Ehansen007/33 Machine Build page

[ehansen007]

Hey all,

Finally started my build today. Really excited. Just realized there were more parts than expected to powdercoat. I'm surprised the 3 link setup does not come powdercoated but since it's an option they must not do it with the frame. It took a few minutes to clean them up the welds (they got more balls sticking out than the US Men's Olympic swim team) and I'm off to the PC. Then, back to inventory!

Here's my photobucket album!

http://s897.photobucket.com/albums/ac177/ehansen007/

Also, I got my rear end from a local performance shop called GRC. It was used off a mustang he swapped out for a racing rear end. Umberto over there is swapping out the bearings, converting to disc, changing the oil and even hacking off the dog ears and painting it for an even grand. It's a 2.73.

I'm also considering having him build the motor for me since he can get me a 302 fully rebuilt with some new lifters and nice heads that should make an even 275HP or so to start. It would also come with a 3 year warranty and he's local. We'll see if I can't find something better on Craigslist before I take the plunge on that.

Take it easy!

http://www.ffcars.com/forums/picture.php?albumid=411&pictureid=3028

Here's my photobucket album!

[ehansen007]

I also just ordered some ceramic coated shorty headers off Amazon for $160!

http://ecx.images-amazon.com/images/I/51nYtDpOpSL._SL500_AA300_.jpg

[ehansen007]

Last weekend I built up the front end, brakes and installed the pedal box. The front end was not without it's little challenges but you just work through them little by little.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1270.jpg


That stud thing in the pedal box it a real PIA. They should just have Wilwood weld it in so you can tighten that low profile nut and leave it.

It was fun fabricating the resevoir brackets. I agree that this is a personal preference and although the aftermarket ones look nice, I prefer to have them hidden as I'm trying to keep the engine compartment totally clean. If anyone wants a pair, I'll sell them for $25 shipped anywhere in the US. Just let me know. FYI, they will look much better than mine as those were just a prototype.

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[ehansen007]

Here's the "new-er" rear end. All new bearings and seals. I stayed with the 2.73 for now which is low but it was such a good deal, I can always change it later. I'd rather put that $300-500 towards getting the car rolling. Besides the gears look great. I plan on doing one more coat of paint on it as I was looking for a semi gloss to match the rest of the rear end and the car. I've got a new diff cover coming today which has a girdle system in it for $100 on ebay.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1288.jpg

It also came with the brake kit and the axles. I'm in between painting the calipers or leaving them silver and just painting the brackets. Not sure yet.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1289.jpg

[ehansen007]

Got my new steering wheel in and it is nice. I went with suede since I'll be cruising with the top off a lot in the summer and it wont get as hot as leather. Also, there's no better traction than suede with gloves if I'm going to take her to the track! :icon15: Even the horn button is suede! There's a good chance the chicks will probably dig this..... :shifty: I also like that it's a 350mm wheel vs a 320mm which is what most after market wheels are. I'll need that extra diameter to steer those 245s up front with no power steering!

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[ehansen007]

Having learned from experience, I make sure I paint most areas of the brakes to avoid corrosion and make it easier for brake dust to wash off. I even paint most of the rotor that is not in contact with the pads to avoid rust as well. This is more important than them looking cool but while I was at it, I figured I'd follow the black and red thing FF set up with the springs/shocks.

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I also installed the rear end (which I swapped out the gears as well for a 3.55 ratio). The rear end went in fine with the exception of of the top shock mounts. The manual tells you put the bolts in from the front with the nuts on the rear so you can remove them down the road once the body is on. This is all good but there are at least three pictures showing them installing the bolt from the rear. Come on FFR! :sneaky2: Not only that, but the bolts are ridiculously long and hit the aluminum trunk panels when mocking up. Suspension components should be easy to remove on a racing chassis so having a bolt this long is not useful. I cut these down to get the trunk in. If I remove them again, I'll put in new bolts. Also, the instructions on the panhard bar are a bit off. Make sure to slide the left side eye rod into it's bracket before mounting the right side in it's bracket. Otherwise you'll never get it in!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1338.jpg

[ehansen007]

This one is easy compared to the other stuff....that is...if you have a nice little bench-belt sander handy. I had to trim the laser cut edges at multiple joints to get around the welds in the frame in the foot box area and the far outsides of the firewall where it meets the body. I had to take them off about 6 times on the lowers to get it right. Then, I used my large bench sander to take off at least 1/8" off the top of the firewall like most of you hear only mine was on the passenger side?

