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Compliments of haynmerc @ http://classiccougarcommunity.com
Been away for awhile, but been busy and things are coming along pretty good. Got my car from Upland CA, and started stripping it for a restomod, looked for a rotisserie, but shipping made me make one for myself...used plans from Redwings Steelworks.
Got it down to a shell today, will do some welding on the frame in the rear for frame inserts, then put it on rotisserie after that. I have the R&C Motorsport Mustang II front X-member in, then installing the Chris Alston G-Bar system in the back, both are coil overs. Also will weld in Maier Racing frame ties. Will put up picture as soon as I remember how...lol
Some of these progress pictures are out of sequence...but for the most part I have some welding, for rear suspension and frame, then sandblast and hope I remember how everything goes back...LOL
Today I got the vinyl roof off, all the window goo off...that stuff sux. And all the rest of the little things off the car, including headliner. Looks like roof was just starting to spot rust under the vinyl...think I caught it early...wheeew....
Today I started to mock up and install the Chris Alston G-Bar 4 Link cradle. It fits a Mustang easy enough, but on the Cougar you need cut a tunnel for it reach all the way up to body. The supply you with a sheet metal to weld in and create a tunnel. I cut the hole, and fit the upper cradle into place...just need to weld in the tunnel. Am I really capable of all this? Not really, but so far so good...lol
Today I hooked up the rotisserie completely, and got it off the jack stands. I installed the balancers and took the rest of the day trying to balance the car, so I can rotate it easily. IDK what I'm doing wrong, or if there is a trick to balancing it. Does car stay level? Lower in front or rear? I took it as high as I can, with reference to the pivot tube....pivot point. But no luck....can't get it to balance....not sure who to ask for help...
Well, after a lot of hemming and hawing, cutting and welding, I was able to turn the arms upright with new brackets that mount to the bumper holes in rear...finally got the car to balance and it turns over by hand....wheeww. Held me up for awhile as this is my first time with a rotisserie.
I finally got all welding done, front x-member, panels that fill in for shock towers, and tunnel added in rear for Chris Alston G bar cradle.
It looks ugly but I had sprayed some rust stopper on all welds and steel....will look better after sandblasting and body working welds and panels.
Finally got body to High Tech Coatings for sandblasting and then epoxy primer. WoooHooo!!
Lowered and strapped to jackstands for stability...
In the yard, ready to go into booth....of course it rained! LOL
Sandblasting done, then a quick coat of epoxy primer...bring it home tomorrow.
Cleaning sand out is endless...
yesterday on way to sandblasting, thought was kinda funny....fast Cougar for not having a motor...
Sandblast and primer is done, got car back home today.....yes, we did find some hidden treasures....LOL, two patches under rear window, roofline above rear window, right lower rear quarter has a few holes, and we knew drivers floor will need work.
Other than those the body looks absolutely great! Let the fun begin......
Sorry I been away for awhile...was restomodding a '56 Ford truck for a friend, started simple but as most of you know, it got bigger as we peeled it back...until it became a "complete". One thing after another, but it turned out really nice!
I was able to finish welding in the rear suspension cradle, frame ties....long story....and now got dash mods and painting of dash and steering column. Also did the steering column mods to shorten it 1" and convert the end to "double D shaft" with center support bearing...something erkthejerk73 will be doing also.
So now I'm making a gas pedal support, and a sheet metal mount for the computer...both required to invent and make yourself for Coyote motor. The gas pedal is electronic and calls for a funky mount to be welded on the floor...will try for some pictures soon....
Happy New Year to everyone!
See if I remember how to post pictures....
Frame ties from Chris Alston
Dash prep for paint
Welding in upper cradle
cradle mount with sway bar attach point
Going to make a fiberglass hood, this hood will build the mold. Kicking around some ideas for a cowl induction hood with two scoops in front....kinda like hood we built for Ranchero. Kinda want it set back on hood....not sure yet....
Here are the steering column mods for erkthejerk73.
Remove the column lock shaft by removing a half inch bolt near the top of column. Rotate cover below key util you see bolt in hole.
Cut 1" off bottom of column (for better angle to R&P). Layout, cut shaft and weld in double D shaft.
Install shaft, center support bearing and lock retainer. Weld bearing to column and you're done...not hard at all...the instructions that come with kit are very good.
Today I made and finished welding in a gas pedal mount. Totally made it up myself, it looks weird but provides a flat surface for the electronic gas pedal to bolt on. The Coyote set up is electronic, no cables.
It has to conform to firewall and floor, yet make sure the gas pedal is actually in same area as stock factory pedal. I welded nuts behind so new pedal can be an easy bolt in.
Here it's welded to floor
Final bolted in
Today I spent my entire day off working to make a new fiberglass hood, using the factory hood to make a mold. First was to layout and mark centerline and all reference marks to make sure left and right sides will be exactly the same.
Next was to create a copy of the factory rise and hood line running front to back, so when hood is finished it will still have factory rise and lines from the nose on back.
Finished factory rise with center hood lines....will be top of hood and scoop rise.
Here you can see foam inserts to give hood a gradual rise, yet keeping original lines in center.
