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Stooge's longer term car projects

johno

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not a whole lot, mostly boring floor and firewall patching, rebuilt/ re-gasketed the carb, fixed my power steering lines. these are ripped from my c10forum thread about converting the gm pump to work with the ford steering rack.

Move along, not much worth seeing here....... my tahoe needing some attention after a brutal winter and being 11 yrs old, front calipers, rotors, pads, new cv's, alternator and looking for a new exhaust before mine falls off.
just about done with the floor and seat brackets, trying to keep it simple and pretty low profile since the seats themselves are a little tall and im about 6'1. ordered a new temp switch for the electric fans since i somehow lost the original one when i decided to put the temp gauge sender on the passenger side where the switch was and a new carb gasket kit until i decide on a new carburetor as i might try and get it on the road with this current one.

i had been planning on buying the Heidt's power steering pressure regulator to keep from blowing out the ford rack and so the steering wouldnt be so touchy at speed, but with the regulator, all of the necessary fittings and pressure hose, i was a little over $250. did some research and purchased the Borgeson pressure valve reducer for $16 instead, and i actually rather like that instead of throttling back pressure at a regulator, it actually reduces output line pressure by reducing spring pressure, (if i understand it right :character0042:)
its basically just some thin washer shims, an extra o-ring and a clamp sleeve to protect the threads on the valve so you can put it in a vise without mucking up the threads.

removed from the power steering pump, the outer threaded adaptor came right out since there is a little spring pressure, but used a small magnet to pull the inner valve out.
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$16 worth of kit
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the stock valve has 2 shims under the nut
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according to the included chart, and referencing what the ford racks are rated for 850'ish psi, i used 4 of the 5 included shims.
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and back in the pump, obviously the outer threaded piece for the pressure hose to attach to isnt in yet but i was rushing through this last night because i was bitter and hungry from working on my daily
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hope this helps someone save some moneys! this was done with the pump still bolted to the engine in the truck $16>$250

I tried that kit with my car, it didn't produce noticeable results for me, hope you have better luck.
 
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Stooge

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I tried that kit with my car, it didn't produce noticeable results for me, hope you have better luck.

yeah, im hoping but i guess i will have to wait and see, im not as worried about the touchy steering as i am about not wanting to blow through steering rack seals. i've heard both sides, people having good luck with them and fixing the issues associated with too much pressure going to the rack as well as people saying they felt no difference what so ever. i figure for the few dollars, its worth trying and if it doesnt work for me, i can always put in a Heidts regulator or fit an accompanying ford pump.
 
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Stooge

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Replacement tail light panel came in for the gto yesterday. I was expecting it to be an actual replacement panel that underlaps under the quarter panels like the original, but its looking like the whole piece just gets chopped off at the quarter and **** welded....which looking at the following pictures could be a good thing.

Just started stripping all the paint and a whole lot of bondo









And a few pop rivets here and there for good measure


Not pictured was the base of the panel thats spot welded originally but now was about 50 here-and-there gobs of plug welds that took a solid hour to grind away, although i did manage to get a few with the rotabroach spot weld bits.
 
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Stooge

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Not much to see, did a lot of the fine tuning and hammering to get the quarters and taillight panel to line up perfectly and got carried away with the clecos, really aiming for no filler in these new pieces. There are 2 dime sized openings on the sides on the new panel from the manufacturer so they could make their bends that will need fillers made, but other than that, im happy with it. after i get it tacked in, i'll make some small channels to lead from the new panel into the factory trunk weatherstripping channel to get rid of the last of the brazing that was in there. This was before i ended up getting roped into doing the brakes on an acura mdx,( a little bit frustrating) and brakes all around on a 2003 saab that was alot a bit frustrating yesterday.