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[ehansen007]

Picked up a T5 in good shape for $200. Brought her back and gave her a quick flea bath and she's as good as new! On the outside that is. I plan on opening her up to see how she looks on the inside. It's out of a wreck so at least I know there was nothing wrong with it when it came out. The guy said it has 90K miles.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1353.jpg

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[ehansen007]

I'm doing a combo of gloss and flat black throughout so I did the Firewall in gloss PC. It's very reflective!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1394.jpg

I also put in the steering column and my son helped with the wheel. I do have a horn button on this new wheel but I'm unsure has to how to hook it up. I connected the spring loaded wire into the wheel but I know I have to probably ground the black wire coming out of the column to make it work?

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0095.jpg

Factory five shipped only one steering coupling so I installed it into the firewall. Still waiting for the lower one. I had to shorten this steering rod to get it fit. Did anyone else have to shorten theirs? I took like 1" off.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1398.jpg

[ehansen007]

Factory Five/Russ Francis does a nice job of making this plug and play although it's a lot of wire. The instructions are a bit fuzzy but they do the trick.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1399.jpg

[ehansen007]

Picked up this little pearl from a wrecking yard for $500. It's a 90 Lincoln Mark whatever and it's got 109K on it. These engines are kind of hard to find right now and most are pretty rusted and beat up. This one was immaculate compared to the others and it started right up and ran great. It sounds like the drunk who crashed her kept it in very good shape. Anywho, I'm now wondering what to do with it. I plan on getting all the essentials first like stand rotation water pump, belt system, manifold, carb, and maybe a dress up kit for the valve covers and air cleaner. Nothing too elaborate. The goal is to get her in the car and running without tearing her completely down. She runs fine and if I put some nice heads or cam in and she goes I'll tear her down then.

Any suggestions? What would you do? :001_smile: I do have one question. Is that yellowing at the end cooling ports typical of anything or is it normal? Seems like it would just be coolant and errosion.

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[ehansen007]

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[ehansen007]

This was a fun project cleaning this up. Luckily it wasn't too bad but I have gone through a lot of prep and paint to get it here. I still dont' have the manifold, carb, pulley setup, starter, etc but hey, I'm putting her in the car so I can start building again!

What a difference 5 days makes.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1874.jpg

Headers from CR performance.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1876.jpg

Tranny is rebuilt using a Hanlon kit and their DVD. Man I hope it works!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1877.jpg

[ehansen007]

The whole thing went in like butter. It was a bit tight and I can't imagine the 4.6 guys putting in the motor! The most helpful element of the whole install was having the floor jack under the tranny and rolling the whole thing back into place. I had to flip the tranny bracket around to get it to work compared to the manual.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_8707.jpg

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Even my little guy got in on the action. Three generations building one car. He loves it.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_8712.jpg

[ehansen007]

Been working hard getting the engine together. I ordered a Holley Street Avenger 570 refurb off ebay for a good price. I also got a spacer so it sits up a bit and pushes the air scoop through the hood. not sure if I will have to rejet it with the increased plenum volume so we'll check the plugs and see. I've mocked up a small alternator bracket and my buddy is machining it so I'm anxious to get it back. I'm also waiting on a Gilmer belt drive setup for xmas and an HEI distributor to finish her off. Yesterday was a fun day where I got my Shotgun air scoop and that thing is huge but I do like it. I think it will look good just peaking out of the hood a bit. It's amazing how cheap they've gotten on ebay so I figured I'd try it out.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_8791.jpg

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[ehansen007]

I'm also almost done with the fuel system. I decided on an airtex inline pump which should work well and I like the fact that I can mount where it's invisible. I also put in the Oooo-gahhh! horn and I'll probably paint the cone black to hide it.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_8854.jpg

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[ehansen007]

I also ran into a bit of a snag yesterday when actuating the clutch. I noticed that the angle of the cable was whacked out and it was wearing on the plastic sleeve. I knew I had the right Clutch Fork so it turned out I have the wrong bell housing. Apparently they made it different from 94-95 and it won't work. Nice. So I've located another one on Craiglist so hopefully I can get that one. They are hard to find. I just can't believe I hot tanked it, bead blasted it and painted it and now I'll be selling it! :sneaky2:Check out my Jokers Wild shifter made from a stainless pipe and a racketball! Just for fun.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_8858.jpg

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[ehansen007]

I got a new HEI distributor, Pro 5.0 shifter, and a gilmer belt drive pulley system. I'm not sure if the Gilmer is going to work out or not. I may have to find a way to shorten the crank pulley up. I also painted my shotgun scoop and mounted it. I put together a linkage for the flaps using some old RC car parts!

