sealer after everything was painted. It shouldn't rust.
(Posted in: Floor pans and carpet)

floor4.jpg
123 hits | 68.55 KB | Posted: 3/9/16
Rust repair on the floor pans. Pics of the rust and cutting sheet metal won't load for some reason. Just spot welded here.
(Posted in: Floor pans and carpet)

floor5.jpg
118 hits | 65.04 KB | Posted: 3/9/16
Fully welded patch panel. I don't care about grinding the welds since it will be all under the carpet and insulation anyway.
(Posted in: Floor pans and carpet)

floor7.jpg
122 hits | 63.83 KB | Posted: 3/9/16
Passenger side panel fixed. Any remaining rust got hosed down with rust converter, then rusty metal primer, then rustoleum. I don't want to be back here again. The bottom gets the same treatment plus undercoating at some point.
(Posted in: Floor pans and carpet)

floor1.JPG
130 hits | 65.93 KB | Posted: 3/8/16
Summit Racing sport seats sitting on modified stock seat brackets. I thought I took more pictures of this.
(Posted in: Floor pans and carpet)

bt2.JPG
102 hits | 37.66 KB | Posted: 3/8/16
The car has a convenient factory hole to run wires to the trunk. The factory trunk lighting wires run through here with no grommet so my battery cables should be fine in the flexible conduit I'm using.
(Posted in: Trunk mounted battery)

bt3.JPG
107 hits | 50.56 KB | Posted: 3/8/16
Flexible conduit run. This is all behind the rear seat and behind various panels and whatnot. It's invisible once the interior is in.
(Posted in: Trunk mounted battery)

bt6.JPG
126 hits | 41.73 KB | Posted: 3/8/16
Joining the flexible conduit to the battery box. I used a special bulkhead fitting. Should be nice and airtight once it's all said and done.
(Posted in: Trunk mounted battery)

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)

bt8.JPG
137 hits | 77.29 KB | Posted: 3/8/16
The former battery location is full of air filter. Running the two cables through the conduit was not easy; it took a lot of lube but it worked out okay. The battery is grounded to the trunk floor and then to the frame in the rear and the engine bloc...
(Posted in: Trunk mounted battery)

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)

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)

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)

finished1.JPG
131 hits | 48.93 KB | Posted: 10/24/15
Finished piece. Intake elbow side. You can see the 5/16"-18 tapped holes for the plenum studs. They are blind tapped so there's no chance of leaks.
(Posted in: Carb intake to throttle body elbow adapter)

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)

Front inlet no go.JPG
131 hits | 63.02 KB | Posted: 10/24/15
This is the way I'd have liked to run the throttle body. Didn't work out that way. Too close to the distributor and not enough hood clearance to get around it.
(Posted in: Carb intake to throttle body elbow adapter)

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)

Layout1.JPG
140 hits | 48.98 KB | Posted: 10/24/15
There's a lot of layout work getting to this point but it all comes down to this. Lines on aluminum. This is the throttle body elbow side. I'm using a 99-04 Mustang upper plenum but Reshaping the port slightly and adding a divider. I also drilled the...
(Posted in: Carb intake to throttle body elbow adapter)

layout2.JPG
132 hits | 55.14 KB | Posted: 10/24/15
Laying out the intake flange side of things. This is an idealized version of the ports. The intake will need minor work to match. I'm keeping the divider all the way to the throttle body to keep the airflow to each side even.
(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)

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)

rough holes.JPG
141 hits | 75.09 KB | Posted: 10/24/15
Got the straight through section of the ports roughed out. Now to grind the angles in to match both ports. I used a aluminum-specific carbide burr for this.
(Posted in: Carb intake to throttle body elbow adapter)

roughed in1.JPG
140 hits | 42.73 KB | Posted: 10/24/15
The ports are a bit rough but at this point it's a functional piece. Everything else is polish.
(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)

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)