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Also, was out with a buddy who had to go check in on his father’s house while he’s away and walk his dog, ended up meeting one of his neighbors who I guess really likes his Pontiacs. Im not the greatest on 60’s muscle cars and I had a few adult beverages just before, but from what I remember in the garage, there were two 66 pontiac catalinas, (apparently another 2 in his other garage and he has every combination of 389 and 421 in auto and manual, all with either factory or converted power windows and vent windows) a 67 pontiac executive, 66 or 67 oldsmobile starfire, 53 mercurey Monterey with original flathead8, a Pontiac safari wagon, a 66 pontiac grand prix convertible that’s a combination of catalina, Bonneville and grand prix, also with power vent windows, factory ac and the added option of an 8-track out of a 67 complete with jerry lee lewis 8track being played when we were there, a 77 pontiac can am and a few other cars under tarps that we didn’t have a chance to look at, he said at last count he has 16 all together, all of this in an unassuming residential neighborhood owned, maintained and all currently on the road, registed,etc by a sprite 73yr old. I managed to grab a few pictures but everything was so jam packed in there it was hard to get good pictures.

I want to be like that when im 73!



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dlcwent

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Thanks for those pics Stooge. I'd like to be like that when I'm 73 also. But I'm going to have to win Powerball for it to happen.:lol_hitti
Nice job on the gto.
 
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Stooge

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Hey thanks guys! Pretty happy with how the gto is coming along, would be quicker if it was just replacing a stock piece than working around someones previous work but im being compensated well for my time and efforts and im happy to be working on it, cool car to have in the garage and get the experience of it.

I really thought i had more pictures of the cars in his shop, there were some blurry ones i deleted but i guess i was mostly focused on the merc. He had asked me about doing a patch panel on the can am around the driver's side b-pillar but not sure when he's thinking. Doesnt look bad to do, just some rot under the plastic vent thing, unfortunately no pictures. I guess the story is,back a few decades ago, he sold his local donut shops to dunkin donuts before they were what they are now, (dunkin donuts was started 2 towns over in Quincy) made some nice money off of it and gets to live the dream of a nice house and a dozen pontiacs!
 
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Stooge

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Forgot to pick up the right sized bolts for the new dimple dies that i picked up so i couldnt get the full effect of them but cool enough for now! i dont have much experience with dimple dies, but just a rusty piece of scrap, 18ga i believe, interesting to see how much more rigid dimpling makes just some thin sheet metal.



Chased down a few intermittent grounds in the truck wiring and slowly chipping away at what i can get done for incab wiring. kind of at a stand still until i get my gauge cluster back so im trying to get as much done on the gto in the meantime.
ripped a new lip for the edge of the trunk pan, and got it all fully welded in. I was a little worried since the lip is just shy of 6 feet and theres an arch above the fuel fill tube so alot of place for error between cutting the old one out and cutting out a new one. Happy to say i couldnt get closer with my fitment if i had to do it again....im usually kind of ****** with stuff like this and taking my time.



All cleaned up after alot of welding and grinding, few pinholes i'll fill in when i fill in the handful of trunk and backseat floor rust spots


The old rusty one



34 Holes for plug welds every 2" ,probably overkill but 2" seemed like a nice measurement.



All primed with Sem weld through primer, and clamped back in with the holes drilled for the clecos when i had it in before. Wanted to get it all set in before the new lip was put in to get it close to stock fitment and cutdown on potential issues. really happy with it, i'll start welding sometime during the week where in sure i'll run out of wire or gas, low on both! Need to stock up on clecos and sidegrips too!

 

xtremek

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First, I love your work. Now a quick question. Do you make your own trailing arms and brackets, or buy off the shelf stuff?
 
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Stooge

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i originally bought a set of upper and lower triangulated 4 link bars from Nfamus Metal, when i originally set up my rear suspension. when i cut out the first setup, ( upper trailing arm crossmember specifically) i made a new pair of upper round tube bars to get it how i wanted it and was happy enough with the pinion angles through out movement. i do plan on getting a set of upper adjustable ones when i get my new rear wheels though, and will be going through, most likely Nfamus Metal again, or perhaps Ballistic fabrication. i dont need anything too crazy, just solid rubber bushings with a threaded end.

Edit; didnt read the whole post, ive made quite a few of my own brackets but i ended up buying a whole bunch of misc axle and link and shock brackets from AVS (avsontheweb.com) during a sale they were having awhile back. For what alot of vendors sell them for, unless its something weird, its not worth the time and sourcing the materials to make my own.
 
