Project 1990 country squire resto/modification - Page 55 - Ford Forums - Mustang Forum, Ford Trucks, Ford Focus and Ford Cars

andyfanshawe · 02-13-2013, 13:33

Ok. Confession time!
Tried to fit brake pedal box but it wouldn't fit. I welded the firewall up without bolting it up to check! Yeah, I know.........should have known better.
So, had to cut across my welds and pull the firewall out at the bottom a bit

Then making sure the pedal box is in, cut out the plates I so lovingly welded in before (serves me right).

Pedal box in as first plate is welded in

Oh dear!!! Soon be back though!
I've also just got my block and tackle pulleys to hoist the body off the frame very very soon!!

Andy.

andyfanshawe · 02-17-2013, 11:45

Fitted timing chain cover, water pump, oil pan and crank pulley and harmonic balancer.
Why has the water pump got to be such a PITA thing to fit?
Small block chevys are a damn site easier!!

Fitted my block and tackle in the roof and took the strain!

Intentions are to pull the engine off the stand, fit the flex plate and install the engine. Then hoist the body off the frame, wheel out the chassis and finish weld underneath. Then paint entire underside and bolt back permanently to the frame.
Then its painting green time!
Andy.

andyfanshawe · 02-18-2013, 12:22

Isn't it just typical...... when you want some help to do a quick car job, everybody disappears. Especially when it involves a bit of work-like helping to put an engine in.
So on my own it is.........
After a short time it was in. No swearing, cussing or anything like that. Just a smug smugness!!

Tomorrow its starting to hook things up like trans shifter cable, heater, vacuum lines etc. But I can't hook the throttle up until the heads and plenum are on and I haven't got the head bolts till about Wednesday.
In the meantime, 2 more block and tackle pulleys to go up in prep for lifting the body off the chassis.
Andy.

andyfanshawe · 02-21-2013, 10:54

Time to fabricate all the simple things on the firewall now. Starting with the hole for the Trans shifter cable and ECU slot.

After hours of messing about, this is what we have ended up with

Now at least I can refit the ECU bracket and shifter cable.
Now onto the parking brake. The hole where the cable goes through has moved up 10 cm so will no longer be any good - although I could cut up the bracket and relocate the cable.

and relocated about here

I'll post a photo of the finished product later on.
In the meantime, the pedal is too long!
Needs this much cutting off

And rejoined but had to be flared to match the contours

The almost finished product

Heater box next.
Andy.

andyfanshawe · 02-21-2013, 11:14

Just spotted that I have lost my hood release cable hole! Here it is/was from an old photo

Put it on my list! I've got a big list.
Andy.

andyfanshawe · 02-25-2013, 13:16

Remember this rusty thing?

That was acid dipped to look like this?

Well I welded it up and painted it. Now it looks like this

Funny how the simple little things like this are really pleasing!
Onto my hood release cable. Not to make it too simple, I drilled the right size hole through, then enlarged the sheet steel on the outside of the firewall to smoothly join with the emergency brake cable slotted hole!

From the inside

Heater box next!
Andy.

andyfanshawe · 02-28-2013, 12:33

Had an optimistic completely mad thought that the heater box would just about fit! Never know, just MIGHT......
Well, did it fit? Err,......no. Not a piggin' chance. Why did I even think it might?
More photos to come-as if anyone else will do something as stupid as this!

Andy.

**CatSkinner** · 02-28-2013, 17:22

An old saying: It's difficult to remember that your original objective was to drain the swamp once your up to your a** with alligators. Been there, only mine wasn't a car, it was a house.

andyfanshawe · 03-04-2013, 13:12

Bolted the heads down on the block so I can start to see where various things need to go! Photos soon.
Meanwhile for a break from the metal fabrication, its seeing if I can get the heater to fit time!
First the "air inlet assembly ducting" as its called in the shop manual.
This thing

Here's a temporary fit and you can see where the bottom of it is touching the firewall before it sits flush

So I need to cut the bottom off so it has a chance of sitting flush.
Here's the cut line planned to completely flatten the bottom

Here's my airsaw in action

Here's the bottom cut off flat

And a side view looking across the bottom showing the flat profile

I'll make a new base and bond it in, then produce a water drain hole.
Then its onto the other heater boxes...
Andy.

andyfanshawe · 03-09-2013, 13:55

Been assembling the engine so I can trial fit the throttle linkage etc.

Back onto the heater box. Fabbed a closing off plate for the base and a water drain hole. Now its completely flat on the bottom and actually fits the firewall now!

and a view to the inside

Andy.