Author Topic: Pinto Powered Mustang Roadster (Read 129097 times)

rob289c · « **Reply #210 on:** October 01, 2023, 07:52:45 PM »

Some progress but not a lot. I plumbed in the rear brake line and the port from the master cylinder to the inlet of the distribution block. All brake lines are now in place. I didn't tighten those at the MC as I am going to bench bleed the MC in the car. I made up lines that will return the fluid to the MC so I don't have to take it from the vice to the car and install it full of brake fluid. I fabbed some additional steering column supports and did some trimming of other home made supports under the dash so I can actually get the dash in its proper place. One of my under dash supports was in the way so I trimmed it and relocated another one ever so slightly so it was no longer in the way. I got the heater box out of its hiding place so I can see if will fit under the modified dash. It is going to be an open air roadster but If I can make the heat work, it will be one less thing for my wife to complain about. If I can make it fit, I will likely have to modify the glove compartment: make it less deep, or hopefully not, eliminate it altogether. If I can make the Heater Assy fit I will replace the heater core before permanently installing. Today I also realized that my supposedly 75-78 Mustang II grill is really from a 74 and doesn't quite fit the 76 or 77 header panel I recently procured. 74 was a one year - only design. The good news is it's in really good shape considering the year and I can modify the grill and header panel to make it work. The header panel was broken in the lower left corner so I epoxied it together. It will be completely cured by morning. I will put in a "splint" to strengthen the joint (perforated strapping), then fiberglass and body filler it to hide the repair. I am going to have to cut off the mounting tabs and fab my own to mate the 74 grill to the 76-77 header panel. Hopefully it will be for the most part un-noticeable. Hopefully in the next couple of weeks I will have all the dash and firewall work done so I can remove it, and do a final prime/paint, then permanently reinstall so I can get closer to running. As always, I will post progress until it gets put away for the Winter.

Wittsend · « **Reply #211 on:** October 02, 2023, 12:58:16 PM »

Hoping winter delayith its coming. Then thou may completeith thy project!

OK, I left this as it appears (there actually it text before the smiley face). SO MANY TIMES I will type in the default 10pt type..., and when it posts to the forum the font is teeny-tiny! Why? Typically it happens when I back space more than once. It never shows in the typing pane as small but it switches to the tiny font AFTER I SEND IT. This has happened at least 100+ times. The only solution seems to be after I type I need to highlight the text, go to the Font Size and select the 10 pt. (even though it is already 10 pt.) and THEN it actually appears as a 10pt. font and not something miniscule.

rob289c · « **Reply #212 on:** October 02, 2023, 01:14:45 PM »

You and me both...Last year I was able to stay on it through November and even did a little bit in December. The problem I have is that once Winter comes, I am in the Propane business and it is our busy season, not to mention, I end up with 6 cars, two motorcycles, and a bunch of other stuff in the garage so I can't get to this thing until Spring. I will keep plugging away while the weather cooperates. I am taking off Fridays and Mondays through October starting this Friday so I don't lose vacation days and I should get some more done. I removed the vice grips from the header panel this AM before I left for work and it stayed together so the epoxy held. I will massage it later in the week and make it stronger and prettier.

rob289c · « **Reply #213 on:** October 05, 2023, 06:50:18 AM »

I cut the headlight buckets off the header panel. It is fiberglass so my cutoff wheel made it a quick, easy job. I am making a "nose cone" with the '74 grill to cover the radiator. I will try to get the grill installed in the header and mock up the header panel, front bumper and headlight assemblies that are supposed to arrive from Speedway today so I (and you all) can see what the front end is going to look like. I will have to remove everything afterward and do some sanding, welding, and prepping for primer and paint. The header panel needs to be massaged with some body filler to get it ready. I repaired the crack in the lower left (right as you look at the pic) corner with epoxy and did some rough sanding to smooth it out a bit. I will reinforce with some strapping and tiger hair, then massage the whole thing. I am entering my marathon stage with Fridays and Mondays scheduled off from work through the month of October so am going to try to get as much done as possible over the next few weeks.

