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Old 08-16-2005, 08:57 AM   #301
 
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Hi All,

Yesterday things went pretty slow. We didn't receive the fittings for the oil cooler / filter relocation kit until the afternoon. That only gave me enough time to mount the oil cooler. I now have to mount the filter relocation housing. I can easily mount the housing, but running the lines is going to be a bit problematic in that the fittings I have to use take up quite a bit of real-estate. I think I have things figured out, but I thought I would review the installation with Wayne and the guys in the shop before I drilled the mounting holes.

Here is a photo of the installed cooler. We were trying to decide if we need a shield to protect it from rocks thrown off the front wheel. We are going to debate this one a bit before we



Wayne got the fenders and hood mounted. And, as with everything else, he had to do some fine tuning for fit and clearance. The passenger side fender will need some modification to achieve the proper gap at the hood. We also had to modify the caster camber plate setup to gain a little bit more clearance between the strut shaft and hood. Here are some photos of the hood from a couple different angles









We are still waiting for the correct tube bending dies so that we can fab up the heat exchanger plumbing. Maybe they will come in today. I can only hope.

Catch ya'll l8r
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Old 08-18-2005, 08:44 AM   #302
 
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Hi All,

There has been a lot of discussion in regard to the oil cooler installation as far as location goes. Most are concerned with damage and others concerned with air flow. We have reviewed the situation over and over again, but I feel that we have the situation under control. I will be posting photos of the finished installation once complete and then we can all critique it.

Wayne is moving on to the front fenders. He is positioning the flares and working out the design of the leading and trailing edges. Wayne and Dave came into my office yesterday and asked about the lower front valances that were available for the Eleanor kit. They were wondering how that lower valance would look on this car. They said that their jobs would be a whole hell of a lot easier if they could use the molded ends that blended into the front edge of the front fenders.

Well... To make a long story short, we decided not to use the Eleanor front end and to stick with our original plan. Wayne will fab the leading and trailing edges of the flares. We will use the factory front valance (modified with vents for the heat exchanger). Also, to answer a few other questions, we are going to use the factory chrome bumpers front and back. Some argue that a car of this type should have some type of spoiler or a Shelby front valance. I can see their points, but I just can't envision a spoiler that will do the car justice. Also, while I like Shelby clones, I just could not bear to put a Shelby front valance on this car. I know, I know. Using the Shelby "R" style front valance would save me tons of work. No bumper brackets to fab, etc, etc. And we would have plenty of air flow for the radiator and heat exchanger. BUT, I am going to resist the knee jerk reaction to take the easy way out. I think this car should stand on it's own merit. I could not stand it if people walked away from the car thinking It was some altered Shelby clone.

Anyway... It is coming up on 8AM and I have to get to work.

Catch ya'll l8r
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Old 08-19-2005, 03:17 AM   #303
 
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It is good to hear that you are resisting the knee jerk reaction to take the easy way out. Stick to what you feel will be right for the car. I also believe the car should stand on it's own merit so it will not look like some altered Shelby clone. There are too many altered Shelby Clones out there already. You are doing a great job and I enjoy following this project. Stay in the driver seat and continue to manage this project the way you think and feel it should be done.
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Old 08-19-2005, 10:42 AM   #304
 
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Hi All,

Wayne worked late last night on the drivers side fender flare. Before I left for the night (undedicated part timer that I am :-) ) I helped Wayne set the suspension to get the correct attitude. I also established where I wanted him to position the top of the wheel opening. I had already gone through this exercise once before (when the car was on the frame rack on blocks) so all of the "rough" layout lines were pretty well completed at that time.

In the photos below you can see how we positioned the flare, marked up the panel, segmented it and screwed the flare to the fender with sheet metal screws. The positioning of the flare is quite difficult on the Mustang front fender. The problem area is where the fender intersects the bodyline just above the wheel. The flare has to be trimmed back so that the outside edge of the flare ends up exactly where you want it (in relation to the outside edge of the tire).











All Wayne has to do now is form the metal at the leading and trailing ends of the flare. Then we can bond the flare to the fender, finish off the inside surfaces, undercoat the fender, add a layer of fiberglass to the outside edge of the flare, fill and sand and fill and sand and fill and sand....

Catch ya'll l8r
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Old 08-25-2005, 07:37 AM   #305
 
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Hi All,

Sorry that I haven't updated the site or posted much lately (5 days since the last update), but I have just been buried over the last week. Working on the car. Working on, sigh, work. Rebuilding my new laptop (Corrupted files drove me to the most drastic of measures. Wiping the system clean an reinstalling all the software and systems). Taking time to show my daily driver at a local car show. On and on...

