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Discussion Starter #421
The throttle cable for the 97 Expedition is a little long, but will work ok. I had to cut down the cable, and the sheathing is still a little long, but it works so I shouldn't complain. Knowing my over zealous quest at perfection, I'm sure I'll find a way to shorten both the cable and the sheath so it fits perfectly, I just need to find the required hardware.

I was finally able to pick up a stock GT500 shifter for a decent price, so here are some pictures of the stock shifter shaft. Notice the offset on the one end (shifter side) and the boot concealing a universal joint on the other end (transmission side).

<a href="http://www.flickr.com/photos/[email protected]/3692525813/" title="Shifter shaft2 by Mikeys Pics, on Flickr"><img src="http://farm4.static.flickr.com/3580/3692525813_07e4626bdc.jpg" width="500" height="373" alt="Shifter shaft2" /></a>

<a href="http://www.flickr.com/photos/[email protected]/3692525709/" title="Shifter shaft3 by Mikeys Pics, on Flickr"><img src="http://farm4.static.flickr.com/3575/3692525709_c0a7560b48.jpg" width="500" height="373" alt="Shifter shaft3" /></a>

The location where I mounted the shifter in my car, is approx. 3" closer (Y), and one inch up (Z), in reference to the transmission, from the shifter location in the Mustang. So I had to cut 3" out of the shifter shaft. I also removed the bend, so it would move the pivot point up. In this picture, the shaft and end piece are ready to weld.

<a href="http://www.flickr.com/photos/[email protected]/3693330032/" title="Shifter shaft1 by Mikeys Pics, on Flickr"><img src="http://farm3.static.flickr.com/2583/3693330032_01c58a76e0.jpg" width="500" height="373" alt="Shifter shaft1" /></a>

I tack welded the end piece on the shaft, and then bent / twisted the end until everything was straight. After it was lined up correctly, I fully welded the end. The material they used for the shift rod is thick wall mild steel, so it welded like a champ.

For the brace, I cut one off the stock shifter, flipped it over, and bolted it to the shifter. It turned out a little flakey, but it is solid and I don't expect that it will give me any issues in the future.

<a href="http://www.flickr.com/photos/[email protected]/3693330156/" title="New Shifter Setup by Mikeys Pics, on Flickr"><img src="http://farm3.static.flickr.com/2593/3693330156_bca3897323.jpg" width="500" height="373" alt="New Shifter Setup" /></a>

As for hood clearance, the pulley hits (not a surprise), and the air inlet tube hits. For the air inlet tube, I'm toying with the idea of making one out of carbon fiber. For the pulley, I'm deciding if I want to go with a different hood, or I may drop the front K-member about 1/2". I don't think the 1/2" drop on the K-member will affect the suspension geometry enough to notice.

On the hood subject, I've seen a few of 94-95 cars with 96-97 hood and headlights. Can anyone who has done this, fill me in on what you had to do to get everything to fit up properly? It appears to me that the 97 nose meets the hood further forward than on the 94-95. So the nose piece hits the head lights, and doesn't stick out far enough to match up with the hood.:( Any info would be much appreciated.

Mike
 

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he is right on my first 95 4.6 I had I swapped out the whole front clip just cause I wanted the clear headlamps from a 96-97 t-bird. its not the most simple to do but after the swap is done you will be less concerned with visibility. also the hood of the 96-97 tbirds are raised about an inch so you may have a lil space but not much. If I were you I'd find a 3in cowl hood like the cobra R hood you will have plenty of space for the engine insted of doing the drop on the k-member.
 

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Discussion Starter #424
Hey all!

It's been hotter than... well, really hot out here for the last couple weeks. With the weather and work, I haven't made very much progress.

I'm running the Cobra R hood, which has about 3.5" rise, and with the K-member dropped 3/4" I still had to rotate the inlet down a little bit so the MAF would clear the hood. After I get the hood on for good, I'll check clearences and then bring the K-member back up as far as I can. I'll probably have to mold a custom inlet pipe before there is a chance of fitting the 3.5" rise hood with the K-member at stock height. But even with a custom inlet, the pulley will probably still hit.

As far as the 97 headlights on the 95 front end, it doesn't fit. The header panel I picked up is an aftermarket replacement, which may be the issue, but I can't see a replacement part being that far off. The headlights are hitting the center of the bumper cover, and are jammed into the corner lights. Also, the front bumper cover is pushed further forward, so it doesn't fit very well either. I'm sure there are solutions for these issues, but for some reason I think everything on my car has to fit perfectly, so the 95 headlights and clear corners should come in later this week. The hood went out this last weekend for modification. I'm having a couple areas modified so it will fit the car better, and while they are at it, they will modify it to fit the 95 headlights.