rob289c · « **Reply #214 on:** October 07, 2023, 04:32:46 PM »

Today I disassembled and cleaned the heater box. The mouse nest is now gone. the dead, dried up mouse that was caught in the blower wheel is gone. I test fit it, then tried to put the dash in place. The cowl duct wouldn't fit under the dash. I cut that section off and now it fits with the dash in place. It pulls incoming air from under the dash now. The temperature damper will still be used to have heat or no heat. The fresh air vents and defrost ducting and outlets won't be used and have metal welded over the former outlets. Since I won't have a windshield or a need for the defroster, I removed the heat/defrost damper and will repurpose it to block off the top of the plenum that formerly fed the defrost duct. I will lose the glovebox storage area. The heater box takes up that entire under dash space with the narrowed cowl and dash. I don't know if I will use the heat but it is there in case I need it. I will be ordering a new heater core. The existing looks to be in good shape and appears to be original. I'm not taking the chance so a new one will go in before assembly. Yesterday I finished with my steering column bracing so today I removed the steering column and bracing and then the firewall/dash/tranny hump. It will get a good cleaning, caulking, then primer/paint. Then I can reinstall permanently and start the completion process. Tomorrow I will weld my under dash support brackets solidly while the assembly is out of the car. I will solidly weld the steering shaft to the u-joint while it is out of the car too. I have a little more body work to do on the dash and cowl. This part of the project has been tedious and once done it will go together much more quickly.

dga57 · « **Reply #215 on:** October 07, 2023, 10:40:18 PM »

Those four-day weekends all this month should be a real boost to your efforts! I love your updates!

Dwayne

rob289c · « **Reply #216 on:** October 08, 2023, 05:39:22 AM »

Substantial progress is my hope and plan, and also get my PTO bank down to the 56 hour carryover threshold so I don't lose any. I have "donated" lots of vacation time over the years and it's use or lose. Just recently NY mandates a 56 hour carryover policy.

Unfortunately our weather has taken a turn for the worse. Our high temps are only going to be in the 50's and low 60's for the rest of the month (normal) which isn't optimal for body work and paint but that's part of my short term plans. Not final body paint, but a little filler, sanding, epoxy primer and black enamel.

I think I will install the header since the firewall is off as it will probably be easier to fit that way, That means I should probably get the rest of the exhaust system figured out, purchased, and installed. Like everything with this project, it's figure it out as I go. I originally wanted to repurpose parts of the single exhaust I took off my Mustang 30 years ago but it comes down the wrong side of the car and over the wrong side of the rear axle. I may be able to cut it, re-position it, and weld it back together. I'll have to see if that's possible. Otherwise I'll have to buy a 65-66 6-cyl Mustang intermediate pipe and slightly modify it to make it work. Then it will be fuel supply and return lines. Every bit I do gets me closer to completion. Then I can have fun driving and showing it and doing other things that aren't getting done! I will report more later after today's tasks are complete.

rob289c · « **Reply #217 on:** October 08, 2023, 03:00:56 PM »

Progress today: I caulked all the seams in the firewall. I use 30-year silicone caulk vs seam sealer. Works just fine. In an early part of the project when this thing was going to be a trike, I had cut the cowl off the firewall. After deciding to make it a shortened 4-wheeled buggy I had to weld the cowl back to the firewall. It wasn't a fun job as I was welding jagged sawzalled edges through seal sealer that catches on fire. Almost as bad as welding the roof on through lead filler! Anyway, the seams needed caulking. I also caulked the floor patch seams. I welded all the connecting points of my brake pedal/steering column mount. Now it is rock solid. Don't mock my welding on the left side...the thing was still in the car when I fabbed and tacked it together in an awkward position with under dash stuff in the way. Doing the rest in the vice came out much better! I welded the steering shaft to the u-joint and the two shafts together and primed. Lastly, I made the defrost damper into the defrost plenum block off plate so now all warm air will be directed to the under dash heater outlets. I ordered the new heater core last evening so I will be able to button up the heater box by next weekend. Tomorrow I have to do some Impala exhaust work so my progress will be less than I want.