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Stooge

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Day 1 of my long weekend was spent working on some newer cars for people. Plugs, wires, coil packs, pcv, front rotors, pads and unexpected calipers on a buddy's 4runner, manifold sensor on my mother's maxima and rear struts on an a different maxima.
4runner with this judging face while i worked



And this morning, after some not so interesting gto stuff
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And some recently neglected truck stuff! sort of figured out why i was having a starting issue, due to the battery cable inline cut off switch, ( those 2 post switches with the big red, removeable lever). Not sure if i just have a cheap one and fried itself. I may just forego the switch and put an interrupter somewhere else as a safety/theft inconvenence. took some dash measurements and started filling the notch around the steering column that was cut for the stock column versus my new 1 3/4 one, filled a few holes that i had drilled for the first location of the ignition switch and mounting plates. Then started cutting out the new ashtray that was generously donated by DV8 and grafting it in. One off kustom stuff is great! Trying to copy a one off that you already did and trying to repeat it months later a few inches to the right, is a huge pain in the *** to get to look right.


Trying to preciesly trim a piece of tin that doesnt weight anything and needs to keep its shape, wedged between some heavy steel blocks. Super secret dent remover tool skateboard wheel lurking in the background.



Template for cutout.



Couple hours later of cutting, wellding and grinding.








i was expecting to have to block off the original ashtray opening, but its looking like i might be able to just open it up with a die grinder a bit and the converter lockup controller should slide right in and i'll already have a hide away cigarette lighter/charger. Still have alot of weld cleanup to do around the new one, but it needed to cool down a bit, i'll finish it tomorrow maybe.


Some switch bezels by way of Shoebox Central, and a new knob to replace the plastic one that came with the wiper switch. I like em, placed above the left side of the steering column, above the ignition switch and tach hideaway.



 
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Stooge

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Also managed to light my pants on fire at 8 in the morning Saturday, thanks to trying out a new weld through primer, (Sem brand) so im a little hesitant to use it again, likes to "pop" and spatter alot. Happened while doing the plug welds on the gto's taillight piece to trunk pan lip. 34 miserable holes and probably toxic smoke that was billowing from them.



Also forgot friday after work, went to grab a bite to eat with a buddy and ended up playing around with his impala trying to get it started for the first time in a few years. 1964 impala SS hardtop, matching numbers 327, dealer A/C, although he has had the original fuelie heads off for a bit procrastinatung sending them out for a rework. I think the carb needs a rebuild, new gas tank and for some reason theres no fuel filter. Holefully it will be out driving around this summer.









 
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Stooge

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Hey thanks buddy! truth be told, i actually set a cheap material, pair of shorts on fire a few years ago using an angle grinder in the same spot! Saturday, i was sitting on a chair and my lap was pretty level with the trunk pan and the weld through primer was making doing the plug welds pretty difficult and was just popping alot, until i felt a warm feeling and smelled burnt hair! ...then i decided i should do the rest of them standing up atleast.
 
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Stooge

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Hah! Garagio pants sound pretty fancy! usually for welding days,i have a few pairs of thicker canvas style type pants or those duluth fire hose pants that havent seemed to catch fire yet. I wasnt planning on doing any welding that day, was just killing time while i was waiting on someone who's car i was going to work on got there so they were just some ratty old jeans.

popped down this morning to do a few things, braced the back of the dash to replace some pieces that had been cutout along the way and to keep the cleaning up the welds from oil canning the bottom edge, pretty happy with it so far. Ground all the welds down with the edge of a 3"cutting wheel and some roloc pads, still work to do but it atleast is presentable. Also finally took some initiative and sanded the remaining black paint off so it doesnt look as trashy.







And did a little work on the speedometer "bubble", not much to see, just some hammering and a few welds here and there, need to make a few little filler pieces for the transition to the dash but i didnt feel like working too hard today.

 
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Stooge

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Waddya mean, that WAS my fun sunday! :willy_nil

I did manage to squeeze in most of the other people's car stuff in on what ended up being a very long Saturday. a buddy of mine brought his 5yr old son, who's taking an interest in old cars, down to the shop for the day, so it was fun having him poke around, come running back to ask a question, then go back to look at whatever it was again, or open all the new parts and ask questions, hand me stuff while working. im upgrading some of my common use hand tools soon so im planning on putting together a little tool kit for them as I go, as the father is taking just as much interest as the son.

