Author Topic: 1980 ESS Turbo Restomod (Read 5456 times)

Alpine615 · « **Reply #30 on:** June 19, 2012, 11:30:12 AM »

I was wondering if the "bushing" as I was calling it was sold separately, but now I have my answer. Thanks!

Pinturbo75 · « **Reply #31 on:** June 19, 2012, 11:46:07 AM »

same here, help section and had to slightly modify it....

Pinto5.0 · « **Reply #32 on:** June 19, 2012, 01:58:51 PM »

Don't bother with NOS Ford ones. That nylon material doesn't like underhood heat & eventually crumbles. My draw thru turbo pipe cooked mine worse than yours was. The HELP parts are rubber & will hold up much better in the heat.

Alpine615 · « **Reply #33 on:** June 20, 2012, 10:52:47 PM »

I found the old pictures I was looking for...

The first is a shot of my brother (sitting on bumper) and I standing in front of the beach house my parents rented one summer...

And the second is a shot of both Pintos (the one on the left is the one my dad was T-boned in) in our driveway... I wished I knew more about cars at this point, because I would've stripped so much more off the wrecked Pinto than the shop did, that's for sure...

(EDIT: This picture is pre-salvage. We got the hood, driver's side door, rear quarter windows, rear glass, lots of mechanicals and interior pieces, etc...)

Alpine615 · « **Reply #34 on:** July 18, 2012, 10:52:59 AM »

Wow, it's been almost a month since my last post! I have been busy accumulating lots of parts that I need, including:

- 15" x 7" American Racing Ansen Sprint wheels with a 5 x 4.5" BC from Summit Racing
- 205/65-R15 tires from a friend's old car, just to roll the chassis around on; the engine is still a long ways from actually running
- 11" Mustang II Disc Brake Kit + SS brake lines from RJay's Speedshop
- Pinto/Mustang II control arm kit from Speedway Motors
- 45.5" Aerostar Aluminum driveshaft from local pick-n-pull + new U-joints and U-bolts from RockAuto
- Ford 8" rear with TracLoc posi and 3.25:1 gear ratio (I wanted to modify the 8.8" from the 88 TC, but time was the ultimate factor...I'll save that for my next project)
- New axle pads from ESPO Springs N Things
- New leaf springs from JC Whitney
- New shackles & hangers from CarParts.com
- Every kind of polyurethane bushing that Energy Suspension makes for the Pinto
- Rubber steering rack bushings & sleeves from RockAuto
- Help! steering coupler from AutoZone
- A front sump oil pan, oil pickup tube and various chassis and trim pieces from Fred Morgan (thanks again, Fred!)
- And finally, today I plan to order a rear disc brake kit from The Streetrod Manufacturing Company, minus the calipers and pads. For those, I'll be going to RockAuto again, as they are a bit cheaper.

Last night I tackled a problem that's been a major thorn in my side. The driver's side steering rack sleeve and bolt were absolutely frozen together; no amount of WD-40, P.Blaster, Kroil or even map gas would unstick them... So my buddy and I resorted to using a Dremel to cut up the length of the sleeve, and finally we were able to hammer the damn thing out. The threads on the bolt are horribly corroded though, and I'm not sure if it can be salvaged. This may be a stupid question, but where does one go to purchase replacement fasteners for the steering rack? I've looked through the ARP catalog, but they only appear to sell drivetrain-related fasteners...

I expect by the end of next week to have the engine and transmission mounted, all new suspension and brakes installed, and to mount those tires on my new rims. I am horrible at posting pics, but I will try to post some by the end of this week.

Cheers!

Alpine615 · « **Reply #35 on:** July 18, 2012, 12:21:48 PM »

I'm toying with the idea of getting a remanufactured steering rack, as practically everything else going into my car is new or rebuilt. I'm not 100% on it though...the money is starting to dry up.

