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)

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226 hits | 36.33 KB | Posted: 2/8/14
Fan switches installed. Turbo returns installed. Just need to order the 1/2 NPT to 3/4 hose barb fittings for the heater hose.

The fan switches are factory parts from early 80's Chrysler cars. The low temp is from a 2.6 around 1983 and the high temp...
(Posted in: Fan switch manifold)

IMG_1513.JPG
232 hits | 65.5 KB | Posted: 6/7/14
Complete install. Took a few cycles to get the air bled out of the pump and gear but it seems to work fine. I hope it holds up; there's too much time in those brackets for me to want to start over with another reservoir.

Half of the feed line to the...
(Posted in: Remote power steering reservoir)

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187 hits | 49.36 KB | Posted: 6/7/14
The start of any bracket fabrication - cardboard. I like old soda boxes but any will do. This is just the first try. Lots of trimming and fiddling left to go.
(Posted in: Remote power steering reservoir)

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202 hits | 57.67 KB | Posted: 6/7/14
The top bracket is pretty close so it's time to start on the bottom bracket. The two pieces will eventually get welded together to form a single bracket but I need to get the general shape first.
(Posted in: Remote power steering reservoir)

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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)

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185 hits | 46.86 KB | Posted: 6/7/14
Steel rough cut for the lower bracket. I ended up having to trim this down quite a bit. The angle section hit the air filter and the long section wasn't long enough because I didn't think bout having to put the voltage regulator back in. Not a big de...
(Posted in: Remote power steering reservoir)

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215 hits | 51.33 KB | Posted: 6/7/14
About to weld the upright to the main bracket. In this picture the upper and lower pieces are together and trimmed so that I can rotate the reservoir into place. I wanted to weld a stud to the bracket so I wouldn't have to use two wrenches in a tight...
(Posted in: Remote power steering reservoir)

IMG_1510.JPG
212 hits | 58.94 KB | Posted: 6/7/14
Both brackets. The big bracket holds the reservoir and the smaller holds the 5/8" to 3/4" adapter for the hoses. The pump has a 5/8" nipple and the reservoir a 3/4" one. Not a big deal and having the bracket means the hose is more...
(Posted in: Remote power steering reservoir)

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242 hits | 66.71 KB | Posted: 6/7/14
Bracket installed. You can see the trimming I had to do so the bracket would clear all the reinforcing ribs and such under the plastic lip. Not sure how Chrysler secured this originally. Mine lifts straight up after you loosen the two bolts on top an...
(Posted in: Remote power steering reservoir)

IMG_1512.JPG
197 hits | 70.08 KB | Posted: 6/7/14
Four Seasons 5/8" to 3/4" adapter. I welded it to the bracket and ground the welds flush. Not much strength needed. The adapter was a press fit into the sheet metal anyway. It bolts to the oil inlet flange on the turbo center section. The n...
(Posted in: Remote power steering reservoir)

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205 hits | 54.77 KB | Posted: 3/2/14
Made my own bell mouth adapters to bump the 2.5" air intake tubing up to the 3" required for the air filters. Just a 3" header reducer welded to a section of 3" exhaust pipe. Should be pretty good flow wise. These are just clamped...
(Posted in: Details)

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181 hits | 75.92 KB | Posted: 5/6/14
Driver's side turbo with the finished air intake. Routed the blow off valve to the intake. That's an upper radiator hose for an 83 Buick Century with a 3.0. Took a bit of searching to find a 1.25" hose with a 90 degree bend the right length. Ben...
(Posted in: Details)

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184 hits | 71.6 KB | Posted: 5/6/14
Passenger side pretty much done. Heat shield protects the air intake. More heat shield on the fuel lines. Crappy battery hold down was the first thing I made for the car. The radiator fan switches and water returns from the turbos are on the other si...
(Posted in: Details)

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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)

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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)

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182 hits | 49.81 KB | Posted: 4/28/14
Picture of the bracket I made to keep the clutch cable away from the header heat. It just clamps to the intake tube but I spent a good amount of time getting the bends right and painting it. I like things to look close to factory. Factory experimenta...
(Posted in: Details)

image.jpg
218 hits | 55.86 KB | Posted: 4/13/14
Aluminum sheet heat shield for the passenger side air intake. Not that complex of a shape.
(Posted in: TractionLTD)

image.jpg
236 hits | 55.74 KB | Posted: 4/13/14
The Saab relay box mounted to the Taurus fan. Pretty clean I think.
(Posted in: TractionLTD)

image.jpg
248 hits | 62.85 KB | Posted: 4/13/14
Engine compartment as of April 2014. I'm just flushing the cooling system right here.
(Posted in: TractionLTD)

image.jpg
176 hits | 57.89 KB | Posted: 4/13/14
Manifold installed. Had to make a heat shield for the air intake so I mounted the manifold to it. The low temp switch is toward the firewall so it turns the fan on when the coolant returns from the turbos gets above 185. The high temp switch turns on...
(Posted in: Fan switch manifold)

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)

Xpipe 005.jpg
372 hits | 76.38 KB | Posted: 3/8/08
Pistons in a box, on a cam, above a big hole where a 600hp motor resides.
(Posted in: March 08' and xpipe)

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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)

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237 hits | 59.23 KB | Posted: 3/2/14
The wire harness for the Taurus electric fan. That's a Saab relay block. It holds two relays and four fuses; perfect for a two speed fan installation.
(Posted in: Details)

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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)

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187 hits | 41.69 KB | Posted: 2/8/14
Drilling a straight hole through 6 inches of aluminum when your drill press only has a 2 inch stroke is challenging but possible. Here the 3/8 inch pilot is drilled. I had to drill it from each end. The two holes were only off by a few thousandths in...
(Posted in: Fan switch manifold)

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189 hits | 24.69 KB | Posted: 2/8/14
3/8 inch pilot drilled out to 3/4 inch. Still straight enough. It took a lot of stepping up drill bits to get here. Clearing chips from 3 inches down the hole is a chore.
(Posted in: Fan switch manifold)

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189 hits | 60.95 KB | Posted: 2/8/14
All the holes drilled. Just about to start tapping.
(Posted in: Fan switch manifold)

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180 hits | 75.54 KB | Posted: 2/8/14
Starting the tap. Long extension and socket make it easy to keep the tap straight when starting.
(Posted in: Fan switch manifold)

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180 hits | 34.74 KB | Posted: 2/8/14
I put 3/8 NPT tapped holes opposite the 1/2 NPT holes for the fan switches in case I ever need to use different temperature fan switches. 3/8 inch switches are more common.
(Posted in: Fan switch manifold)

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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)

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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)

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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)

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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)

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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)

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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)

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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)

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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)

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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)

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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)

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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)

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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)