I did take it easy Monday though, few hours in the morning playing with the dash, and took the rest of the day to relax :thumbup:
 

dlcwent

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Waddya mean, that WAS my fun sunday! :willy_nil

I did manage to squeeze in most of the other people's car stuff in on what ended up being a very long Saturday. a buddy of mine brought his 5yr old son, who's taking an interest in old cars, down to the shop for the day, so it was fun having him poke around, come running back to ask a question, then go back to look at whatever it was again, or open all the new parts and ask questions, hand me stuff while working. im upgrading some of my common use hand tools soon so im planning on putting together a little tool kit for them as I go, as the father is taking just as much interest as the son.

I did take it easy Monday though, few hours in the morning playing with the dash, and took the rest of the day to relax :thumbup:

Little guys are always fun to watch and hang with when they are not being a PITA. My youngest grandson is a real guys guy. He gets mad when his mother won't let him come into the garage first when they come to visit.
 
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Stooge

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Yeah it was fun having him around, made the frustration a little easier. Admittedly, im not too used to being around little ones, mixed with working on a rusty daily drivers meant alot of catching myself halfway through swearing as well as struggling with kid talk.

Text i got later in that day -
"Tell Dan this looks like the air compressor he was using today"
(My regular compressor's hose wouldnt reach outside, had to use the big mobile one)



back to today, did some wire fiddling on the truck fist thing, changed some gaskets, made some new battery cables to bypass the interrupter switch for the time being, got the engine running consistantly and did a little carb tuning. A little choppy, sounds nice. Im sure it will be fine, but i'll hook up a vacuum gauge tomorrow and make sure my brake booster wont just be eye candy on the road. someone popped by with an altima and i replaced a windshield washer tank on it then i made some little filler pieces for the gto, just wgere i had cut out some of the brazing gobs and to connect the weather stripping channel piece to the tailpiece. Nothing really interesting and i didnt take any before or during pictures, still need to pretty it up sometime.


 
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Stooge

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Took the day off, had high hopes of getting alot done and instead mowed the lawn and fell asleep until midafternoon. Im getting worse at remembering to take pictures, finished the taillight pan and massaged, welded in and ground down the weather stripping channel sections from new to old. had to section out about 1/3rd of an inch from outter most lip of weather stripping channel since its shaped slightly different from the original which was causing the passenger side of the trunk to kick up slightly as was a pocket where the trunk corner hit one side of the pail piece,just alot of hammering mostly.

Started roughing in a shape for the sail panel/ b-pillars on the gto. I was planning on making some sheetmetal bucks/ribs like i did on my dash, but that seemed like alot of work so i just grabbed a piece of scrap and started hitting it with a hammer. On its way, still alot to do but it was good to get an idea of where to go with it.





Wanted to get that started, had some parts come in this week so big plans for wiring on the truck tomorrow. Spendy Flaming river battery disconnect since my $5 one i bought from a speed shop that was closing down **** the bed, so im trying the $100 one, (plus $18 for a spare key!), some new connectors,a courtesy light kit from American autowire and a 12v charging port for the second ashtray.





Also went for a quick drive in the '38 ford!
 
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Stooge

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Wanted to get that started, had some parts come in this week so big plans for wiring on the truck tomorrow....

Nevermind.....i got tricked into helping/Doing the brakes on my neighbors minivan because he basically just has adjustable wrenches and plumbing tools, no jackstands or jack for that matter and i managed to do it for free....

While i was already filthy from that, i just played with the patch panel for the gto a bit more. Im staying clean tomorrow and doing wiring









alot of fine tuning left to do but its getting there
 
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Stooge

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I did! not as much as I was planning on and I would like to thank the highway dept for that and their desire to dig up roads and leave them that way for a few months before repaving them. looks like the Tahoe is getting a new exhaust sooner than later :lol_hitti
although I had been neglecting this and knew it needed some attention after this past winter, I was planning on replacing it within the next few months but some giant potholes and road work decided I should replace it now.
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I did manage to get muffler back on to the intermediate pipe, but its a little fragile, one of the tailpipe hangers is rotted away from the pipe so that didn't go back on, so it stops at the muffler. time to pry the wallet open and get something overnighted I suppose. maybe just a stock replacement or something, I don't want to spend too much on this truck.

did some wiring on the truck, had to relocate the new battery switch to accommodate the bigger size and get around the underside cab floor bracing, ran the power wire for the door solenoids so I can still get the doors open with the battery killswitch, and had the keyless entry and center console door solenoid momentary switches working, just need to put the spring pins back into the door sills. I thought I took a picture of the some of this stuff but I guess I didn't. just of the new vs old switch, new one weighs about 1.5lbs, has a really nice locking mechanism and just seems like a real quality piece so hopefully it works as such, but so far the first few times firing it up, its worked great.