So this weekend will be the first car show. I'm not trying to get any awards, so it doens't matter much that the car isn't finished, or won't have a hood. I still have a lot of work to finish this week before the show. I need to get a brace on the front K-member and get the car aligned again. I'm also hoping to get some dyno time to check the tune. I drove the car yesterday, and it was missing pretty good when I first started it up. After it came up to temp though it was running fine. So I guess it's a good thing the Lamborghini that rolled up beside me on the freeway didn't want to play, since I still haven't checked the tune.:D Most Lambo owners wouldn't expect an old Ford to be a challenge anyway.

The next update should have some good pictures!

Mike
 

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Do make sure to steer clear of deep puddles with the CAI mounted down there.
im sure the SR 71 blackbird wont be running around much in heavy rains or floods... now will it mike?

ps i like the look of the factory SVT supercharger better, but im sure ill quickly get over the "looks" once i climb back into the passenger seat (where i started off at) from the rear seat after takeoff... may i sugest bigger rear tires now...?;)
 

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Discussion Starter #426
im sure the SR 71 blackbird wont be running around much in heavy rains or floods... now will it mike?

ps i like the look of the factory SVT supercharger better, but im sure ill quickly get over the "looks" once i climb back into the passenger seat (where i started off at) from the rear seat after takeoff... may i sugest bigger rear tires now...?;)
Now that you mention it, I do smell burned rubber every time I get on it in second. I'll have to see how long the back tires last. If I go wider on the back I'll have to have the wheels machined to get the tire further under the car. No sense in wasting good rubber on the fenders when there's so much pavement around. And no, no heavy rains or floods. But I do plan on driving it to work everyday. I'll probably put some baffles behind the fog light, and over the hole below the filter to keep water from splashing around in there.

Mike
 

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headlights should of worked, its been done many times. i forgot you need the 96/97 corners as well as the headlights/hood/header panel
 

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Discussion Starter #428 (Edited)
headlights should of worked, its been done many times. i forgot you need the 96/97 corners as well as the headlights/hood/header panel
I have the 96/97 corners. Has anyone else that has done this swap had clearance issues?

Thanks,

Mike

Edit: Nevermind, went to the exterior section and there are some new threads since I searched last. Yes, other people have had clearence issues. I'll get some pictures this week and put up some posts. It seems the 94/95 bumper cover is slightly wider in the center, and the 96/97 header panel pushes the 94/95 bumper cover forward in the center, which causes it to be tight on the sides. I'll go back to the 94/95 hood/light style for now. I'm toying with the idea of picking up a $400 junker to try out flaring the fenders. If I do get one, I'll try massaging the front bumper cover and header panel a bit while I'm at it.
 

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i have 285's in the back of my bird with it being lowered.All I had to do was roll the rear lips a bit.

Check out the SCCOA cover car. Its a 94 with the 96 setup..He sanded the nose to make it all fit well..Looks great and factory in person
 

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Discussion Starter #430 (Edited)
Hey all! :)

Made it to the dyno this morning. Despite pegging the MAF at 5500 RPM, the car managed to put down 524rwhp(Dynojet). Torque was around 470 if I remember correctly. The shop that did the dyno runs forgot to save the data, so they couldn't give me a print out. They offered to do another run, but I didn't really care since I'll have to run it again once I get the MAF straightened out. I recorded the second pull with the Delta Force (sniper) software, so I'll be able to look at the data a little closer. One thing I did notice, is that the fuel pressure increase that I put into the tune didn't take, so I'll have to call Delta Force and see what is going on with that. A/F at idle was a touch lean, and the mid range was a little rich, but over all it was pretty good. With the MAF pegged at 5500, the mixture stays safe until about 6k, so I'll just have to keep it under 6 until I get it fixed. (I don't really need to turn it past 6 anyway.)

Pretty exciting morning. On the way to the dyno, I got pulled over for no hood(he let me go:)). Then someone tried to pull into me. When I romped on it to avoid getting hit, the throttle stuck wide open. I was in second, so it bounced off the rev limiter 3 times before I could get the ignition off. As it turns out, one of the vac hoses for the oil catch can had worked up under the throttle body, so a quick re-route of the hose and we were back on the road.