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[ehansen007]

Well, after a lot of researching, it turns out all I needed was the Pro Comp fluid Harmonic Balancer to solve the problem. I recessed it just enough to get it behind the steering rack and still be able to get the belt on. I got the whole thing set up with some temporary spacers and it should be very close to production.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_9044.jpg

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http://i897.photobucket.com/albums/ac177/ehansen007/IMG_9042.jpg

Then there was that unfinished bracket for the Alternator......

[ehansen007]

Well, I did have some extra time on my hands to day since I had the day off so I went to work on the Alternator bracket. My custom bike days must have been coming back into my head today as I got started. I wanted to keep the "X" patter so it would look balanced so here we go. (sorry if some are sideways, photobucket is having a tough day.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_9046.jpg

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[ehansen007]

Picked these temp wheels and tires up from Craiglist last night for $200! Apparently they were taken off an Altima which is funny since the are 17s in front and 18s in the back! The front tires are good but the back ones are shot but that's okay, I'll use them for some burnouts once I get her running. Seeing all the black makes me want to go with Silver wheels but I'm still not sure. I change my mind on wheels almost daily (I'm sure none of you do). It's great to get her on the ground though. Helps me make some decisions on certain things like exhaust etc. Man, these cars look so mean! I love it!

http://i897.photobucket.com/albums/ac177/ehansen007/DSC00046.jpg
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[ehansen007]

Been a while since I posted up some progress. Lately, I've been working on building my exhaust tips, a trailer hitch with a bumper, and acquiring all my stereo gear. I also got my new custom gauges from Speedhut.

Now I just need to get some wiring done and get her started! Getting close!

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[ehansen007]

Here is the bumper I just put together. It should give me some protection and it covers the hitch and gives me a license plate mount! It will also be an option if I sell any.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0222.jpg

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[ehansen007]

These are the exhaust tips or "Zoomies" as some call them. I had these powdercoated in titanium.

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[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0184.jpg

Basic center console. I'm going to do the gauges from the center out and do an EQ and a back-up camera in the console.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0069.jpg

[ehansen007]

Okay, here we are at the 6 month stage. In the last few weeks, I've finished up my trailer hitch and bumper (and sold a couple to happy customers), and, while at the powder coaters, had them do my shotgun scoop in wrinkle black to match my new Ford Racing Valve covers. I think it gives it a nice rough look and I sanded down the fins to match. I also picked up a one wire alternator as no one could advise on how to wire the one that came with my lincoln motor. It does need an external regulator which I wasn't going to set up so I spent the hundo and got a black one from summit. I now realize it sticks out like a sore thumb but oh well!

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[ehansen007]

I also installed the e-brake. Turns out I drilled down through the frame and right into the exhaust clamp I put down there so that was fun. I guess you need the stock mustang cables to hook it up. Where do I get those?

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0272-1.jpg

[ehansen007]

The throttle cable is hooked up but it was a pain. I drilled my first set of holes where it was "comfortable" (according to FFR's manual) and then realized you need to put it where the arm is ABOVE the frame rail on the inside of the firewall. So I drilled another set of holes where it would actually work. Bummer! Even with it mounted in the right place, there is a lot of adjustment to get it to work smoothly with a carb hookup and avoid the "sawing effect" you can get with the angle of the cable and the "S" bend. It's working now though! I also ran some welds on the the pedal mounting bracket to strengthen based on Terry's near death experience.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0266.jpg

I wired a lot of the engine with sensor wires for the new gauges, electric choke, horn, starter, etc. The nice thing about the air gap intake is that it gives you a nice place to put the wires. I don't think there will be enough heat under there compared to just outside of it, do you? If I see any issue, I'll relocate them. I covered all wires with conduit as well as a buffer.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0265.jpg

[ehansen007]

I got some new brake lines for the front from Jegs. The 19's are the perfect length if you swap the left and right for bleeding. Speaking of bleeding. I picked up the air bleeder from Harbor Freight and man that worked great. I got them bled by myself in minutes and it was only $25!

Overall, I'm getting really close to firing the motor. I hope to get a ford expert over here to go over all the details before doing so in case it's all screwed up. I basically made a $500 motor with 90K on it look like a crate engine so I guess we'll see what we'll see. Wish me luck!