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Stooge

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A little work from this morning, not too important, but playing with how i'll make the trim on the dash so i can eventually start bodyworking it. I was looking online for something universal off the shelf i could put on but didnt find anything that would look right and wasnt just chrome stickers. Found some 1/2" tubing and sort of fixtured it up and rana thin piece of tape from one end to the other and marked it off.


Cut out about 1/4" out of the circumfrence









Took awhile to cut with a 3" wheel on a die grinder but in happy with it, thinking of maybe trying to stick some button heads in there for attachment but they might take up too much space.



Also plugged away on the wiring for a few hours,not much to see but i did make some harnesses for the auxiliary door solenoids and their leds. Didnt photograph too well, the green and blue lights are alot more pronounced in real life, also need to recalibrate the lokar shift indicator but i had lost the instructions so i'll have to do that some other time. Having shaved doors and a battery kill switch is making wiring a little more time consuming, but it seems to damn easy to break into one of these trucks so th battery kill is a little insurance.



 

dlcwent

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Nice looking trim. Very cleaver of you to make it. I'm sure the lights are more impressive in person than in a pic. You're still making me think that you should be doing this sort of work for a living. Maybe after a few more people see you're talent, you'll be turning down projects because you're too busy with the ones you chose to do.

I know it's nice to have a sure thing job, but life is a gamble. I once had to make that choice, and I've never looked back. You have more talent than most people and a lot of them are making big money working for themselves. Just saying.
 
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Stooge

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Wow, thank you, that's quite the compliment! truth be told, this is something i would like to do more regularly i guess but i im still pretty far away from there. i still don't know what im doing and everything im doing, im basically doing for the first time so theres alot of learning to be had still. there are a few future jobs up in the air from club members out front on some muscle cars and hot rods and a possible something for the owner of all of those Pontiacs i posted a page or so ago, along with the handful of people with later model cars who just need little things like brakes, suspension, exhaust, etc. perhaps in the next few years, if i can start working on more and more stuff, then i could move into a bigger shop, then maybe i'll have some decisions to make.

i just need to find a nice traditional hot rod shop/ metal shaper who i can trick into hiring me as an apprentice/ worker so i can learn and not be completely poor.
 
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Stooge

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finally bought some rear tires and the first time its been of jack stands this year.These will be great for new england weather!





Some cheap *** angled pictures that got my pants all dusty





 
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Stooge

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Move along, nothing to see here :dunno:

Start of the Bluetooth kicker stereo thing,





some speaker box/mounts I made. had to make a sealed cut out for the new battery disconnect as it is considerably larger than the previous switch.







a lot o cutting apart on the gto, a little reconstruction but not much for pictures.

[/QUOTE]

Some pictures




Some under dash lights


The wiring will get ziptie wire stickums aftet i paint the back of the dash to replace the masking tape.



Torque controller is just sitting there, still need to make a mount for it but did manage to put in the aux charging port in lieu of the old stock cigarette lighter












[/QUOTE]

Made the longer trim piece, about 25" , with a 3" cut off wheel on a die grinder :lol_hitti



[/QUOTE]

found my stock gas sending unit, cleaned the 30yrs of gunk off and ripped off the sending unit so it just had the pickup tube and sock. Then started taking apart my new sending unit i bought from a late 40s/ early 50s ford and mercury vendor and cut some of th extra stuff off, and ground down the brackets. saves me alot of grief thinking i was going to have to weld in a gravity fed outlet for the fuel line or make up a new drop down spot for the new sender.