Here is how far I got....foam inserts are installed on all sides, including rear. A total of 1.5" rise from flat part of hood. A gradual blended rise from nose. Now it's ready for body and putty work, rounding edges etc...Then make the mold. Recessed and countersunk hood scoops will be "plugged" from bottom later after the mold is made.
OK, so moving on decided to add a little more to hood design. Came out with runner going towards scoops, and tapered the rise in the middle.
This is the finished work on factory hood, ready to lay up the actual mold
This is the actual mold, laid up on the factory hood. This is what we will use to make hoods.
Today I rebuilt the clock as I'm getting ready to reassemble the dash....
Out of two clocks, one runs perfectly but has a broken adjust knob. The one with good adjust knob does not run due to a broken wheel inside the clock mechanism. So I decided to convert the clock with good knob to Quartz. I got the kit from Instrument Services Inc. in Illinois, came with good instructions and is running perfectly....keeping good time.
Now I just need the reproduced lens from WCCC...
OK....so here's the final rebuilt clock...It's ready to go back into dash, keeping perfect time and looks new thanks to WCCC's new reproduced lens!
So, after a lot of thinking, planning, fitting and figuring....I chose to put the computer (ECM) for the Coyote motor in the right side cowl, behind fender. It's all weather and can get wet, but here it won't get too wet and stay cool....they recommend putting under cowl, passenger side wiper motor. I will make a cover for connections and wiring that will route up and under inner fender.
Initial cuts, to put in a piece of sheetmetal, for a flat mount area.
Here's the finished pics....just need to form a cover.
So things been a little slow, helping others and waiting on some things to get going. I decided to do a "Partial paint"...so I painted the bottom, inside, engine compartment, trunk and door jams. This way I can install the rearend and front suspension and see if there is any unforeseen work with front and rear fenders and wheel clearances.
I set up a paint booth in the garage and it worked pretty well...spraying clear got cloudy, but worse was the fact that smell went into my neighbors house....not good for the old folks so I won't do a paint booth again....
Finished installing the Chris Alston G-Bar Coil over rear suspension. Fit is perfect and all pieces are quality....There is a ton of infinite adjustability with this suspension...lots to learn!
Today I put together most of the front suspension. I pained the sway bar hardware and will put sway bar in tomorrow...
Here is the steering rack...Everything is either dark gray or black with body being a really dark green...
Put in swaybar today, only to find out I made a mistake when mounting the frame brackets. I welded frame brackets 1 inch too far aft....resulting in lower A arm bushings tilting aft into spring. Hard luck and inexperience on my part I guess.....so, looks like a cut out or modify the bracket 1 inch forward. Will figure it out this weekend.....bummed.
Today I was able to completely rebuild the A/C & Heater box. Got all the parts from Classic Auto Air, everything fit perfect and is quality for sure. Believe I bought everything from a guy on this forum...CougarRon?
Will install box, then wire harness then lower dash...it's true what they say: "The car was built around the A/C box" LOL
So, it's been awhile, got busy with other cars, work etc....but mostly it seems as I go along, some things go ok, some things need to re think....also, waiting for shipping, brake kits etc....needed to put holes in axles to get socket onto nuts to retain axles....it goes on and on....but still making good progress. Got car off of rotisserie.
I got dash in so I could route computer harness and power distribution box, Brake and clutch pedal, steering column and completed steering linkages.
Todays big milestone was I finally found some old wheels that would fit (barely), and got car on it's own feet....now can roll into paint booth.
car is lower than I thought it would be, hard to tell in picture....
My axles did not have the 1" hole for a socket to secure backing plate nuts. You have to ask for holes when ordering....oh well. I took them to machine shop and drilled them out no problem.
The lower dash is in, pedals, AC box. So I could route computer harness and Power Distribution Box, including harness to electronic gas pedal. Everything barely fits, after some small mods to gas pedal...LOL
Axle after I drilled access hole....sorry blurry.
Today it rolled on to a trailer and went for final painting, nice to see it on wheels and some movement!
Got body painted, and even though it's hard to see....it's a dark green with unreal metallic gold pearl....it really pops in the sun, and is almost black in the dark. we are super happy with this color!
I mounted a winch to garage floor, awesome idea I got from a friend....pulled car off trailer, up driveway and onto lift......so easy! LOL
These pictures are hard to see cause of reflection, but this my homemade fiberglass hood....can't wait to see it on car. We rose the middle so we could put scoops, then put a slight rise over cowl area.
I had another project for a friend, and finally getting back on my own car.
I got the tail lights apart to restore, chrome grills are out for powder coating blackout, and received some parts from WCCC. As I restore the housing, I used a paint from SEM called Aluminum Chrome, to restore the reflective parts behind the light bulbs. Not sure what other folks use, but this paint looks almost exactly the same as factory....What do other folks use?
Hopefully these get loaded...still trying lol....
Been awhile since I been here, car just needs alignment and plates. Oh and the windshield wiper motor is not parking.
But I did make it to the car show last weekend and it got a lot of compliments...
I was also able to get the spoiler I saw when I was in Cypress for Cougar show (Kat Brown?).
I opened it up wide open once in second gear just to see if any hesitation, boggs or would accelerate cleanly....It was incredible! This Coyote pulled so hard, and screamed into high RPM without missing a beat.
This week it gets alignment and plates...