[ehansen007]

Okay, so I've got the motor started and I had a big party for people to come and help and man did it ever. A really nice guy (xlr8tor) from San Diego drove up in his Daytona and just went to town helping me get her dialed in. Here's the video.



http://www.youtube.com/watch?v=t8KeMX33y7I

She fired on the first try. We then noticed a misfire and tried rewiring the distributor which didn't work. Finally we just moved the plugs one post counterclockwise to line up with the rotor on TDC and it worked great. Now it starts so fast it's silly!

[ehansen007]

Today was a nice warm day so I decided to haul the body in the side yard and undercoat it. I decided to try the Rubberized spray and man was it easy and fast. You could do it with just two cans at $8 a piece but I used 2.5 cans. It goes on easy, looks good and stinks like tar! I hope that goes away and doesn't reveal itself on hot days as I sprayed under the dash as well. I noticed an immediate difference in the sound of the body as I picked it up and carried it. It was much more solid which should be great. Here's a pic.

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[ehansen007]

I also got motivated and put the car on the ground and drove it around the block a couple of times. It seems like she really wants to steer so that must have something to do with the camber. I'll get that adjusted once I cut those lower arms like everyone else despite what factory five says. I also noticed that the front brakes have no bite. I bled them well and maybe they need to break in but man it's really bad and dangerous to have those be so poor out of the gate. I may invest in something more aggressive on the pads and rotors.

Here she is out in the sun!

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HEEEEE HAWWWW. Look what I dun built!

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[ehansen007]

Been taking a few laps around the neighborhood lately. The alignment is still way off but she runs pretty good. I also trailered her down to the Huntington Beach FF Show on Saturday and that was great! Quite a few 33's turned out.

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Apparently, Lang's green rod went to auction that night. Not sure how much it sold for though.

[ehansen007]

Thanks! Although the wheels will be changed soon enough for some deep dish monsters. I will still keep these for track days possibly.

I just got the doors on the car and posted up a video on how I did it. I also did the alignment based on rumbles specs and cut 1/2in off the steering rod, the tie rod end and the LCA. Now I have plenty of room for adjustment! It now appears to be aligned and drives very straight. It's crazy driving a car with no power steering though! Been a long time since my 69 bug in high school. Thanks again Rumbles for your write up on alignment.

[ehansen007]

What a PIA! The cables mentioned that should work (FOR-M-2809-A)were 2 3/4 too short (apparently from the new handle assembly). Shortening those was a real task. And I would not recommend this cable to anyone with the new ebrake handle.

I also have a question. Is this the way it's supposed to work? Is that flange supposed to catch the bracket a little for an extra safety catch? At first I thought I would have to grind down this bracket but then I figured maybe it's supposed to work this way? I would understand if they used angle bar here for strength of this tab but, unless I route the cables underneath that previous frame truss and not through it, it will hit this bracket no matter what.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0395.jpg

[ehansen007]

Been busy doing a bunch of things including the door installation video and trunk. The trunk was a real pain given that it doesn't fit out of the box and you need to make sure you've solved that problem before installing the latch. If you don't, it will throw everything off. I made this mistake and I drilled and put my rivnuts in for the striker bracket too low and it hit the latch box. So, I spent two days trying to get that lined up and working right. I think it's important to NOT install the trunk floor until you've got the latch working properly. It's so much easier to align it if you can get to the latch and make sure it's working from under/below the car. Also, I found that you can reach behind from the back of the cockpit to adjust/tighten the hinges with the trunk down so you're not having to open, adjust, close, etc.

Here is my bracing solution to get the trunk to match the curvature of the body. The broom is optional and I'm looking for a telescoping version so I can actually fit it into the trunk. ;)

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[ehansen007]

So I'm thinking I'm going to absolutely attack the wiring in this harness as the next undertaking when I take the body off for paint. Everything is together and working but it's a mess and I've seen some nice wiring jobs out there. I'm thinking some wiring blocks would do the trick. Any advice would be good. I've also created this little center console to hold my switches (Brights, Fan, Fuel, and Backup Cam), EQ, and backup camera screen (bottom). I also plan on putting in a start stop switch but I haven't decided on the location.

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[ehansen007]

The trunk "formers" (as I believe they are called in the aircraft world a.k.a wing ribs) were just made from aluminum sheet. Instead of trying to bend angle stock, I just used my little bandsaw (a jigsaw would work too) and cut the shape and added tabs a the top and bent them over. I'm going to redo them and possibly have them hardened with a dimpler.

[ehansen007]

I finished doing the hole in the hood for the scoop. I think it peeks out just enough to break up the hood line will still allowing me to run the flapper mechanism under the hood. What do you think?

