Dubstep Shep's Build Thread

Dubstep Shep

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Well guys, seeing as I'm finally getting the ball rolling on my projects, I figured it would be a good idea to start a build thread.

This is going to be a constant work in progress, and likely I'll be updating this thread for years to come. I'll update this post as necessary if my posts get lost on down the line.

NEW UPDATE 8/21/13


To start, I'll introduce myself and my baby.

My real name is Wade, and I'm at the time of this posting a Mechanical Engineering senior at the University of Oklahoma. I've been into cars since I was a little kid, and have always loved good 'ol American Muscle. I'm about as OCD and Anal Retentive as they come, and I'm also a Grammar Nazi. As an engineer I find thoroughness and perfectionism befit me, and I apply that mentality to my everyday life and vehicles as well.


My Mustang is a 2008 Mustang Bullitt #4054. My dad and I bought the car back in February of 2009. We bought a front clip from a 2006 mustang and cannibalized the frame and body to repair this one. The local Ford dealership did the frame and body work; all the mechanical stuff my dad and I did. In any case, the car was repaired by July 2009, and basically sat in the garage for four years. We just recently sold my truck in June 2013 and my dad gave me the mustang. Needless to say I hit the ground running looking for things to improve on it. Because it's a rebuilt title, I can't really sell the car, and so I've decided I'm keeping it until the wheels fall off. And then I'll just get new wheels.

Before
013_zps4a1901a5.jpg


After
036_zps805614c3.jpg

20130818_205451_zps825bb7ac.jpg


I'm sure some of you guys recognize Jim's car. That'll come up later hehehe.



Now onto my build. Basically, I'm planning two basic build stages.

Stage 1 is an all around build at a entry level. My goal is a daily driver that can tear it up at the track as well. The goal is to reach a point where I've done just about everything I can without choosing to go down the dedicated track car route or the awesome street car route. Basically Stage 1 ends at that fork in the road.

Stage 2 will be a ways down the road, probably at least five to ten years, and I'm still not 100% sure I want to do it. If I do, I'll be rebuilding my motor and spending some serious money; probably in pursuit of a true track monster or a mean street machine



I'll breakdown my Stage 1 plans here:

Department of Boost Supercharger system:
Jim (Crown Aviation) got me started on this one. I did a ton of research for a couple months and finally pulled the trigger on a DOB kit. I bought a few extras, got my gauges installed, etc., and then got the SC system installed August 16th-18th. Still working on some kinks from the original wreck that were never caught, so I'll update when those electrical gremlins have been exterminated. Found the wiring that was never repaired from the wreck and got in done. Runs perfectly now. Not sure about the knock sensors, I need to datalog to check.

Overall, I FREAKING LOVE THIS SYSTEM, AND JIM IS AWESOME. Why?
The cost of the kit is lower than basically every other positive displacement SC system out there.
The kit can be upgraded to serious HP numbers later on; Jim is running like 750 RWHP without NOS.
You get to build the kit. For some that's a downside, but for me I want to have a hand and an eye on everything that goes on with my car. Jim did the install and did a fantastic job, and I helped some. With anything like this there are going to be things that cause problems, but he had no trouble at all resolving them. The problems with the AC, Temp, and knock are from the original wreck, not the system or Jim's work.
It's reliable. You'd never know my car had a SC based on it's mannerisms or drive-ability until you put your foot into it. I LOVE IT!

I need to get a new clutch now though hehehe.

Griggs Racing Street Suspension:
I've also been in kahoots with Griggs racing talking to them about a full Short/Long Arm system. I'm not wanting to fork over over $8,000 for suspension for my Stage 1 build though, so they suggested the SS system. Likely I'll be ordering that system piece mail over the next couple years. I'd like to have it done within about two years of completing my SC system. Right now I have the adjustable LCAs, Torque arm, and Watts link ordered and paid for. I'm just waiting for them to ship.



Current State:

Department of Boost Supercharger Kit - Complete!

Gear Swap
I'm going back to 3.55 gears from the current 4.10s I have. I'll be keeping stock rubber for now, so I felt going back that far is necessary to keep tires on it. Plus I hate the road and engine noise from 4.10s. Ordered the gear replacement kit from American Muscle. Now I just need to find the time, tools, and expertise to try this myself lol. Likely I'll recruit my friend who did all the work on his 600+hp 2004 Cobra.

Prothane Bushings
I originally bought new Prothane Engine mounts to lower my engine. Reason being I wanted to make sure the SC would clear the unique Bullitt cross brace that has the VIN and 4054 production number. Unfortunately, I discovered I can't lower my engine with the JBA Shorty headers I have on there now so I left the mounts at stock height. Even more unfortunately, the cross brace won't fit over the intake from the SC. I'm going to look into other avenues, like different or even a custom cross brace, or perhaps replace the headers and shave the mounts. A lot here that's tabled for later work; I want the cross brace but it isn't a pressing matter
I also bought a full Prothane Bushing Kit. I'm not a fan of rubber bushings, and I've always felt that Bushings are a good place to start on suspension as well. Unfortunately, It's going to be awhile before I can get around to installing these. It's quite an undertaking apparently.