So my question is: does anyone know the length of the steering rack input shaft for a 1980? RockAuto lists three types for power steering racks:

- TRW gear with 2-1/4" input shaft
- Ford gear with 2" input shaft
- Unnamed gear with 1-1/4" input shaft

I think I read that 1978 and up use the Ford CII (or C2) gear, but that only eliminates one of the above choices. I suppose I could dismantle the unit I have and measure, but I'm not sure how easy or hard it would be. If someone were able to tell me that would save me some time and frustration. Any replies are very much appreciated!

blink77 · « **Reply #36 on:** July 18, 2012, 03:59:14 PM »

Steve
I just did this and looked up the paperwork
#22-200 w/1-1/4 imput shaft. Includes inner
tie rods w/ 2 or 3 mounting holes-are interchangable .
It lists for 242.99 w/ a 91.00 core charge. I paid 115.00
from a friend in the business. He didn't charge me for the
core, but I owe him the old one or one just like it. It was
one of the nicest things I've done for my 79 wagon yet.
If you need more info call me. If you don't have my #
anymore p/m me and I'll send it to you.
Bill

Alpine615 · « **Reply #37 on:** July 18, 2012, 10:16:31 PM »

Hi Bill,

Thanks for the info! I do still have your number, I will try to give you a call tomorrow.

Alpine615 · « **Reply #38 on:** July 20, 2012, 10:48:02 AM »

Last night I installed the front stabilizer bar and upper and lower control arms. This afternoon I'm hoping to get the rest of the front suspension installed. I also think I found a suitable replacement bolt for the steering rack. Grainger sells all sorts of industrial strength hardware, which is exactly what I wanted; and not the crap from Home Depot.

Alpine615 · « **Reply #39 on:** July 23, 2012, 12:24:51 PM »

Sooo had a slight setback on Friday night. First, I found out that the stabilizer bar tends to get in the way when installing the rest of the front suspension, so I removed that. No big deal. Well, then I tried to use a jack to raise the lower control arm & compress the coil spring, and the whole car began to lift off of the jackstands!! Looks like I will need to put the engine and transmission in first to help give the car some front end weight.

New order of operations is this: install steering rack & steering column, engine and transmission, THEN front suspension.

I feel kinda stupid posting this, but as I said from the beginning, I am learning as I go along and this will be a catalog of all my successes AND failures...

Pinto5.0 · « **Reply #40 on:** July 23, 2012, 08:13:40 PM »

I installed my front suspension with my engine/trans. removed. I put my jack under the ball joint & it went together easily. Make sure the spring is fully seated at the top & clocked properly so the end of the coil will seat in the notch on the control arm.

Get it to this point with the jack in place then.....

Simply jack it up until the upper ball joint goes into the spindle & spin the nut on.

Alpine615 · « **Reply #41 on:** July 24, 2012, 10:14:52 AM »

Pinto5.0 - That's brilliant, thank you for the advice and photos. Will give that a try this weekend, hopefully sooner.

Pinto5.0 · « **Reply #42 on:** July 24, 2012, 03:43:00 PM »

Quote from: Alpine615 on July 24, 2012, 10:14:52 AM

Pinto5.0 - That's brilliant, thank you for the advice and photos. Will give that a try this weekend, hopefully sooner.

I hope it works for you. Mine snapped together like Lego pieces on the 1st try. Make sure you either leave the grease fitting out or use a THICK towel under the ball joint so you don't snap the Zerk off.

I'm assuming you are running 4-cyl. springs. I don't think V-8 springs go in without banding them.

When you jack it up to the point where the front is about to lift off the jackstands you should be able to pull the upper control arm down enough to start the nut on the ball joint. Just be sure you have the bottom coil lined up with the notch, otherwise that side of the car will sit a little high & there is no way to spin the spring to correct it unless you disassemble it again.

Also check the rubber spring pads at the top before you install the springs. Replace them if they are shot so it doesn't squeak. If one is bad change them both or you will have a slight height difference as well.

Alpine615 · « **Reply #43 on:** July 24, 2012, 04:49:46 PM »

During my failed attempt at compressing the spring, I was concerned about damaging the grease fitting, so I placed the floor jack on the front lip of the lower arm...a little too dicey for my liking, as I was lined up directly with the spring (as opposed to your picture, where you go in from the side.) One small slip and that spring could've expanded with explosive force. I like your method because it gives more support to the arm, but I agree I'll need to remove or protect the fitting.

10-4 on lining up the bottom of the coil with the notch in the lower arm. I think I want to replace both rubber spring pads (coil spring insulator, as RockAuto lists it) but the picture looks different from what I removed from my car (I'll upload a pic when I get home tonight). Can you, or anyone else, provide a replacement part # (like Dorman/Help!)?

And yes, I am re-using the stock springs, which have been coated with Eastwood rubberized rust encapsulator.

Pinto5.0 · « **Reply #44 on:** July 24, 2012, 07:34:41 PM »

During my 1st attempt at installing the coils I had the jack where you tried but it lifted the car so I went to the end under the ball joint for more leverage.