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[ehansen007]

Rear camera added! I'm hoping this works well for when have the top on and need to back up. Also, I'm hoping it will work well as a rear view mirror since I will have it on all the time. It's more of a fisheye but at least I can see in my blindspots on my 3/4. We'll see I guess. I haven't hooked it up yet.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0060.jpg

I also got my nose cone on and that was a challenge with the body being as tweaked as it is. It doesn't meet up perfectly so I'm hoping I'll find some adjustment there. I was tapping the bolt hole on the grill when the tap snapped off on one side! I managed to get it out without having to take the grill off (thank god)

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0061.jpg

Here's the interior thus far. I mounted the seat belts and have been taking people for short trips up and down the block and this thing really hauls butt with just a stock 302! I don't know how you guys manage to keep traction with those strokers! But it must be insane.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0058.jpg

[ehansen007]

I put on my new mirrors I got in the mail and then went straight to the tail and headlights. I haven't installed the trunk insides or the waterfall or the hood. Do you think that will be a problem with the CHP?

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0145.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0147.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0144.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0146.jpg

[ehansen007]

And they work too!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0148.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0155.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0157.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0153.jpg

[ehansen007]

Wow, I guess it's been a while since my last update. I've been working on the the overall ride and mostly getting the car registered. On Tuesday I offcially turned in all my paperwork to the DMV. Like a dummy I forgot to make copies of everything but as long as I get what I need back along with the registration I'll be happy! Overall the process wasn't too bad. You just have to make your appointments. I didn't need all the receipts all the time. Usually I just told them, "I was told I didn't need it" whenever I was missing something. Sometimes it worked other times it didn't. BOTTOM LINE: Take your all your receipts with you all the time. Here's a breakdown of the experience:

1. DMV- One of two trips. I had all the paperwork and was then shocked when she asked I had the car for VIN verification. But I said, "I thought the CHP does that?" She agreed and kept processing. Then I wrote a check for $1996 and I got my TOP paper with an "8" on it *(which means good through August), put it in the window and was good to go. BTW, I drove the car everywhere and was never stopped. I also put a copy of my TOP on my license plate as to avoid questions from the police.

2. Brake and Lamp inspection- Two/three trips. I wrote up a long story on this one in another post but the long and short of it was I was able to get it passed without having a backup light (which is apparently required in California) by going to a place that didn't care about it. So that worked out. Putting a working backup light on my car was going to be a PIA.

3. One trip. The CHP was a decent experience. Make an appointment early on as they typically only do it once a week and they get booked up! The only question was where to put the VIN plate. He said it had to be visible and on a non-removeable part of the car. So he stuck it right on my frame rail! Lame!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0609.jpg

4. Smog- Two trips. The only place local to me was a college about 30 miles away where they teach smog to up and coming smog cert pros. This one took me two trips as I forgot the receipt for my engine and I needed to close the crankcase system and add a PCV valve. My car runs pretty good with it so I may just leave it!. Another problem was where to locate it. Same as CHP. They guy puts it on my firewall!. I'm supposed to put some sort of plexiglass over it to protect it I guess. Overall, a very formal process.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0685.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0610.jpg

5. DMV- Second of two trips- again, no appointment so I got lunch while I was waiting so it went quick. NOTE: Keep your paperwork stapled together and don't let the other guys take it apart! DMV gathered my stuff and sent it to Sacramento. I got another TOP which has a "9" on it so I should have my stuff by Sept.

Erik

[ehansen007]

I can't believe how much sleep I lost and how much time I put in on this one. I'm a big fan of wheels and what they can or can't do for a car. I fell in love with the original drawing for the Hot Rod Mag car which had these racy looking mesh-type wheels so I was sold. But man it was hard to find anything affordable that looked like that that wasn't forged! Over the past 8 months I vacillated over this decision time and time again looking at offsets, wheel lips, tires, fender clearance, etc like so many of you have. Well, after placing an order for this brand new wheel I saw at SEMA, and waiting for three months, this is what I got.

XXR 526 Black with chrome lip
18x9 front +25 offsest 2.5" lip
18x10.5 rear +20 offset 4.25" lip
Nitto NT-05
265/35/18 Front
295/35/18 Rear

So far the tires are nice and sticky and I think I have just enough sidewall on the back for a decent ride. I originally had 1.5" spacers in there but took them off. I may still opt for some 7/16" front to help with steering a bit as I do get some rub on full lock. Maybe the back too if they rub.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0720.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0723.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0607.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0606.jpg

[ehansen007]

How is the windshield without the top frame when driving? Any issues with movement? It really looks a million times better!