rob289c · « **Reply #218 on:** October 09, 2023, 05:23:36 PM »

Not a lot of progress today. I spent 2+ hours welding a rusty exhaust system on my son's Impala, then shortly thereafter we had a power outage. I cleaned off the firewall with compressed air, then solvent. Then a little bodywork on the cowl section. I scuffed the epoxy primer I sprayed two years ago so I can re-spray. I had intended to do that today and spray black enamel on Friday, but with the power outage, now it looks like epoxy on Friday and black next Sunday or Monday. Hopefully those days will be at least 60 degrees so I can spray and it will cure properly. Unfortunately, the next two weeks is supposed to have below average temps. I checked my spray gun to be sure it would be ready and noticed the fluid tip seal was missing. That explains why it was fluttering when I sprayed the front clip of the Impala earlier in the Summer. Working out of town the next few days so nothing to report until at least Friday.

rob289c · « **Reply #219 on:** October 12, 2023, 05:27:00 AM »

Received new heater core yesterday and installed last evening.

dga57 · « **Reply #220 on:** October 13, 2023, 09:20:37 AM »

That's pretty impressive progress, considering the Impala work and the power outage!

Dwayne

rob289c · « **Reply #221 on:** October 13, 2023, 04:54:15 PM »

Today I sprayed the primer on the inside of the firewall, cowl area, and radiator support rods. Sunday or Monday I will spray the black enamel. Whichever of the two days has the best weather will be spray day. My gun sprayed perfectly today as opposed to when I did the Impala. The missing fluid tip seal was the culprit! Also ready for black will be the steering column shaft and brake pedal/steering column support and associated bracketry. I am going to install the header while the firewall is off. It will be easier than doing it after it is back in place.

rob289c · « **Reply #222 on:** October 16, 2023, 04:10:59 PM »

The firewall is now black. It was 54 degrees in the shop when I sprayed. It will take a few days to cure. Supposed to get up to 65-67 degrees by Thursday. I'm working out of town T-Th so I won't be tempted to touch it. I spent a good deal of time making and installing brackets to hold the '74 Mustang II grill into the '76 Mustang II Header Panel. I had to cut the grill mounting tabs off the header panel and make other modifications to get it to fit. The grill will have to come back out so I can prep the header panel for paint and while out I'll have to modify the grill mounting brackets to move it to the right about 1/2" so it is centered better. I also made brackets and modified existing brackets to mount the header panel to the Pinto radiator support. This coming weekend the firewall will be re-mounted, hopefully for the last time and I can really start to assemble the car. I still have to finish the bodywork on the dash but I think all the interior parts (dash, dash pad, steering column, inner quarters, package tray) will have to wait till next year to be painted. I tried unsuccessfully to modify the over the axle portion of the exhaust yesterday. I cut it and thought I could turn it to get it to go over the right side when the original configuration is over the left side. Anyway, I had to abort the mission and welded it back together in it's original position in case I or someone needs it for a 67 Mustang single exhaust for a 289. I will get the exhaust figured out at a later date. I'll have plenty to keep me busy over the next few weekends but I won't hear it run till next year. Too many other thing to do both on this project and other obligations. More to come...

rob289c · « **Reply #223 on:** October 23, 2023, 07:22:26 PM »

Progress over the last few days: Installed header. I did it before reinstalling the firewall so I had more room to work. You would think it would be a quick and simple job...maybe 1/2 hour? How long should it take to screw in 8 mounting bolts? I spent no less than 4 hours! I had to heat and beat the #3 tube to clear the frame. I had to cut the mounting tab off the frame that attaches the bracket from the crossmember to the frame. Had to remove the bracket, cut the welded on nuts off, the flip it upside down and re-position. Final attachment to be done later. I had to dimple the tube next to the lower mounting bolt on #3 so I could get the bolt in. It looks cool but what a PITA!