Clutch
Literally just got the SC in and I need to resolve the knock sensor issue when possible.


So that about wraps it up for right now. I peruse the forum almost daily for info related to these projects, but if any of you guys have any pertinent info or suggestions, I'm always more than happy to hear what you have to say.

Cheers!
 
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fullmetal7777

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mind telling how much you bought this car for? you and your dad did a great job repairing it. ill be headin off to a&m soon for an engineering degree myself :D
 

Dubstep Shep

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We paid about 9k for it at first. I think total cost was around 32, but 10k of that was frame work from Ford. We wanted it done right.
 

Dubstep Shep

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New update. Basically found out there was a bad connector that hadn't been repaired from the original wreck. Rather than buy a whole new harness for $700, I just soldered the wires together. It's not a perfect fix but it's more than adequate for now.
 

Dubstep Shep

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Been awhile since I've updated this.

As many of you know, since my last update about the wires, I got around to putting in my new diff gears, Griggs Torque arm, watts link, and LCAs, and then managed to blow my engine 30 minutes later. I've been dealing with that lately, and the new engine should be done in a couple weeks. More updates once that's in and running.
 

Dubstep Shep

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UPDATE 12/25/2013

Now onto my build. Basically, I'm planning two basic build stages.

Stage 1 is an all around build at a entry level. My goal is a daily driver that can tear it up at the track as well. The goal is to reach a point where I've done just about everything I can without choosing to go down the dedicated track car route or the awesome street car route. Basically Stage 1 ends at that fork in the road.

Stage 2 will be a ways down the road, probably at least five to ten years, and I'm still not 100% sure I want to do it. If I do, I'll be rebuilding my motor and spending some serious money; probably in pursuit of a true track monster or a mean street machine

So I've decided the car will become a dedicated track monster down the road. I've accepted a job offer with National Oilwell Varco in Houston, so starting mid July I'll be down there. The money is good, and I need to build some credit quickly for a house purchase, so likely I'll buy a used vehicle and make payments for a year once I start work.


Griggs Racing Street Suspension:
I've also been in kahoots with Griggs racing talking to them about a full Short/Long Arm system. I'm not wanting to fork over over $8,000 for suspension for my Stage 1 build though, so they suggested the SS system. Likely I'll be ordering that system piece mail over the next couple years. I'd like to have it done within about two years of completing my SC system. Right now I have the adjustable LCAs, Torque arm, and Watts link ordered and paid for. I'm just waiting for them to ship.

So I managed to get the LCAs, TA, and Watts link installed. Took awhile because I was going back to 3.55 gears from the 4.10s, but once I got it all installed, it was night and day. The car just grips so much better in so many situations. I had to leave the sway bar off for now, as it was rubbing on the watts link, but I'll be finishing off my rear setup with some coil overs, sway bar, and some other odds and ends from Griggs soon enough.

Current State:

Gear Swap
I'm going back to 3.55 gears from the current 4.10s I have. I'll be keeping stock rubber for now, so I felt going back that far is necessary to keep tires on it. Plus I hate the road and engine noise from 4.10s. Ordered the gear replacement kit from American Muscle. Now I just need to find the time, tools, and expertise to try this myself lol. Likely I'll recruit my friend who did all the work on his 600+hp 2004 Cobra.

Got the gears in. It was a total nightmare getting the patterns right, especially because I didn't have a lot of the tools I should have. Once I broke down and bought the tools, it wasn't bad, and I only have minor gear whine above about 60mph.




There have been some new developments in my build as well. About 30 minutes after I finished the gear and Griggs suspension install, while my buddy and I were testing it out, I managed to blow my motor. Here's the thread on it:
http://www.s197forum.com/forum/showthread.php?t=107356

So I've been dealing with that lately. I did a bunch of research and so forth, and ended up getting an engine builder somewhat locally that's quite competent. The engine should be done in a couple of weeks, so once I get it back in and running I'll update this with specifics.
 

RetroGT2006

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Sub'd, can't wait to see the progress! Thanks again for all the TR3650 parts bro! Can't wait to get them!
 

Dubstep Shep

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There have been some new developments in my build as well. About 30 minutes after I finished the gear and Griggs suspension install, while my buddy and I were testing it out, I managed to blow my motor. Here's the thread on it:

http://www.s197forum.com/forum/showthread.php?t=107356



So I've been dealing with that lately. I did a bunch of research and so forth, and ended up getting an engine builder somewhat locally that's quite competent. The engine should be done in a couple of weeks, so once I get it back in and running I'll update this with specifics.