Olli

It won't move as long as you do this. Totally secure and it's made all the difference in the world. Less turbulence coming off the windshield as well. If you're 6-0" or around there and using the stock seats, that upper frame is right, and I mean RIGHT in your line of sight. So much so, I was getting surprised by red lights from time to time. What's also crazy is the amount of distortion you get at the top of the windshield...everyone and everything looks "Funhouse" tall!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0208.jpg

[ehansen007]

Just updating my build here. Lately I've been putting on more miles and I'm well over 500 now. No major issues and the body's pretty much just sitting on there. I now plan on taking everything apart and doing the electrical and get started on the body work. I'd like to get both roll bars (hoops and square) fitted and functional before lifting the body off though. That will take a bit of welding. I put on the new brakes from Powerstop and they are one of the best upgrades per dollar that I've done. Here are some pics.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0768.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0771.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0774.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0783.jpg

[ehansen007]

Couple more pics of the car in the driveway.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0613.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0614.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0611.jpg

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0960.jpg
Started on the bodywork by scuffing everything with 80.


http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0959.jpg


http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0957.jpg
In order to get the holes right for the dual roll bars, I made some plumbs with coat hangers. Worked great. Cutting the holes is a challenge as they are not at all round and require constant adjustment and fitting the the roll bar.

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1126.jpg
Here's the entire car scuffed.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1127.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1128.jpg
Most of the parting lines from the mold disappeared.

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1129.jpg
My buddy Geoff came by and helped me float the door line up to the bulkhead/dash area as they are pretty far from from the factory. I know some guys are pulling the doors apart and refitting but I'm just not at that level yet!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1130.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1131.jpg

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0966.jpg
After reading the horror stories about folks not grinding out the parting lines and filling with Poly or HSRF, I decided to go ahead and do it myself. It wasn't bad except for on the the roof where it was pretty uneven.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0965.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0968.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0970.jpg


http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0969.jpg

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0984.jpg
Quite a bit of filler was needed on the bulkhead.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0986.jpg
The top wasn't too bad but I sanded right through the lower back edge like everyone else. I just cut that out the thin area and filled the crap out of it.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0987.jpg
A lot of people complain about the valley in the hood that takes about a half a gallon of filler. Problem solved!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0985.jpg
Just cut it out in favor of a hood scoop!

[ehansen007]

Now that the body's been blocked (not completely though) it's time to take it off and take her to the body shop!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1012.jpg
With the body off, it's time to tackle that nasty wiring.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1016.jpg
Although Russ Francis does a nice job of making it plug and play, it sure is a lot of extra wire

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1014.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1017.jpg
I'm going to make a label list for all wires to put above the wiring blocks.

[ehansen007]

At the body shop

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0363.jpg
Having a nice table for a buck sure helps.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0365.jpg
We blocked out everything as much as we could with Gel coat and rarely got down to fiberglass. All in all I used about 3/4 gallon G2 featherfill on the entire car.


http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0366.jpg
We used the PCL Hi build Poly primer and it worked pretty well.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1135.jpg
crappy iphone photo but this is the car being blocked after guide coat. Something I found out, if you want to avoid clogging, do yourself a big favor and use the 3M dry guide coat instead of the standard cheap spray can method. It lets you sand immediately and doesn't clog.

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0368.jpg
Spraying the polyprimer. I got to do some of it but felt it was best left to the experts.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0372.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0374.jpg
Like I said, we used very little filler on the side doors trunk or hood. it was mostly in the body.

http://i897.photobucket.com/albums/ac177/ehansen007/th_IMG_1129-2.jpg (http://s897.photobucket.com/albums/ac177/ehansen007/?action=view&current=IMG_1129-2.mp4)
Click to see video
My buddy like to use a pencil or a sharp tip to fill pin holes with polyprimer, not body filler. it's much easier to sand and keeps you from creating more pinholes when sanding filler on top of primer.

