Jump to content

Idle hands: assorted projects


Recommended Posts

With the 620 in a state of relative completion it is time to get back to working on my Mustang aka other lifelong project.  For those that didn't see my intro/build thread...

AdQoV9u.jpg

 

The plan was fairly simple, some new motor mounts, patch a hole in my crossover pipe for the turbo, and rework the intercooler piping a bit.  To give you an idea of how well I am sticking to that plan here is a pic of my new "motor mounts"

 

IiNLTve.jpg

 

In fairness it did come with poly mounts.

 

So far I have removed all of the front suspension, minus the sway bar. I have removed the exhaust after the turbo and the intercooler piping pre-intercooler.

jaf8a5o.jpg

 

Since I spend more time on this forum now than the various mustang forums I am a member of I'll be posting progress here.

  • Like 2
Link to comment
  • Replies 447
  • Created
  • Last Reply

Top Posters In This Topic

Top Posters In This Topic

Posted Images

Got some more work done today. Turbo and all of the hotside piping are out.  I had forgotten how much of a pain in the ass that crossover pipe is to get in and out of there.  I'm looking forward to seeing how much easier it will be with the new kmember.

 

obligatory oics

Emd8ikx.jpg

 

iOIQHUM.jpg

 

And just to give you an idea of just how far off course I've gone from my original plan...

G5H0Xqo.jpg

 

Not everything on the list is really within the scope of this project, just things that came to mind, and some of it is just standard maintenance.

  • Like 1
Link to comment
  • 2 weeks later...

Finally putting things back together, although only about half way through the list.

 

I have patched the crossover pipe and just need to wrap it before throwing it back on.

 

Headers are back in, bushings are all removed, ball joints, strut mounts and oil filter relocation adapter replaced.

 

SnTZlOJ.jpg

 

EV4oQSw.jpg

 

Nl041lv.jpg

 

While I was at it I painted the control arms a hammered black to somewhat match the new kmember and I gave the coilovers a decent clean.  Also not pictured, I have removed the fender liners and cleaned behind them and painted the exposed areas so they blend in.  Struts are back on the car as well and I will hopefully have the new bushings mounted and the control arms back on by the weekend so I can start getting the exhaust piping and turbo back in and start planning out the new intercooler piping and figure out where to re-relocate the oil filter to.

Link to comment

Sk8tbVg.jpg

 

iRY69PW.jpg

 

Control arms and spindles are back in, so crossing things off the list.  Also added to the list, opting to go ahead and replace the oil pan gasket while I have everything out of the way.  After that turbo piping will start going back in...as soon as it is rewrapped or gets a new coat of silicon.

Link to comment
Starting to look like a little more than half a car again.

Brakes are back on and the crossover pipe is re-wrapped.  I ended up removing the sway bar so I could have enough room to use my soft persuader when getting the control arms back in, so now I'm in the process of cleaning it up for some new paint.

I'm going to go ahead and replace the oil pan gasket before pipes start going back in.

 

yKV2Dvi.jpg

 

quOhCsE.jpg

Link to comment

Crossover pipe is back in, and I had forgotten how much of a PITA it was.  Clearance is marginally improved with the new k-member though, so where previously the driver's side pipe was resting on the rear lower control arm mount there is now a mm or two gap.

0qEvPf3.jpg

 

20NSj32.jpg

 

hFMaqve.jpg

 

Since my last update, but not pictured I have also finished painting my sway bar, reworked the lower radiator hose to eliminate some kinking, I made an EGR block-off plate and I have thoroughly cleaned the underside of the car.  I'm hoping to have the rest of the exhaust piping and the turbo back in this weekend so that starting early next week I can start reworking my intercooler piping. 

Link to comment

yep, that's a turbo.

cMSrIOE.jpg

 

Also got my oil filter re-relocated, required since the new turbo pushed the down pipe over just enough to come in contact with it.

SOY93QB.jpg

Luckily I was able to just rotate it up and out of the way so I didn't have to drill/tap any new holes or worry about getting new oil lines.

 

I got my vacuum distribution block installed as well. Got pretty lucky with this piece, the mounting holes happened to line up perfectly with a couple of mounting points on the intake manifold that I wasn't using. Even the supplied hardware was the right size. I did have to shave some off the back of the block to clear the intake runners.

luZE4E9.jpg

 

Got the swaybar mounted back up and the tierods reattached to the spindles.

Link to comment

Got a bit more accomplished this morning.

 

Oil lines are run to the filter, O2 sensors are back in and intercooler piping is ready to go minus a couple of flanges which I will need to get welded on.

 

5O0ALhE.jpg

I wanted to smooth out the air flow a bit headed to the throttle body, so out with the 90 and in with the 0.

 

1lPprPv.jpg

Went from 3" to 2.5" between the turbo and the intercooler, mostly because I could, but partly for more clearance under the radiator mount.

 

6r9RAdr.jpg

Hoses errywhere.

Link to comment

Got the various holes and slots cut out of the intercooler pipes and dropped them off at the welder to have the flanges attached.  Endlinks are re-installed and adjusted and I got the k-member brace installed.

 

FTPSu93.jpg

 

Suspension is all torqued so that portion of the project is finally finished.  Now just need to run some vacuum lines, mount up my catch can and pipes when I get them back and I'll be done under the hood as well.

  • Like 1
Link to comment

Back from the long weekend and back to work. Picked up my intercooler pipes from the welder and started getting them installed last night.  