On a positive note, the body shop did get two projects from people who have been following the build on the internet. One is a 67 Mustang convertible and the other is a Honda rice rocket. The 67 vert needs to be restored after a "small" electrical fire (drivers side engine bay). The "rocket" was in a slight fender bender, but needs a total paint job (Another body shop butchered what was supposed to be a high end "custom" paint job. Here is a photo of Wayne scraping the finish off with a razor blade.




Anyway, I digress...

As far as the car goes, we have been busy little beavers, with Wayne performing a lions share of the work. I have been working on the oil cooler installation, the intercooler mounting, the prop rod installation, etc... Wayne has been working on the drivers side fender and the front grill / valance installation. Following are some photos showing the progress of the past few days. If these aren't enough to keep you satisfied, we have downloaded many more photos at our site.

Prop rod details (Note the installation of the hood bumpers)
[img[http://sn65.com/images/SN65%20Images/05-08-24%20040.jpg[/img]


Oil filter / cooler details (I still have to install the debris shield). Pay special attention to the lines and fittings used. The lines look like your standard automotive hose, but they are a little bit more industrial than that. These armored hydraulic lines have a burst pressure of 9,000 psi. Also, the internal shielding makes these lines virtually impact resistant.





Flare details (Note the extractor vent)




Intercooler heat exchanger details


Catch ya'll l8r
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Old 08-27-2005, 07:09 AM   #306
 
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Hi All,

Just talked to Chuck at Maximum Motorsports. They are helping with all the suspension details and setup. They have helped me resolve a number of issues throughout the project and they just helped pull my a$$ out of the fire again....

I modified the caster camber plate arrangement for clearance and ran the idea past them (of course after I had already made the modification). It seamed like a simple mod straight forward to me. They said that they would run it past engineering and get back to me.

Well, they called back just after I left for the day. Wayne said that they wanted me to call them back ASAP.

I called them back the next morning and Chuck told me not to drive the car as altered. Our simple little modification has reduced the strength of the plate assembly by approx 90%. One little bump in the road and BAM the strut will come right through the hood. He said that the engineer actually came running into his office with the calcs. "The modified plates may not even support the weight of the car just sitting there" he said.

I went over all the details with them and they came up with a "safe" workable solution to my clearance issue.

Thanks MM for saving my butt again.
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Old 08-30-2005, 09:52 AM   #307
 
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Hi All,

Time is getting tight and I only had time to updated the website today. I have posted Info on the rear bodywork and revised stereo components. Thanks to all for the input on the stereo. I think you will like the revised system. :-)

Bob
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Old 09-01-2005, 11:52 AM   #308
 
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Hi All,

I am getting ready to go an a little labor day get away. So I will be out of the office until next Wed.

Happy holidays, catch ya'll l8r.
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Old 09-08-2005, 10:10 AM   #309
 
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Hi All,

Well, I am back from the wilds of northwestern Wisconsin. I am all rested and ready to make one final push to get SN65 roadworthy. Wayne, on the other hand, spent the holiday working. What was he working on you ask? Well, sanding and priming and sanding and priming of course. He is now concentrating his efforts on fitting up the front drivers side fender. I could go into a lot of detail as to what he did and how he did it. but I will let the photos speak for themselves.



I don't know about you, but I really like the way Wayne created the flares / extractor vent detail in the front fender. The finished panel is gorgeous. Wayne did an incredible job on the rear flare detail, and needless to say, the front flares are more of the same. When Wayne came in this morning, he found me just standing in the shop staring at the drivers side of the car. I was walking back and forth and back and forth and back and forth. I can really start to picture the finished results and (even though I can be a critical SOB on occasion) the quality of fabrication and the way all the design elements work together far exceed the picture I had painted with my minds eye.

Here are a couple of "fans" that stopped by the shop. They wanted a brief look and Wayne spent about half an hour answering their questions. I am sure that they would still be talking about the car if a paying customer hadn't shown up.



What have I been doing you ask? Well.... as I said earlier, I spent the holiday in the backwoods of northwestern Wisconsin. A few days relaxing about the house, going out on the boat and pounding down a few drinks (happy hour is at 5PM) have got me ready to rock. I am going to finish the last few plumbing details and fire this sucker up. After that, it is all going to be a downhill rush to completion. I will post some photos of the plumbing configuration this week. I am very happy with the way the final configuration cam out.

Need more photos??? Just stop by the SN65 website.