[ehansen007]

Onto the Bat Cave!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0395-1.jpg
here we are getting ready to shoot the sealer.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0400.jpg
Sealer is making it look good.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0401.jpg

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0396-1.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1146.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/th_MVI_0402.jpg (http://s897.photobucket.com/albums/ac177/ehansen007/?action=view&current=MVI_0402.mp4)
Jeff layin' down the paint. Click to see video. I still can't believe he doesn't use a respirator but it sure does explain a lot of those posts he puts up! :)

http://i897.photobucket.com/albums/ac177/ehansen007/th_MVI_0403.jpg (http://s897.photobucket.com/albums/ac177/ehansen007/?action=view&current=MVI_0403.mp4)
Click to see video

[ehansen007]

Let the final assembly begin!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1155.jpg
Body back on. I noticed with the carpet over the sills that it sets the body up about 1/8". Just enough to start throwing things off. Too late now though. Recommendation: just get some door sill covers and cut the carpet to the edge of the body.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1156.jpg
Trunk metal in. Not so bad.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1154.jpg
I decided to do the trunk and hood underneath with the SEM undercoat. Man, that stuff just flies out of the can at first but they tell you for a smoother coat to stay close. Lesson learned. Feather that stuff in from like 2 feet away!

[ehansen007]

I wasn't liking the center piece I had made for the dash so I made the decision to design a new console and try my hand at Engine Turning (Thanks to John Cameron for showing me how on Car Warriors)

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1174.jpg
First, get your sheetmetal all clean and mark your piece to be cut but don't cut it! Cut edges will ruin what ever your turning with. Leave the overlap for now so you're on flat metal all the time.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1175.jpg
Mark your grid for proper spacing and overlap. I decided to use a drill press with some Red scuff pad wrapped around a bolt with a zip tie. I thought I'd just test it and liked it so I kept going. But Craytex is much better. I checked my pattern on some scrap and adjusted the spacing accordingly. Mine is not even close to being perfect but it also looks hand done as well! Now get ready to be pretty bored and in the same position for the next few hours!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1176.jpg
Using some clamps and a ruler I created a gate so my lines were perfect each time. Man I have some ugly hands, no wonder I never got those call backs for those Palmolive commercials....

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1177.jpg
Turning Turning Turning. For about 4 hours! Kept having to change the scuff pad out since I started with a used one.

[ehansen007]

Here's the console in place. I used 1/8" MDF so it's light and easy.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1178.jpg
Test fit.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1196.jpg
Finished product covered in black vinyl. Man I need to stop using my iphone to take pics. It's just so damn convenient.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1594.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1645.jpg
Getting close!

[ehansen007]

Getting down the wire now. Like I was saying, I've been busting *** this holiday season so I could get a fresh start to the year but it's dragging out!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1644.jpg
I just got my "Novelty" license plate in so I'm not broadcasting in blue and white! So much better.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1595.jpg
I like big butts and I cannot lie.....

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1641.jpg
I'm picking up some plexiglass so I can run the windshield this low. I call it the chopper version.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1643.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1642.jpg
My hamster shooter poking out. I didn't want the hood hinges in there so I made my own front hood catch that holds under the grill and ordered some billet hood pins to hold down the back. Originally I ordered all black from EMS but they were out of stock and offered these "Highlight Series" which were $40 more at no extra cost.

I won't be running the hood all the time so I wanted to find a way to keep the the grill area clean along with the firewall and access panels, so this was it. A fully removable hood. More pics to come.

WHEW! That was a buttload of posts. Hope you guys enjoy em'!

e!

[ehansen007]

And now, for my moment of zen.....


http://www.youtube.com/embed/IoDX0mH65WQ

[ehansen007]

Thanks Brett!

Yes, I've got a tranny leak. Of course I learned that it has to come out the top if you want to leave the motor in. I learned this right AFTER I carpeted the interior! I tried to start pulling up the carpet but it just destroyed it, so I patched it back up and decided I'll fix the tranny leak when I pull the engine next. THERE IS NO way to get it out the bottom without pulling the motor (Unless you want to cut the frame of course) which blows.

As for the hood. Here are some pics of how I did it.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1646.jpg
I used some aluminum and formed a spring loaded system that will flex just enough to slide it in place.


http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1647.jpg
As you can see, I also use the factory D Gasket as well as some of the rubber grommets to maintain the hood height.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1650.jpg
Then I used the hood pins from EMS to mount the rear.

[ehansen007]

Windsheild cut down.


http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1649.jpg
As you can see I'm running it pretty low. I bought some 3/8" plexiglass and had the top line polished. Then I cut the frame and rounded the edges down. It took a lot of effort to get it in down there and Ive put some good miles on it so far and it hasn't moved but I'm still going to use some 3M windshield glue to keep it in there. So far it works better than I thought. The wind just hits the top of my head and I thought it would be much worse and hit me in the eyes but nope.

http://i897.photobucket.com/albums/ac177/ehansen007/photo.jpg

[ehansen007]

If you remember, I had cut the top windshield frame and left the top caps on to secure the windshield. This time I cut the entire male end off the frame and just rounded the edges. Much lower.