I re-installed the firewall, radiator support rods, the brake pedal and steering column support. Installed the heater box with heater hoses poking through the firewall. Re-installed the master cylinder and proportioning valve. Tightened all brake line connections. Bench bled the MC in the car. Easier that way than doing in the vice then having to carry a full MC to the car and install. Filled MC with brake fluid. Bled rear brakes. Discovered banjo fittings at the front calipers leaking like a sieve. Long story short, I had to flip the hoses over. I installed them the way they looked correct but now I know otherwise. I had to track down new crush washers and a replacement banjo bolt since I broke one. As you can tell, another, "should be quick and simple" job went to Hell. In the end, it is now leak-free and system bled. I fabbed and installed the fuel pump to carb fuel line.

I temporarily hung the muffler that I took out of my Fastback 29 years ago. I had to cut the final 8" off the tailpipe, the turn it 180 degrees and welded it back down. It it's original configuration it exited on the right side. Now it is going to exit on the left side. Swapping sides cause the tailpipe to sweep upward rather than downward, hence the need to cut it off and turn it so it now sweeps downward on the left side. I need to use a section of the intermediate pipe that came off my fastback and connect to the header collector. The collector goes from 2 1/2" to 2" which is what the old Mustang exhaust was. I will have to have an exhaust shop make and install the pipe that will connect the intermediate pipe to the inlet of the muffler. I can't use the old one because it came over the left side of the axle, and now it will come over the right side of the axle.

I squirted motor oil down each cylinder, rolled the engine over several times, then a few more squirts of oil, then reinstalled plugs.

Upcoming projects will be to attach the brake lines to the frame and firewall. I need to install the fuel tank, then plumb in the fuel supply and return lines. I need to finish the bodywork on the dash and repair the dash pad. All interior and body paint will have to wait until next year after it is warm enough. I will clean my wiring harnesses and start reinstalling. I will be re-wiring the ignition circuit. It was suspect when I got the car. I got it to run, but lots of insulation issues. I have a Duraspark wiring kit so I should be able to fix it up better.

Back to work tomorrow. Hopefully more progress next weekend.

rob289c · « **Reply #224 on:** October 23, 2023, 07:23:22 PM »

A couple more pics...

Wittsend · « **Reply #225 on:** October 24, 2023, 03:13:12 PM »

It is really starting to look like..., well..., a car. Until now I was unsure of what this would look like. Here's to hoping you can get a lot accomplished before it gets too cold.

rob289c · « **Reply #226 on:** October 25, 2023, 02:52:15 PM »

Yep, I'm getting there. I have many "next steps" planned to make the best use of my time. I'm looking forward to hearing it run, but that won't be till Spring. I will report more next week.

dga57 · « **Reply #227 on:** October 27, 2023, 02:28:43 AM »

I think it's really starting to come together! Good job!

Dwayne

rob289c · « **Reply #228 on:** October 28, 2023, 07:47:06 PM »

This morning it was still fairly warm (65 deg), so I pretty much finished up the dash bodywork before the cold front swept through and dropped the temp to the low 50's. It's not perfect and there are some sanding scratches but it's "good enough". If you remember, I created all this extra work for myself when I mistakenly narrowed the width of the dash. Anyway, it's stored away and I probably won't touch it till Spring. I need to fix the cracks on the dash pad. I've watched some YouTube videos where they do it with body filler. Probably not the best way to go but I have no better ideas at this point. In the end, it will all be black. No more orange.

I also did a tweak to my brake pedal. After bleeding I have good pedal, but I felt it went to close to the floor when felly depressed. You may remember that I had to install spacers between the master cylinder and the firewall to get the pedal to sit lower. My original spacer length was a little too long. I cut about 1/4" of each one and now the pedal sits a little higher than the accelerator as it should and the travel isn't too close to the floor.