Still a little trimming needed and i have to dig out my box of rubber tubing plugs for the return and charcoal canister outlets, but for a pretty half assed experiment, im happy enough with it.
[/QUOTE]

And finally last weekend, a few steps backwards :eyecrazy:



Stripped the tanks, compressors, accuair sensors and what ever else and started cutting. Im doing the raised bed floor frame over again, and integrating the fuel tank mounts, accuair manifold and brain mounts and the upper shock mounts into it, along with capping the upper link crossmember and adding a few gussets and finish welding a few places.

[/QUOTE]
 
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Stooge

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eh, not really, just little stuff here and there, did some ' no turning back now' cuts on the gto sail panels to start fitting the replacement ones im working on. I need to stop by a buddys and grab some measurements since this gto had enough rot and bondo around the edge of the sail panel/ trunk deck that I was having some issues getting a smooth solid surface.










and started on the new raised bed floor frame work, shock mounts and I need to figure out/ make some final decisions on if i'll be running the stock suburban gas tank I bought awhile back. moving the shocks outboard of the frame freed up some space behind the rear end but its still a little tight.



Holes drilled through both sides of the rect tubing and welded on both ends, probably isnt needed, but will be adding a horizontal gusset to the backside of the tubing.

 
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Stooge

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It had been a few weeks since i made any progress on the gto so i started to try and fit the new pass side sail panel. Everything i touch on this car has been Ham handed by someone with poor eyesight and little patience before. Started sanding the rest of the sail/upper quarter to find 1/4" of cave and pave bondo to cover up a hastily welded in previous patch panel. The plan for that is to cut out where the old patch overlapped the stock quarter,massage out the low side created by the overlap and **** weld in a new piece and make it pretty.


Ends of mig wire and a few pop rivets


















made some gas tank straps and some mounting points for the 84's new tank





did a little setting up of the air management, put in the rear height level sensors,plumbed the tanks and compressors and started hooking some things up. After i make sure everything with the accuair is working, i'll shorten up the e-level sensor cables quite a bit, left a little bit of extra length on the air lines for when i permanently install them with the clamp clips to make it nice and neat looking, big zipties for the time being. Next is nlow apart the front end and re-do a few things, put my new control arms and put it back together to make sure everything works right...so i can take it all apart again for chassis and suspension painting.



 
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Stooge

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Mar 24, 2013
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3,533
Location
South Shore, MA
A few little updates
Had to repair the old, underlapped patch panel someone did before i can start burning in the sail panel. Doesnt look like much, i didnt replace the whole patch, just the offending seam, massage out the low spots that had been bondo'd over and smooth it all out. Few more little spots to fix around the drip rail where they just gobbed in weld and bondo but i had enough for the day.







and got to use my new dolly for the narrow confines of the rear quarter.









Also put the new tubular control arms and height level sensors up front in the 84, did some plumbing for the air lines and got moat of the wiring for the air management mocked up and got to give it a sucessful run through after an initial calibration. A few things to change and make a few final decisions before i pull the rear all apart for chassis painting











 
OP
S

Stooge

Well-known member
Joined
Mar 24, 2013
Messages
3,533
Location
South Shore, MA
i ended up using Porterbuilt's tubular arms, was thinking of going with the Michigan metal works flat plate ones to maybe save a little money or the Ride tech ones to cut down on lead times, but since I am using the Porterbuilt narrowed front crossmember and sway bar, I just bit the bullet and bought there. Beautiful pieces, both design wise and build wise.





theres still a lot to do on the '66, but after I get the passenger side sail panel in, the driver's side should be a breeze since its not nearly as corroded. I already have the new panel made for the driver side, I just haven't cut out the original since I've been using it for references, and that's the majority of the work. still need to do the lower front windshield piece, take care of a few holes in the floor and a small spot on the driver's side fender, but those shouldn't be nearly as involved!

Also, finally heard back from the gauge company, and my speedometer cluster should have shipped yesterday! 5 months from when I sent it out in April, but the price was significantly lower than I was psyching myself up for so I can overlook the wait time
 

dlcwent

Member Emeritus
Joined
Feb 24, 2014
Messages
8,427
Location
coastal maine
Thanks for the update. Rome wasn't built in a night.

Maybe it's just the picture, but how does the air line not interfere with the steering box? They look like they are using the same space. I can see you've got it hooked up, so it is working, but it looks like there's not enough room for the line.
 
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