UPDATE 3/21/14

The engine is in! Finally!

With headers:
aquge8ab.jpg


Mocked up with the anodized DOB manifold and Frankencharger:
a6a8ahy5.jpg


Going in the car:
zaba3uda.jpg

udedesat.jpg


And finally, bolted into the car:
vydy6epy.jpg


I'm still waiting on a few odds and ends. Flywheel, bell housing dowel, A/C compressor bolts, and so forth. I think I'll have it running by the first week of April. Depends how long parts take.
 

Dubstep Shep

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UPDATE 3/24/14

Everything as far as the engine bay goes is almost done.
ygyjaru6.jpg


I have a couple of bolts and electrical connectors left to put in, plus radiator and intercooler coolant, oil, and power steering fluid.

At this point I'm mostly just waiting on my flywheel exchange from McLeod.



Until then, I'm gonna finish up the bolts, connectors, and fluids, and get started on my exhaust and custom shifter handle.

For the exhaust I have to weld up the MAC prochamber and get a bung put in for my wideband sensor.

As for the shifter handle, I'm going to try and move it up and over towards the driver slightly. Good test of my machining skills in the University machine shop.
 

Dubstep Shep

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UPDATE 3/31/2014

IT LIVES!!!

Part One of the motor start up
https://www.youtube.com/watch?v=ORF3k7P5mco

Part Two
https://www.youtube.com/watch?v=EvKkuHuuTbo

I'm the tall guy with the Ford shirt. The other guy is my mechanic buddy Spencer, and my girlfriend was there for emotional support as well hahaha.

The smoke was from the header wrap, as we mention in the video.

Procedure was just a 20 minute start and idle, as per the instructions of my engine builder.


I did have a couple issues with the car though.

The "recurring issue" I mention in the video is that my coolant temp gauge isn't working. The ECU is reading the temp correctly, but the gauge shows zero. This was also an issue immediately after installing the DOB kit for the first time, and was coupled with my knock sensors not working as well. I had thought I fixed it by wiring out the connector that was broken, but clearly not. I'll have to revisit that area and see what happened.

Additionally, my reverse lights are constantly on. I'm thinking the two wires that control it are reversed. I'll check tonight.

There were also two codes my SCT picked up. P0182 and P0193. Not sure why those are occurring. The SCT said they were high fuel pressure and low fuel temperature. The only fuel system stuff I even messed with were my fuel rails and injectors. Nothing else was touched.

We actually drove the car around my neighborhood later that night to check for other drivability issues. My rear brakes are tight as hell after installing the new pads, so it kept wanting to stall. Plan is to loosen those up so it's not an issue.

Also I think we have an exhaust leak about where the prochamber is. I'm not surprised as we redneck rigged the exhaust up just so I wasn't dumping it under the car for now. I plan on going back and welding the prochamber up and mounting some hangers under the car for it.

Other than these issues everything seemed to work perfectly.



My impressions of how the car drives are really good. Considering it has a completely new motor, clutch, transmission, and brakes since the last time I logged any miles, it seems to drive just like it used to.

The RXT clutch is a really weird feel compared to the factory clutch though. It's sooooo soft. Hard to believe it'll hold 1000hp. Guess that's just good engineering.

The Livernois Stage 3 Blower Cams sound SICK. You can't really hear it in the video but they're nice. Not too loud at idle or anything, and the lope is just barely noticeable. Probably less pronounced that Hot Rods, but still there.


Next stage is to resolve the issues I'm having, then get a dyno tune.

My engine builder recommend a guy for tuning. He's out of Hennessey Oklahoma and own the Conoco gas stations in that area. He tunes cars because the business pretty much runs itself. His dyno is apparently mustang specific, and puts out much more accurate numbers than most others. He does SCT tuning, which is really nice, and is apparently quite good at it.


That's it for now. If you know anything about those codes, let me know!
 

s8v4o

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Sounds like you possibly have a ground issue.
 

s8v4o

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With what? The codes or the temp sensor?

Most likely all of the above. Bad ground and/or connection. It's what makes the most sense to me, especially since they all started at the same time.


P0182 - Fuel Temperature Sensor Circuit Low Input

- Faulty Fuel Temperature Sensor
- Fuel Temperature Sensor harness is open or shorted
- Fuel Temperature Sensor circuit poor electrical connection



P0193 - Fuel Rail Pressure Sensor Circuit High Input

- Low or no fuel
- Faulty Fuel Rail Pressure Sensor
- Fuel Rail Pressure Sensor harness is open or shorted
- Fuel Rail Pressure Sensor circuit poor electrical connection
- Faulty Fuel Pump
 

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