Catch ya'll l8r
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Old 09-08-2005, 10:23 AM   #310
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The car looks amazing !!! So much work and so different,
can't wait to see it in person
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Old 09-08-2005, 11:51 AM   #311
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wow, she looks beautiful!! i cant wait to see it with that brushed aluminum looking paint on there!!!!
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Old 09-09-2005, 08:09 AM   #312
 
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Quote:
Originally Posted by Jimbo1221
wow, she looks beautiful!! i cant wait to see it with that brushed aluminum looking paint on there!!!!
Hi J,

Ooopps....

You must have missed the whole paint conversation where we changed the final color to 05 screaming yellow.

Hope you like yellow. :-)
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Old 09-09-2005, 11:41 AM   #313
 
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Hi All,

just a little note. a new update is posted at the site. I'm real busy right now.

Catch ya'll l8r.
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Old 09-12-2005, 08:01 AM   #314
 
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Hi All,

This weekend (as with everything else lately) was a struggle. We bolted the entire front end together (save the bumper) and discovered a number of minor alignment issues. The headlight buckets and "eyebrows" posed the greatest problems. Getting the correct relationship between the upper valance, the bottom of the eyebrows, the bottom of the grill, the outside edge of the eyebrows to the fender, the hood to the eyebrows, the top of the grill to the eyebrows was a royal pain in the butt. every correcting adjustment threw another area out of alignment. After a lot of tighten this, loosen that, move this, tweak that, pry here, bend there and hammer & dolly everywhere, we ended up with the alignment we wanted.



After that Wayne went over the body one more time before rolling the car into the booth for final priming. Wayne just needs to finish the passenger side fender and the front valance and we will finally be ready for color. Once we get through these steps and get the car painted, final assembly will fly by.

While Wayne was struggling with the front end panel alignment, I trial fit the dash end panels. One screw holds them in place and they look great. Once we get the windshield pillars painted I will be able to perform the final assembly on the dash. I can't wait for that phase. Once I finish the dash, I can move on to the rest of the interior. Once I have the interior finished, Wayne should have the rest of the front end bodywork complete so we should be able to bolt everything up, turn the key and drive the car over to the alignment shop. That will be a great day. Hopefully it will come soon. :-)



I have included some photos of the intercooler, heat exchanger plumbing. The final assembly of these items will be performed after the installation of the cold air intake system. This may seem backwards, but the 4" diameter cold air intake system mounting flange does not clear the installed heat exchanger plumbing. Maybe I should include this info in the owners manual. Which makes me wonder. When you spend 1/2 mill on a custom car do you get a comprehensive leather bound owners manual or do you get a cardboard box with some of the aftermarket manuals thrown inside. Maybe you just get the keys, a handshake and a "good luck" as you drive off into the sunset.



Catch ya'll l8r
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Old 09-12-2005, 08:02 AM   #315
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Very Nice!!
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Old 09-13-2005, 09:12 AM   #316
 
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Hi All,

While I spent yesterday reviewing engineering specs and BOM's, Wayne continued to plug along. Here we can see the final guide coat on the chassis / body. How does the car look in black? Dave said maybe we should paint it yellow and black so that we can achieve that often attempted, never achieved faux bumble bee effect. A little wet sanding and the car will be ready for the final color.





After the passenger side fender and valance are complete, we will disassemble for paint. At that point, things will really start to fly.

Catch ya'll l8r
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Old 09-13-2005, 11:04 AM   #317
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that looks amazing man! great job
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Old 09-20-2005, 04:45 PM   #318
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This is about the coolest thing I have ever had the pleasure of reading about... I cannot wait to see this car...

One thing...the passenger side front and drivers rear seem to have been flipflopped (tread direction)



Too many years of those stupid where's waldo books...

Absolutely amazing car, gents...
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Old 09-20-2005, 10:41 PM   #319
 
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Hi All,

I have been talking to my wife about a G2G in about 4 weeks. What do you all think???

Wanna come for a ride???

OBTW, we will not be axble to do any full on power shifts until we break in the clutch, but that does not mean it won't be fun.

What ya'll think???
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Old 09-21-2005, 12:21 AM   #320
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WOW! That's really coming along! I can't wait to see it finished! I call dibs on a ride!

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Old 09-21-2005, 07:02 AM   #321
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Quote:
Originally Posted by SN65
Hi All,

I have been talking to my wife about a G2G in about 4 weeks. What do you all think???

Wanna come for a ride???

OBTW, we will not be axble to do any full on power shifts until we break in the clutch, but that does not mean it won't be fun.

What ya'll think???
I'd be down.
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Old 09-27-2005, 09:12 AM   #322
 
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Hi All,

Yesterday, I worked on the final engine plumbing details. Radiator and air intake. Everything went pretty well. Not perfect, just pretty well. :-)

To complete the air intake I need to locate one sensor and plumb up one vacuum line.