I then fit the old intermediate exhaust pipe and fabbed a hanger so now I have exhaust hung except for the over the axle piece that I will have to have made once I get the thing running and on the road. I dropped the gas tank in place and found I had to move the muffler to the left a little bit so the tank didn't touch the tailpipe.

That's pretty much it for the project. I put all my body fillers, hardners, primers and paints in the basement for Winter storage. I will pull it all out again in the Spring. I got new tires for the Fastback yesterday so today I put them back on the car and got it off the jack stands. I filled the tank with non-ethanol and Stabil so it is done for the season. I had to decorate my shop for Halloween so my wife can entertain Tuesday after Trick Or Treating.

I'll do more tomorrow and report.

rob289c · « **Reply #229 on:** October 29, 2023, 07:27:46 PM »

Today's progress: I fabricated and installed "floor frames" to attach the not yet made floor boards. There aren't going to be full floor boards, but I plan to have diamond plate made up to sweep down from the firewall and over the trans hump. No need for carpet in this open air buggy. The framework I made and will have covered will give the driver and passenger a place to put their feet. Entry into the cockpit will require "stepping through" and sitting. With real floorboards, it would be difficult getting in and out.

I installed the radiator and hoses. The lower hose took a weird turn at the bottom radiator connection. I hooked it up anyway but may have to get another one as I don't like the way it fit. I started installing the heater hoses but I'm not sure if I have them routed correctly. I am going to initiate a "Help" post in the "Ask the Experts" section so hopefully someone will have some guidance for me. I think that was all for today. Every session gets me closer to completion.

rob289c · « **Reply #230 on:** November 06, 2023, 11:50:40 AM »

I didn't make a lot of progress over this past weekend. On Saturday I spent time brainstorming how I would mount the headlights. I got the idea that I could mount them at the outer edges of the grill like on a 67 Shelby. To do that, I would have to remove the running lamp/turnsignal assemblies and cut out the grill where the headlights would go. I wasn't set on this option as I liked the position of the turn signals which would have to be relocated, and there wasn't enough space behind the grill to the radiator to make the headlamps appear to be flush with the grill. They would have protruded about 3" and look like bug eyes. I was also going to lose the two upper grill to header panel mounting points. Nevertheless, I went to Harbor Freight and bought a Dremel-type tool so I could perform the grill surgery without hacking it up. I spent quite a bit of time running errands and had other things to do so I didn't jump into the project. Instead, I slept on it and decided to try to find a better option for the headlamps. I have another option that I will share after I do it. For now, I can't elaborate. I think it will look fine and hopefully be sturdy.

I spent quite a bit of Sunday washing motorcycles and my Fastback in preparation for Winter storage. I also began rearranging the shop so I can store everything. At the end of the day I installed the heater hoses in the factory orientation. I had to install a 3/4 to 5/8 adapter as the heater core pipes are 3/4 but the pipe to the water pump port is 5/8. I also struggled to figure out where the bracket on the 5/16 tube that goes between the upper heater pipe to the intake mounts. There was nothing "under the hood" where it would mount. It wasn't until after looking at the stock valve cover that I discovered the mounting point. My T-Bird valve cover doesn't have that hose mount so I will relocate it to the firewall.

Anyway, that was pretty much it for progress. I hope I can do more next weekend. I would like to get the headlights in place...

dga57 · « **Reply #231 on:** November 08, 2023, 07:41:50 AM »

Looks like good solid progress to me!

