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S550 Honey Badger GT350 Build Build Thread Profile - S550 Mustangs

Made more progress this weekend.

The chassis is now fully, fully stripped. Only the rear quarter windows remain. Car parts currently spread across two houses, two garages, and a storage unit. Ha
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I'm estimating dad and I will have about 100 hours into just the seam welding portion of this project. It's extremely tedious and quite difficult to be consistent as there are so many variables (multiple different thickness of materials, bends that stretch the material, contaminates likes sealer/primer, etc.). But we're getting there. Interior cabin is fully prepped and outside probably about 1/3 prepped. About halfway through welding the inside.

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Made some progress these past couple of days. Interior is now entire seam welded as is the back exterior and driver-side wheel well. We just have the underside (which basically all prepped and ready for welding), the passenger side front wheel well, and the engine bay. Hoping to be mostly finished by the weekend - but will depend on how much time I lose taking the Miata to COTA this Friday.
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Unfortunately we had an incident while seam welding the interior part of the wheel well. It turned out there was foam behind the panel we were welding and it caught fire and burned for a bit before we caught as the flames weren't visible (this is cavity between the inside/outside of the wheel well). Result was a fairly substantially damaged exterior paint on the wheel well. Booo.
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Looks like I'll be repainting the entire car now - I'm thinking of going gray/white and wrapping in Ruby Red (or something close). But open to ideas.
 
Insane

Cheapest color if your going to wrap over it. That way more money for track events!

I was leaning towards a simple single-stage paint that I spray on relatively easily so fixing body damage/covering new fab work was easy peasy.
 
Question for ya'll fabricators and the like. I have these two holes in the firewall from the HVAC system. What's your recommendation on filling this? Cutting out a piece that fits inside and tack welding around and then sand smooth? Or oversize it and weld it over the hole and then seal edges with a sealant?

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5,515
6,481
Exp. Type
W2W Racing
Exp. Level
20+ Years
Pleasanton: 1/2 way between Sonoma and Laguna Seca
Question for ya'll fabricators and the like. I have these two holes in the firewall from the HVAC system. What's your recommendation on filling this? Cutting out a piece that fits inside and tack welding around and then sand smooth? Or oversize it and weld it over the hole and then seal edges with a sealant?

View attachment 77850

View attachment 77851
Over size the patch and weld it. Don’t sand the welds you’ll just weaken them.
 
5,515
6,481
Exp. Type
W2W Racing
Exp. Level
20+ Years
Pleasanton: 1/2 way between Sonoma and Laguna Seca
OoooOoh one of my most anticipated parts came in today! I've been a bit sad about how long I am going to be out with this conversion/rebuild, but parts like this just confirm it's going to be worth it. Can't wait.

This is the coyote dry sump kit from Dailey Engineering - approved for CPC use only. This is kit is a pure work of art everywhere you look. Maximum weight savings and performance. Bill and team's attention to detail is bananas.

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Integrated runners for the 4 stages - no unwieldly hoses and maximum clearances.
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Weight removed everywhere possible
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Ultra compact pump with those integrated suction runners

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The ATI damper hub is custom machined to put the belt gear behind the balancer and reduce stress on the end of the crank.

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Now if only I had an engine to install it on and a chassis to drop it into :)
 
The nice thing is you can put it on display until you've got something to drop it into, dang!

I'm thinking of mounting it on my wall for a while. Better than collecting dust in the garage until I can install it! hehe

What nice parts, wow. 👍
I had just resolved to do GT500 pan but that makes it harder!
The GT500 is a really great production-quality piece. Great price to performance ratio. I had zero issues with it outside of the FPC breaking the pickup tube mount. The FP350S pan is a bit better performer, but 2x the cost and pretty mediocre production quality.

This should be a marked upgrade over both - better cooling, rock solid oil pressure, and some free HP from pulling vacuum on the crank case. It is a lot more $$, though. This will run about $7k all in - the stuff pictured above was $5,900 and change
 
10
10
Exp. Type
HPDE
Exp. Level
Under 3 Years
Wyoming
OoooOoh one of my most anticipated parts came in today! I've been a bit sad about how long I am going to be out with this conversion/rebuild, but parts like this just confirm it's going to be worth it. Can't wait.

This is the coyote dry sump kit from Dailey Engineering - approved for CPC use only. This is kit is a pure work of art everywhere you look. Maximum weight savings and performance. Bill and team's attention to detail is bananas.

View attachment 78388
View attachment 78385View attachment 78386




Integrated runners for the 4 stages - no unwieldly hoses and maximum clearances.
View attachment 78387

Weight removed everywhere possible
View attachment 78380View attachment 78381

Ultra compact pump with those integrated suction runners

View attachment 78383View attachment 78382


The ATI damper hub is custom machined to put the belt gear behind the balancer and reduce stress on the end of the crank.

View attachment 78384View attachment 78379

Now if only I had an engine to install it on and a chassis to drop it into :)
Thanks for the beautiful pics. Always good documentation from Kevin. This will be a must for the rebuild when the time comes. If only it had a better name than "dry sump." It ain't dry (well I guess it is right now). I can't think of anything but inappropriate or inaccurate descriptors. Gorgeous engineering.
 

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