I wire wheeled my stock springs & drowned them in chassis black. I also re-used my isolators since they were still pliable & showed no sign of deterioration.

I picked up isolators off Ebay for 20 bucks. They were an exact match for the stockers. Here's the link. I don't think Dorman makes them.

http://www.ebay.com/itm/NEW-MUSTANG-II-COIL-SPRING-CUSHIONS-PADS-GASKETS-1-PAIR-/300745526979?pt=Motors_Car_Truck_Parts_Accessories&hash=item4605d48ec3

Alpine615 · « **Reply #45 on:** July 25, 2012, 06:20:31 AM »

Good deal, I just used Buy It Now on a pair of them for $20...they should arrive Monday.

My old isolators are still pliable, but are showing signs of cracking. I'm sure they would still be fine, but as I mentioned in a previous post, practically everything else that is going in this car has been replaced. Once you start, it's hard to stop...

Alpine615 · « **Reply #46 on:** July 25, 2012, 07:06:58 AM »

While I was snapping pics of my coil spring insulators last night, I decided to I would clean up and take pictures of my recent "haul" out to Michigan. I met up with Bill (blink77) and his wife, Sally, to pick up some parts from him. Why wouldn't I have him ship them, instead? Because one of them was this:

Bill said he didn't want to ship the all-glass hatch, and I don't blame him! Years ago I bought one from Oregon and it broke during shipment. Luckily it was insured, and I got my money back, but these suckers are tough to locate. And when you do, they are usually half a world away! I also purchased front and rear Rallye spoilers, deluxe door panels, wood grain A/T shifter & bezel and a Mustang II center console. In between grabbing parts for me, Bill was showing me all of their rides, all wagons: a red '79 with vented hood, a '77 pro-stock with '79/'80 fenders, and a '76 with a Mustang V8 in it. I couldn't be happier with my purchases, and it was a pleasure to spend part of my afternoon with Bill and Sally, who were very welcoming...

After I loaded up my purchases, I took a 45 minute detour further north into Michigan to meet mrskydog (Kirk) to see his 1980 Rallye first-hand. All I can say is, wow! What a beautiful car! I posted a separate album, see this link: [size=78%]http://photobucket.com/80rallye[/size]

It was a looong journey, but well worth it. Thank you to Bill, Sally and Kirk!

mrskydog · « **Reply #47 on:** July 25, 2012, 10:32:06 AM »

Steve what a great find on the spoilers Very Nice! it was worth the trip. Hope to meet up once the car is complete again.....Kirk

r4pinto · « **Reply #48 on:** July 25, 2012, 11:24:24 AM »

going all glass hatch I see. I dunno if I would wanna do that with mine. I like the rallye look but not sure about the all glass back

Alpine615 · « **Reply #49 on:** July 25, 2012, 11:57:58 AM »

Yeah I've wanted the all-glass look for a very long time. And it wasn't until recently that I found ESS emblems on eBay. But now that I have the Rallye spoiler, I am not sure what I want to do. I think getting the side lettering and stripes reproduced will be extremely expensive, if anyone can/will even do it. I've contacted Phoenix Graphix, but haven't heard back yet.

Anyway, the exterior is the last thing I should be worried about. Three weeks until the parents' house is listed. Ahhh!

Pinto5.0 · « **Reply #50 on:** July 25, 2012, 03:45:24 PM »

Quote from: Alpine615 on July 25, 2012, 11:57:58 AM

Yeah I've wanted the all-glass look for a very long time. And it wasn't until recently that I found ESS emblems on eBay. But now that I have the Rallye spoiler, I am not sure what I want to do. I think getting the side lettering and stripes reproduced will be extremely expensive, if anyone can/will even do it. I've contacted Phoenix Graphix, but haven't heard back yet.

Anyway, the exterior is the last thing I should be worried about. Three weeks until the parents' house is listed. Ahhh!

Just do what I'm doing & make it your own. My '80 has some interesting options of it's own so I'm keeping the stock interior & exterior treatments down to the side stripes. I like the Rallye spoilers so I'm adding them on but I'm modifying the rear to work with my steel hatch. I also have one of Map's ducktail spoilers that may get used if I like the look better with the rear window louvers.

'77 tail lights & bumpers are going on & I have a steel 2" cowl induction scoop that I'm going to weld on to the hood to clear the eventual turbo addition & I may add a filler door over the gas cap since I have pinholes around my gas cap & need to fix it anyhow. That's it, just some changes to set it apart & personalize it to my tastes.