My brother came down Wed, and we fab'd up braces for the front K-member. With the K-member lowered 3/4", I was afraid it might shift without them. After we got the braces in, I ran it over to the alignment shop, and they were able to dial it right in. While we were under the car, my brother noticed that there are scratches on the exhaust from the rear subframe moving forward about an inch under accelleration, so I'll have to get some braces on the back soon.

More to come!

Mike
 

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Any updates? This is like a great book, and I'm left hanging :(
 

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How is the pedal effort with the Supercoupe master? I imagine it must be pretty firm, as well are you using any kind of stop to limit the masters stroke?

Will
 

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Discussion Starter #433
Hey all,

Life has been busy, so I haven't spent much time on the car. I did take it to a car show, which was fun. Unfortunately the pictures I took suck, so I'll have to get more later.

I got the 95 style headlights and clear corners back on the car, and test fit the hood. Everything clears fine, but the front of the car is off a bit. The car was hit in the front passenger corner before I got it, so it looks like the nose is over about a quarter inch. Once the hood comes back from getting painted, I'll see if I can get everything lined up without a trip to the frame rack.

As for the clutch, I'm not running a stop to limit the stroke, and the pedal effort is fine. I would say it is less effort than a stock turbocoupe clutch, and way easier than a SPEC stage two.

I think I mentioned earlier that my fuel pressure isn't going up like it's supposed to under boost conditions... and now I'm thinking that it is due to the pressure relief / check valve in the fuel tank. I've heard of fuel problems in the Cobras from the pressure relief being flakey. Too bad I hadn't heard about the issues before I installed the fuel tank.:D So besides installing the hood after it's finished getting painted, the next thing will be to drop the fuel tank and toss the pressure relief valve.

And then there's the MAF issue. Still can't decide between re-ranging the MAF, or replacing the whole air inlet system. I hate to put money into something that's costing me HP (MAF is too small). But replacing the cold air kit, MAF, air inlet tube, and throttle body is a chunk of change. Maybe I'll just drive it like it is, and save my pennies over the winter.

Mike
 

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Well saving the money and doing it over the winter is a good thought. Can't wait to see the 100% completed product!
 

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Discussion Starter #436
What did you do about the speedo? Are you running a speedcal?

Will
I rewired the car from the dash forward so I could run the Cobra cluster(this included converting the car to a GEM module wiring system). The only thing I had to do to the trans wiring, was lengthen the wires for one sensor. Since the TR-6060 trans is the replacement for the T-56, everything else plugged right in. To finish it out, I flashed the Cobra PCM for the new tire size and gears, and everything works great. This method is not for the faint of heart. I used to work on the control systems for a nuke power plant on a sub. Even with that type of background, I probably spent over a month working on just the wiring. Using the wiring for a V8 bird with a Mark VIII PCM, and some type of speedcal device would probably be more sensible.

Mike
 

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Now I see why so many are opting for just the COBRA intake. :D
 

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I rewired the car from the dash forward so I could run the Cobra cluster(this included converting the car to a GEM module wiring system). The only thing I had to do to the trans wiring, was lengthen the wires for one sensor. Since the TR-6060 trans is the replacement for the T-56, everything else plugged right in. To finish it out, I flashed the Cobra PCM for the new tire size and gears, and everything works great. This method is not for the faint of heart. I used to work on the control systems for a nuke power plant on a sub. Even with that type of background, I probably spent over a month working on just the wiring. Using the wiring for a V8 bird with a Mark VIII PCM, and some type of speedcal device would probably be more sensible.

Mike
So you used to be a Nuke in the Navy?

I can't wait to see more pics, this beast is a beauty of a project...
 

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Discussion Starter #440
any news?
Nope, not really. :( I'm currently in Japan doing some training for my job, and will be here for another 3 weeks. Also, for the past month or so, I've been helping my brother build a garage, so not much done on the bird.

I did get the hood back, and it is sitting on the car. I have the holes drilled for the hood pins, but I haven't finished putting them in yet. I like the pin plates and lock that I bought, but the posts that the pins lock in to is a little flakey. The all tread looking post with two nuts on it just doesn't blend in well with the rest of the engine compartment. I'll probably end up fabricating a custom post and welding it into the core support. I always have to do it the hard way.:D

And yes Dorkfish, I did a bit over 10 years as a Nuke. Luckily I didn't get sentenced to life. :)

I'll update once I make some progress.

Mikey
 
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