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0208.jpg

As for the tranny it's leaking from the front so it's probably the main seal. There is no way to get that thing out the bottom without moving the engine. For you builders out there make sure you make the tunnel removable!!!!!!!!!!! that is, if you're going to put in a tranny that leaks. :001_tongue:

[ehansen007]

I'm posting these up in a few different areas but really wanted them here to finish off my build thread. At least until I get my top on that is....:001_tongue:

http://i897.photobucket.com/albums/ac177/ehansen007/HR33RightQuarterFinal.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/HR33LeftQuarterBW.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/HR33FromAbove.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/HR33Seats1.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/HR33DoorOpen.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/HR33Sunset1.jpg

[ehansen007]

I recently put the top on and drove it around a bit. Then the temp went to 80 and it was beautiful so it came right back off. While it was on I noticed it's pretty noisy in there even with the hushmat on the inside headliner area. But I also have m exhaust out the side so that can't help. To mount it, I simplified the latch system by using the standard three bolts (planning on a quick release there too) in the front but only use two catch style latches in the back. They simply catch the body right inside my seatbelt holes so I haven't even put a single locator pin or hole in the deck area...totally clean..which is what I wanted because I don't want to run the upholstered collar they giv e you. As far as the secure-ness of it, i can't move it side or front to back. The front pretty much anchors it and the latches just hold the back down. And it takes about 15 minutes to switch between the windshield and hard top now.

Been enjoying it so much driving it up and down PCH here in Orange County it's just fantastic. I took my 7 year old daughter on Sunday and she thought it was the best. My biggest recommendation to those building out there: in roadster mode, consider chopping that windshield down a bit and/or getting the edge out of your site line; having a clear line of vision and the wind in your hair is heaven. :eclipsee_steering:

http://i897.photobucket.com/albums/ac177/ehansen007/33HotRodTopOn2.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/33HotRodTopOn1.jpg

[riptide motorsport]

great post......and great work!!!

[chris.ss]

Good job looks nice

[CBURKE]

WOW, I really hope when I get mine it turns out this good! I have a few years of waiting, but still can't wait!

[ehansen007]

I searched around and didn't see that anyone had setup the hydraulic struts for the trunk so here's my take. While the prop rod looks period, I felt that train had already sailed on my more modern interpretation anyway so why not give it a shot. Plus I had so much stuff in my trunk for the shows the prop rod was just a pain and I had the lid land on my head more than once.

I used the gas struts from the hood and then I made some standoff brackets out of some urethane I had lying around and man that stuff is dense! Worked great! I mounted to the inside sheet metal of the trunk which is a bit flexy since you don't attach that to anything and plan on reinforcing it with a bracket. But it works great without it and the trunk stays open by itself. It may not look the coolest but I really need function over form here.

I also made a little spring trunk popper thanks to some of the others here on the forum and their great pics. Now I can release the trunk with the cabin latch and then open it up and it stays up!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1528.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1527.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1532.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_1533.jpg

[Motor_Freak]

Thank you Erik for great build, inspires me more and more!

[ehansen007]

Thanks my friend! Glad to hear it's still giving some inspiration.

[Brave Salmon]

Been a while since I posted up some progress. Lately, I've been working on building my exhaust tips, a trailer hitch with a bumper, and acquiring all my stereo gear. I also got my new custom gauges from Speedhut.

Now I just need to get some wiring done and get her started! Getting close!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0171.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0169.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_0212.jpg

Eric, are u still selling the hitches? I would prefer to build my own but don't wanna pirate you're design. Are you willing to sell me the drawings and cut list for a reasonable fee? I really like your concept with the rear bumper for daily driving and the option of pulling a small trailer for my wife's purse! I can be reached at 916 812-5441 in Sacramento area.. thanks, tom

[ehansen007]

There is nothing better than going back and looking at all this years after the build and they are long gone. Looking at my own comments makes me laugh but this sure was fun. I don't own an FFR right now but looking at these sure makes me think of buying back in. Now if my daughter would only NOT be going to a 4 year school I could!

[wrp]

I always admired your work

[progmgr1]

I always admired your work

Ditto! You were one of the builders who inspired my plunge into the pool.
Keith HR #894

[ehansen007]

I appreciate that fellas. I was just looking at my other builds thinking this would be the one car, if I found it out there in the wild, I would consider buying back. Like an old girlfriend, nothing like your first. :)