 

DdZiMIW.jpg

 

0ulYwhb.jpg

Decided to go ahead and give the maf pipe some extra thermal protection. Internet reviews be like "glue fails over time", challenge accepted.

 

In a serendipitous turn of events the shop I had weld the flanges happened to have some 4" scrap pipe laying around that is damn near perfect for my intake.

DS2mQ9r.jpg

 

Also got my new breather can mounted to the firewall, now just waiting on the hose to show up.

ItUh2pE.jpg

  • Like 1
Link to comment

Nearly wrapped up under the hood, just waiting on a coupler, a few clamps and the hoses for the catch can.  Vacuum lines are all run, strut brace is installed and I got my turbo a blanket.  I've got the rest of the exhaust in so I could make some new hangers, but it will have to come back out for welding.  I also finally got around to replacing my busted e-brake cables so for the first time in 7 years or so I'll actually have an ebrake.

 

8zRnxKz.jpg

 

ym9lwVX.jpg

 

18amCDi.jpg

Link to comment

So very nearly there.  Exhaust is fully back in, intake is made all the various hoses and lines are run, fluids and filters are changed.  AT this point the thing that is holding me up is a freaking o-ring that still hasn't arrived, starting to seem like it is on the slow boat from China.  I also have a few wires to fix, but as it happens I forgot my soldering iron at my mothers house a couple of hours away...I'll be there next weekend so the wires will wait.  Until then I plan to occupy myself by actually making an airbox instead of just having the filter chilling in the corner of a hot box.

 

4dWhgAB.jpg

 

zcfYrMB.jpg

 

uKrxayq.jpg

Got to love beer boxes, they make such good templates.

Link to comment
  • 2 weeks later...

How about a little update.  Been driving the car around a bit, working on getting the old gas out and make sure it all stays together.  Will be scheduling the tune in the next couple of days.

 

Got around to fixing some rock chips turned rust spots on the roof, but at the time the only top coat color I had was white (I don't always plan ahead).  Rather than roll around with funny square white spots I opted to dip the roof.

 

y9WDB9n.jpg

The picture does it too much justice.

Link to comment
  • 1 month later...
  • 1 year later...

Well after destroying one clutch I put in one that would actually hold the torque and was quickly reminded why I went with the last clutch in the first place. 

waB80U4.jpg

 

So now two transmissions and a whole driving seasons later I'm upgrading.

4fYq7IM.jpg

Old T5 on the right new to me TR3650 on the left.

 

Of course that doesn't exactly bolt right in.

bNszvGw.jpg

 

aHzmkxq.jpg

 

Several pain in the ass hours later.

n6tMjjG.jpg

 

Hope to have the drive shaft dropped off to get shortened later this week and be back to driving this thing in the next couple.

Link to comment

wouldn't two smaller turbos spood better and move more air than one big one? And I didn't see bypass valve or a blowoff to vent the overpressure. I have always used bypass valves as they don't lead to overly rich mixtures when venting overpressure.

 

One thing that I liked about the Volvo 480 turbo I had was a turbo cooling. The coolant line going into the turbo had a temperature controlled electric waterpump that kept the cooland running when you shut down the engine. So the oil didn't cook in the bearings of the turbo and you didn't have a need to cool down the turbo before turning the engine off.

 

Still nice stang  - I don't get you guys over there obsessing about chevy vs ford. They both make same kind of cars.

 

PS. If you have a chance to change out polts that hold stuff together and get water on them use new hotcalvanized of stainless ones. I have repairing my friends Ford, as most of the bolts are rusted shut. Volvo had all the undercarrige bolts hotcalvanized or stainless. And aftes 15 years in this salty stuff all the bolts come loose easy.

Link to comment

wouldn't two smaller turbos spood better and move more air than one big one? And I didn't see bypass valve or a blowoff to vent the overpressure. I have always used bypass valves as they don't lead to overly rich mixtures when venting overpressure.

 

One thing that I liked about the Volvo 480 turbo I had was a turbo cooling. The coolant line going into the turbo had a temperature controlled electric waterpump that kept the cooland running when you shut down the engine. So the oil didn't cook in the bearings of the turbo and you didn't have a need to cool down the turbo before turning the engine off.

 

Still nice stang  - I don't get you guys over there obsessing about chevy vs ford. They both make same kind of cars.

 

PS. If you have a chance to change out polts that hold stuff together and get water on them use new hotcalvanized of stainless ones. I have repairing my friends Ford, as most of the bolts are rusted shut. Volvo had all the undercarrige bolts hotcalvanized or stainless. And aftes 15 years in this salty stuff all the bolts come loose easy.

 

I've got a 50mm BOV in there about 6" after the turbo, just can't see it in the pictures.  While twins would be nice and have been done once on one of these engines, no one actually makes a twin kit, in fact no one makes any other kit than this one for the engine. At any rate I have all of my boost right around 3k rpm and this turbo is capable of moving a lot more air than the engine can handle.  I like the idea of the electric water pump for the turbo, but on most modern ball bearing turbos it isn't as much of a concern as it once was.  Pretty much the only factory bolts left under the car are the strut/shock bolts.

 

This kind of thread pisses me off.....

I'm jealous ! 

Guys with the modern pony cars can buy tube subframes.

I can't :(

 

No wonder I hate mustangs.

(and why I take great pleasure picking on them late Friday nights)

 

This ain't no straight line car and don't make nearly enough power to be competitive with any fast cars.

  • Like 1
Link to comment

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

Loading...
×
×
  • Create New...

Important Information

By using this site, you agree to our Terms of Use.