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[Stangra]

Welding the alternator bracket shouldn’t be a big deal I don’t think that little bit would get it hot enough to warp a head if your worried about it

Yeah, I don't think the head would warp either. My concern is more about the timing cover itself. Or the o-ring seal being heat damaged.

 

[Dave_W]

Wait, you sanded down the artistic custom "crackle finish" paint job?

I can't begin to imagine how long that took, and the patience involved, but the result is very nice. Congratulations on the final product.

 

[Stangra]

Wait, you sanded down the artistic custom "crackle finish" paint job?

I can't begin to imagine how long that took, and the patience involved, but the result is very nice. Congratulations on the final product.

LOL!
I'm not sure if I should just be ultimately happy with it or seek treatment, I kept telling myself I must be crazy. Either way the trauma is over!

 

[Stangra]

I went ahead and ordered a new timing cover, removed the cracked one, and learned that my replacement's shipping date has been delayed.

Very soon I'll be able to say I've actually installed a part on this car! Meanwhile a few more details to take care of.
One was that It appears the car had a leaking pinion seal and there was a greasy mess on much of the undercarriage, along with the expected accumulation of road dirt, etc. I removed the goo-covered gas tank and will use the tank from the other car, it's got over 100K less miles on the internals. Also removed the 3rd link, I won't need it when I transplant my Cortex Torque Arm.


Not the home I'd like to put the motorsport goodies from the other car and some new stuff into.



After a mixture of Simple Green and Elbow Grease things look much better now!

 

[Dave_W]

Since you've dropped the gas tank, consider the fuel cell foam mod that @blacksheep-1 did to prevent slosh to the non-pump side saddle and fuel starvation at the pump under high cornering loads. Or there's another thread where someone put a small auxiliary pump on the non-pump side. And if you're planning E85 and bigger injectors down the road, maybe a mild pump upgrade as well (e.g., DW400).

 

[Stangra]

Since you've dropped the gas tank, consider the fuel cell foam mod that @blacksheep-1 did to prevent slosh to the non-pump side saddle and fuel starvation at the pump under high cornering loads. Or there's another thread where someone put a small auxiliary pump on the non-pump side. And if you're planning E85 and bigger injectors down the road, maybe a mild pump upgrade as well (e.g., DW400).

I've been watching the postings regarding fuel slosh/starvation with keen interest. Thank you for reminding me! I've got so many things going on with this project that it slipped my mind. I just ordered a block of foam. My experience with this problem hasn't been as extreme as some others but I've always kept the tank over 1/2, and it still needs to be addressed, The fix @blacksheep-1 used seems reasonable and simple. With the tank out I have nothing to lose by trying it, and I might even avoid his "bloodbath"!

When I had my supercharged car (parts donor for this one) tuned by Shaun at AED for E85, he recommended I use a JMS pump booster. Not as solid of an upgrade as a better pump but it was working out fine until my wreck. This would be a great time go further but for now, since I'm already tuned for this steup and I need to stick to some semblance of a budget, I plan on just switching everything over as it was.

 

[Stangra]

Progress! Not very significant but I reached a symbolic milestone. First parts from old car actually installed in the new. A morale booster! I replaced the entire old fuel system including the filler tube, evap stuff, all the hoses, and the tank with internals. And I installed some anti-slosh foam in the saddle area of the tank. Thanks @blacksheep-1 for a little advice. I got respect for any one doing this in-car, it was a little difficult even with the tank out! My elbows barely fit through the tank openings, if your forearms are longer... good luck!

 

[Stangra]

I was curious about what the stock fuel transfer setup looked like, and wanted to ensure that my foam anti-slosh wasn't interfering with it. Since I have an unneeded fuel tank I took a peek:



The only external moving part is a spring loaded (check valve?), the blue piece. I feel confident that the foam will not interfere.
I tried removing this part during the foam install and am glad I didn't invest much time. If you can't get 2 hands and tools in there, it's not coming out. 4 plastic tabs lock it onto the mount.

 

[Stangra]

I finally got my new timing cover. The old cover broke where marked (red arrow) in the wreck, alternator too.
I modified the new cover to clear the supercharger drive and got the engine closed back up, ready to put my new alternator on.

 

[Stangra]

Ok, I've got all my Cortex rear suspension out of the wreck, it'll go into this car as soon as I rebuild the axle.
I'm taking a plunge here and doing everything... my first time setting up rear end gears. The axles were starting to show early wear at the bearings previously so I had bought new axles, bearings, seals and a Torsen to replace the Trac Loc a couple of years ago but never had time to install them. I just ordered a Ford Performance ring and pinion set (3.31 out, 3.55 in ) and the M-4210- B2 install kit. I think this should be all the parts I need, am I missing something? After a little cleaning up this should be a completely new axle assembly. I was thinking powder coat untill I saw $$$, so it's going to get paint!

I never liked that Ford didn't see fit to spend a few bucks and paint the axle from the factory. The day I bought that car new I took a look underneath and it was already rusty. And it bothered me more when I installed the Cortex stuff... all that pretty hardware on a rusty axle. Not this time!

Somewhere around here I've got a new Ford Performance aluminum 1 piece driveshaft to mate up to it too.

 

[Dave_W]

I never liked that Ford didn't see fit to spend a few bucks and paint the axle from the factory. The day I bought that car new I took a look underneath and it was already rusty.

Don't know if it's true, but this is a story I heard. When a Ford corporate bean-counter balked at the Boss getting a painted axle, someone on the team explained, "Imagine 20 years from now, and a Boss is rolling across the block at Barrett-Jackson. The chassis cam in the floor shows a spotless engine and transmission going by overhead, then a rust-free exhaust with side pipes, and lastly a rusty axle." The bean-counter replied, "Paint it."

 

[Stangra]

In my passion to get this done I didn't get pics of the process. After degreasing, a wire wheel attack of numerous sizes & shapes, a naval jelly bath, paint prep solvent, primer & 2K Satin Black paint, here we are:




Next... Install new ring & pinion, new Torsen, new axles & bearings