Do the blackouts around the side windows & paint the Rallye stripes at the bottom without the word "RALLYE" & same for the spoiler on the back. Make it stand apart from a real one with minor changes.

blink77 · « **Reply #51 on:** July 25, 2012, 06:47:29 PM »

Steve-- Glad everybody is happy. That must be
your girlfriends cat (now your best friend). Nice
looking cat. But you know we love cats. I wish I
had gone with you to Kirk's. But, he is close enough
that I'll see that great car somewhere along the way.
I was happy to meet you and I think the right guy got
the parts. Sally says Hi!! Good luck with the house and
finding a place for your Pinto and your stash of parts.
You are one dedicated guy!!! Keep in touch.
Bill

Alpine615 · « **Reply #52 on:** August 02, 2012, 01:22:33 PM »

Long time, no updates...sorr y 'bout that! I tried doing what Pinto5.0 suggested with my front coils, but the car still began to lift off the jackstands! $:-\$ So I backed it down and will try again once the engine and trans are in. I don't know why it didn't work for me, but I will upload a pic later tonight.

On the to-do list this afternoon:
- Install the steering rack, hook it up to the steering joint
- Lower in the engine/trans and bolt up
- Install the driver's seat and steering wheel

Next week:
- Front suspension???

Alpine615 · « **Reply #53 on:** August 02, 2012, 01:35:35 PM »

Quote from: Pinto5.0 on July 25, 2012, 03:45:24 PM

Just do what I'm doing & make it your own. My '80 has some interesting options of it's own so I'm keeping the stock interior & exterior treatments down to the side stripes. I like the Rallye spoilers so I'm adding them on but I'm modifying the rear to work with my steel hatch. I also have one of Map's ducktail spoilers that may get used if I like the look better with the rear window louvers.

'77 tail lights & bumpers are going on & I have a steel 2" cowl induction scoop that I'm going to weld on to the hood to clear the eventual turbo addition & I may add a filler door over the gas cap since I have pinholes around my gas cap & need to fix it anyhow. That's it, just some changes to set it apart & personalize it to my tastes.

Do the blackouts around the side windows & paint the Rallye stripes at the bottom without the word "RALLYE" & same for the spoiler on the back. Make it stand apart from a real one with minor changes.

Yeah, I think more than anything I like the blackout treatments, which shouldn't be hard to replicate (especially since I have great reference photos from mrskydog's Rallye.) And I have always liked the Rallye package, but also I was thinking it would be a crime to remove (a.k.a. destroy) the Rallye tape stripe on the spolier and re-paint it to match.

It is obviously a decision that will have to be made a little further down the road, and I have other things to focus on. We've already had to call off the realtor walk-through because the car can't be rolled out of the garage, but we still may make the desired listing date of 15-Aug. Wish me luck!

By the way, what you have already and what you plan to do sound awesome! I have to find it again, but I read your posts about the car a while back and I really dig the interior. Black and gold!

Pinto5.0 · « **Reply #54 on:** August 03, 2012, 04:37:53 AM »

That sucks that it wouldn't go together easily. Too bad you don't have a couple buddies who can come over & sit on the core support to add some weight.

Alpine615 · « **Reply #55 on:** August 08, 2012, 01:52:47 PM »

Last week was huge. My friend came over and we installed the engine & transmission (even if only temporary), and then proceeded to install the coil springs!! Even with the weight of (most of) the engine, he still had to stand on the car to weigh it down further. I managed to jack up the lower control arm on the ball joint (with the grease fitting removed, of course) and thread the castle nut on the upper ball joint, connecting the spindle to both arms. FINALLY!

Then, this past Monday I put in the shocks and strut rods (not a great picture, I'll admit)...and as a bonus I put the driver's seat back in...

Later this week: front brakes, sway bar + linkages, modify the Pinto spring plates for the 2-3/4" U-bolts (for 8" rear end), bolt up the rear and do the rear brakes...phew!

Pinto5.0 · « **Reply #56 on:** August 08, 2012, 09:51:34 PM »

Coming together nicely.

Alpine615 · « **Reply #57 on:** August 28, 2012, 10:36:05 AM »

MAJOR UPDATE!

Car has steering, suspension, brakes, wheels & tires installed! Photobucket was giving me trouble at work, and then wouldn't upload on my cell phone and I wanted to wait to post until I could show pictures! Feast yer eyes...