My biggest problem is the lower radiator lines. I have posted some photos (more available at the website) showing the incredibly tight spaghetti bowl of lines and hoses in this area. Everything is pretty good, but I only have about 1/8" clearance between the sway bar and the hose / thermostat housing. There is plenty of flex in the plumbing (if the sway bar pushed on the hose, there is about 1 1/2" of movement). My problem is that there is nothing to tie the hose / housing to save the power steering rack and doing this is a bit problematic. I am thinking that I can make a bracket that ties the bolt of the housing to the rack, but there is nowhere on the rack to bolt to. I am going to have to kick this around for a while until something comes to mind. In the mean time, I am going to place a rubber "shield" around the sway bar to keep it from chaffing the radiator hose.




Any recommendations would be appreciated.

Catch ya'll l8r
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Old 09-27-2005, 11:19 AM   #323
 
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Hi All,

Anyone notice the download I posted on the SN65 homepage???
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Old 10-01-2005, 07:27 AM   #324
 
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Hi All,

Two steps forward, one step back.... :-(

Yesterday, I wanted to help make some headway on the bodywork. I decided that the best place for me to concentrate my efforts was on the front valance. I had already cut the ductwork for the vents. All I had to do was fit them up to the inside of the valance, tack them up, and then wait for Wayne to weld the seam. Simple right? Well after I did the final fit up and tacked them in place, I decided, what the hell, I can weld the seam. After all, I know how to weld. It can't be that hard. That was my big mistake. I followed all the proper procedures and after about 30 minutes I had everything welded up. I then started to examine my work and found that the piece had warped at the end of the passenger side vent. I didn't think it was that bad, but after Wayne looked it over, we decided that we should order a new valance and do it over again....



I was so depressed. I thought I was helping out and, when all was said and done, all I ended up doing was creating more work. :-( On the other hand, my little excursion into the realm of Wayne's world has been a revelation. There is more to properly crafting steel than a basic understanding of the proper procedure. Also, just because you can weld, does not mean that you have the "touch" required to weld these thin sheet metal panels. I guess I will limit my welding to heavier brackets and structural items until I develop a lighter "touch" with the welder.

On the plus side, it does serve as a nice "mock up" of the final piece. When in position on the front of the car, it shows us what the finished panel will look like. It is going to look killer. Also, it has revealed a slight interference with the ductwork and the heat exchanger plumbing. We are going to resolve the interference issue by relocating the fittings on the exchanger from the front of the unit to the sides.

On another note, Wayne did get the front window pillars painted last night so that I can start on the final dash assembly. I will be working hard on this aspect of the build while I leave the bodywork in the hands of the experts.



It is now after lunch and I have been working on the dash assembly all morning. The defroster vents gave me a bit of a fit, but (after a bit of trimming) I was able to get the ducts installed and aligned. We should now be able to run the defrosters as we drive around the Chicago area this winter. :-)




Catch ya'll l8r
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Old 10-03-2005, 11:00 AM   #325
 
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Hi All,

This weekend while I worked on the car, Wayne was involved on a new project. A customer brought in a 70 Camaro that he wants built into a ground pounding, earth shaking, 504 cubic inch big block beast. I could not help but listened to him and his son talk to Wayne. And while he says his intentions are only to do a bit of cruising and joy ridding and maybe hit the local car show circuit, I cannot help but feel that he has no good intentions toward all my faithful Ford brethren. And, even though it is a (cough) Chevy, it is going to be one beautiful ride when finished.

So, while Wayne was busy with a paying customer, I worked on modifying the pony door panels. I needed to remove the raised areas that interfered with the ends of the dash and also, I needed to remove the entire ribbed center section. While, on the surface, this sounds like a relatively easy project, It ended up taking most of the morning. And, I still have to fit the panels up one more time to check the clearance. Also, since I am not using any of the chrome trim, the edges have to be ground to a nice consistent lip all the way around the panel and then I need to radius all the edges (they currently come to a sharp edge). When I am done, they will go off to the upholstery shop where they will be covered in the same leather that was used on the dash panels. The center section will end up with a padded insert. The only hole in the panel will be for the standard Mustang door pull.





I also spent time mounting the two 6 volt batteries. I picked batteries that were gel filled and mountable in any position. Originally, we were going to hang them in the trunk from the cross member that runs the width of the car just in front of the deck lid. This proved to be a poor location. The batteries are quite heavy and we felt the area had to much flex. If we mounted the batteries there, there was a strong possibility that the weight would pull that area of the car down so that the body no longer lined up with the deck lid. After much consideration we decided to mount them under the internal cross bracing where the rear seats used to be.



Well, enough for now. It is time to get back to work.

Catch ya'll l8r

Bob
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