Dwayne

rob289c · « **Reply #232 on:** November 08, 2023, 09:58:10 AM »

Yes, every little bit gets me closer to completion. If I was retired I could work on it every day...that day is coming soon...could be any time, up to 3 years, then I'll do something PT or contract work with my current employer. Working out of town again this week and the next several so no weekday progress.

rob289c · « **Reply #233 on:** November 12, 2023, 08:31:27 PM »

I spent a decent amount of time this weekend in between other chores and errands but I didn't make a whole lot of progress. I fabricated headlamp brackets and tack welded them in place. I started making brackets to attach the narrowed 67 Mustang front bumper. I'm only part way done with that and not sure if my path is correct. Again, it's engineer and improvise as I go. I will be tacking them in place, then the entire header panel and grill will have to be removed so I can weld the headlight bracket and bumper brackets solidly in place (I hope). That will have to be next weekend. The bumper brackets will be painted black like the rest of the chassis so they will blend in better and not be so noticeable, From the pic, it looks like I may have to put a spacer under the left headlight. Back on it next weekend...

dga57 · « **Reply #234 on:** November 13, 2023, 06:14:00 AM »

Every little bit counts! Looking good!

Dwayne

rob289c · « **Reply #235 on:** November 13, 2023, 10:34:23 AM »

Thank you....

rob289c · « **Reply #236 on:** November 19, 2023, 07:16:53 PM »

Zero progress this weekend on the project. I did however go out the breakfast with my car club buddies Saturday AM, got a big chunk of my wife's Christmas present taken care of, got most of the Christmas lights on the house including all the ones that require the 28' extension ladder. I went to the 174th Fighter Wing Alumni Thanksgiving Party today. I am hoping this coming weekend I will get something done on the project.

I am re-thinking my headlight and bumper mounting ideas. I may come up with a different setup if it is practical and can figure out a better way to mount them than the path I am currently on. More to come, but I'm running out of time. After this coming week I will be working 5 hours away until Christmas...

Happy Thanksgiving to all!

rob289c · « **Reply #237 on:** November 26, 2023, 04:19:44 PM »

I did very little on my project over the Thanksgiving weekend, but I am satisfied with what I did. I cut (2) 6" pieces of 2" angle that I will weld a tab onto and bolt to the bumper brackets. You will see in the "above" pic that I have them vice gripped in place. It will extend the bumper forward and give me more surface area to weld the bumper mounts to. There are pieces of of angle under the bumper on each side that you can't see. They are temporarily bolted in place and I will weld them to the angles I will bolt to the brackets. That will solve my "how do I mount the front bumper?" problem.

The next thing I am thinking of is either fabbing a headlamp bracket to be welded to the top of the bumper brackets, and mount the headlamps to it, of maybe mount the headlamps to the outboard bumper mounting bolt hole. It will be solid enough, but pending a warm spell and some extra time, I'm probably not going to tackle that until Spring. It will allow me to eliminate the chinsy headlight brackets I made a couple of weeks ago. I don't like the way they look and they aren't as solid as I would like. I only tacked them in place for easy removal if I came up with a better idea.

Pic # 3 shows that it is in its Winter resting spot. I will be working away from home until Christmas and there will be plenty of other tasks for me to do so this might be all my progress until Spring. I will watch to see what others post and advise of any additional progress I make over the Winter.

rob289c · « **Reply #238 on:** December 02, 2023, 06:28:43 PM »

No progress today and none planned for tomorrow. Today was LOF, tire rotation, and shift cable repair on daily driver. Tomorrow LOF and tire rotation on wife's car. Other obligations sprinkled in. Maybe next week...

rob289c · « **Reply #239 on:** December 10, 2023, 06:38:23 PM »

Some progress this weekend. I fabbed and welded the latest iteration of the bumper and headlamp mounts. One per side. The attached pic doesn't really show how it came together or how it mounts to the car, but it will be under the bumper and mostly unseen. In the Spring it will become black when I get the paint gun back out. I need to drill out the mounting bolt holes and grind down some of the welds to make it prettier. I still need to figure out the actual headlight mounting point but I think I have a good idea for that. If we get any more 40 degree weather, I will continue to make progress.

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Author Topic: Pinto Powered Mustang Roadster (Read 129097 times)