Man Without a Country?

jsimmonstx

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Update - Day 08

Mounted the expansion tank in its new location.
expansion_tank_01.jpg


Had to fabricate a bracket for it.
expansion_tank_02.jpg


We also mounted the coil (also on a custom bracket) and the A/C compressor.
ac_tank_coil.jpg


Finally, I built and installed the plug wires.
plug_wires.jpg
 

jsimmonstx

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We got the tee for the lower radiator hose and installed it. I was amazed at the quality of the part. It's a billet piece with no welded-on stuff. Primo gear. All we have left on the cooling system is an overflow hose connection. That should be handled today.

The fuel lines have been plumbed. I paid half of the cost of a "Koul Tool" for the shop. This is a vice-like machine that allows you to put a push-lock hoses onto an AN fitting in less than 2 minutes (less than 30 seconds if you have air tools). Believe me when I say that you don't want to be without this tool if you're doing push-lock lines. We're still waiting on an aluminum plug for the fuel pressure regulator, and when we get it (should be today), the fuel system will be done. The shop guy wants to weld a couple of fittings for the fuel pressure gauge, and that should also be happening today.

I'm still waiting to hear if we're going to get the headers back today.

The schedule for the weekend includes:

- Finish up the cooling system
- Finish up the fuel system
- Finish up A/C compressor install
- Install air/fuel gauge in a vent pod
- Install the MSD box
- Weld O2 sensor bungs into x-pipe
- Install headers and x-pipe for the final time
- Install TPS sensor on carb
- Install temp gauge sensor
- Install oil pressure sensor
- Start electrical work

Another aspect of this swap that I haven't yet mentioned is the work of a tuner to turn a bunch of stuff off, as well as remapping other parameters to allow the ECU to function without blowing its little electronic mind. As I get details, I will write it down for the sanity of those who follow in my footsteps.
 

jsimmonstx

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Swap Update - Day 10:

Accomplished:

- Finish up A/C compressor install
- Install air/fuel gauge in a vent pod
- Install headers

The lower radiator hose tee installed and connected to expansion tank:

radiator_hose_tee.jpg


The headers came back from the coating shop - $190 including tax.

coated_headers.jpg


The headers installed:

headers_installed_01.jpg


headers_installed_02.jpg
 

jsimmonstx

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Comal County, TX
Update from yesterday:

- The exhaust is finished and permanently on the car

- Power harness is modified and wired up (including starter and alternator. We ended up with only 5 or 6 wires not directly related to power being needed, because most of the harness involved with the power steering rack (that is no longer present).

- MSD module and coil are wired up

- A/C clutch harness is run but not connected yet

- Transmission clutch has been bled and we have what appears to be proper throwout bearing operation

- Battery is back in the car

We now have enough wiring installed to start the car, but we didn't have the regulator plug to finish the fuel system (will have that Monday), and I'm having a bit of difficult finding a 3/8 NPT 90-degree fitting with a 3/8 hose bar on it for the PCV valve (all other solutions have been too tall). I'm gonna hit Lowe's and Home Depot today to see if they have anything.

We still have to wire up the transmission (speedo and reverse solenoid), and tackle the ECU harness. We've identified all of the connectors, and we have to tread carefully when removing stuff because we want to make sure that what we remove doesn't somehow have an impact on what we actually need to keep (throttle position, cylinder head temp, crank position).

BTW, I used the Ford Service Manual for a 2011 Mustang to identify the wires, and some of the wire colors changed for the 2012 model year.

In short, 99% of the nuts and bolts stuff is done, and we're down to the electrical stuff. Not bad - two weeks in and we're almost finished with what I would loosely call a significant swap. Sorry for no pictures today, but all of the wiring is pretty well hidden, and the rest of the engine bay still looks mostly like it did the day before.

A TPS on the carb, for real?

Yep, courtesy of Innovate Motorsports.
 

jsimmonstx

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Location
Comal County, TX
Is there still an issue with the K-member?

You mean the positive camber thing? Honestly it's been on the lift for the last two weeks - we'll finally have it on the ground this week. We'll have to wait until then to see what's up. We do have to adjust the toe though because of the new steering rack.
 

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