Coyote Gas Pedal Solution! (Part 1)
Happy Easter! So, I have the Coyote gas pedal mounting challenge resolved. More about that in a minute.
I really liked what Shark92651 came up with to improve the mounting of the Coyote gas pedal pad to the arm: both in its location (more clearance away from FB inner wall), and the position of the pedal (right side up compared to F5 does it
upside down). Combining his mod with the new flat mounting bracket I made provided abundant clearance for the DBW connection at the top (see my second update). It was a very low dollar cost mod, but it did take me quite a bit of time (understatement).
Link to Shark92651's mod - Part 1:
https://thefactoryfiveforum.com/show...l=1#post330500
Part 2:
https://thefactoryfiveforum.com/show...l=1#post330764
Part 3:
https://thefactoryfiveforum.com/show...l=1#post331713
He did a great job designing the mod, and documenting, so no need for me to go into much detail. Here's how my copy of his approach turned out.
The first (and scariest) step is to cut up the Coyote gas pedal even more than the F5 instructions show--reminds me of cutting into the rear spindles. Scary indeed, but I found it to be very worthwhile, and I think the finished product is very solid.
https://thefactoryfiveforum.com/atta...6&d=1617498336
The next step is to make an insert that nestles into the back side of the pedal. It needs to be about 3/16" thick. I have some scrap left over from the 0.090 firewall, so I cut two pieces and used JB Weld to glue them together (.090 + .090 =.180 = 3/16"). Then, some time with the hand file, and it fits well.
https://thefactoryfiveforum.com/atta...2&d=1617498272
The center screw that comes with the pedal is reused. It just needed to be cut down the same amount I removed from the plastic nut that's molded on the center of the pedal pad.
https://thefactoryfiveforum.com/atta...5&d=1617498318
Following Shark92651's example I made two small brackets to secure the pedal to the aluminum insert.
https://thefactoryfiveforum.com/atta...8&d=1617498671
https://thefactoryfiveforum.com/atta...0&d=1617505385
Here's how it looks all mocked up together.
https://thefactoryfiveforum.com/atta...1&d=1617505402
Coyote Gas Pedal Solution! (Part 2)
Now that the pad for the gas pedal is mocked up I turned to the mounting bracket for the pedal assembly. As I mentioned, the bent bracket that came with my kit placed the pedal too high, provided virtually no clearance for the DBW plug, and the holes in the bracket didn't line up with the holes in the pedal assembly. After thinking on it a bit, and reaching out to the forum, I decided a flat bracket would be the solution.
I remembered reading Edwarb's solution for his 20th anniversary build, which gave me inspiration to try to do the same.
Link to Edwardb's bracket solution:
https://thefactoryfiveforum.com/show...l=1#post215569
I took lots of measurements and through trial and error made a template for a flat bracket. Still having plenty of scrap left over from the thick (.090) firewall I made, I again cut two pieces and glued them together with JB Weld. After giving them some hand file treatment, I drilled holes in the flat bracket, and through the welded mount on the chassis. Lots of measuring here to ensure all the holes would line up, and that the final pedal assembly position would be correct.
Mocking up the flat bracket:
https://thefactoryfiveforum.com/atta...2&d=1617505446
Then I gave all of the aluminum brackets (all five) powder coat treatment using my Eastwood powder coating gun and small toaster oven.
Benefits: lots of clearance for the DBW connection on top, and it butts against the 3/4" tube on the right hand side for additional support. However, like Shark92651 I wanted to make it as solid as possible so I added a small aluminum bracket to the right hand side. Note: this position is at least two if not almost three inches lower than where the F5 bent bracket puts the pedal.
https://thefactoryfiveforum.com/atta...3&d=1617505458
View of the flat bracket from the left hand side:
https://thefactoryfiveforum.com/atta...4&d=1617505480
The finished product:
https://thefactoryfiveforum.com/atta...5&d=1617505499
Breeze Forward Battery Box Installed
It's been very difficult to get any garage time over the last month. Lots of Spring outdoor To Dos taking precedence. So, it was nice to get a few hours this weekend.
I tackled the Breeze forward battery box. Like Mark's instructions note, the forward 2" tube cross members may not be parallel to the 4" chassis tube. This is true on my chassis. However, nothing that the supplied spacers (SS washers) won't fix. Instead of installing the spacers between the rear of the box and 4" chassis tube, I found by placing them between the 2" cross tube members and the front of the tray it fit more squarely. This small project should have been a no-brainer to install, right? Right! Except....
I have minimal (zero?) experience tapping threads. Because I placed the spacers on the front of the box, the supplied 3/16" rivets were no longer an option. So, I decided to tap 1/4"-20 threads. (I recently tapped a number of 10-32 threads in the aluminum brackets for my Coyote gas pedal, so I figured I had some experience). Well, I got the first 1/4"-20 hole tapped, but the T-handle turned pretty hard. On my second hole the tap broke off in the hole. I've never been accused of being a body builder, so my first thought was "I should have bought a better grade tap/die set". Which is probably correct--I have cobalt taps on their way from McMaster-Carr. Well, it turns out TAP Magic Cutting Fluid is pretty handy for tapping holes in steel. I know, I know...big Rookie mistake!
I decided to take the easier (and less frustrating!) route of abandoning that hole, and drilling a new one next to it. Yep, another opportunity to drill through stainless steel (Breeze kit is SS). Did I mention how much I dislike drilling stainless steel? In the picture below, the red down arrow points to the abandoned tap bit/hole. The right pointing arrow points to the 90 deg. grease fitting Breeze supplied. This will make it reachable without having to remove the battery. This Breeze kit is quality.
https://thefactoryfiveforum.com/atta...1&d=1619391853
I'm learning so much. Though frustrating at times, this is a blast!
Thread Sealant on Aeromotive Fittings?
Quick question for the forum: I'm installing my Aeromotive pressure regulator. I know 06AN fittings do not get thread sealant, but what about the 06AN to radius port adapter? In other words, the side that threads into the regulator, does it need thread sealant? If so, am I okay using Permatex thread sealant, or should I use the stretch tape that comes on a roll (same stuff I've used for plumbing connections in my house).
Please advise, and thanks in advance!
Another 06AN Installation Question
Another question for the forum: I can't seem to keep the stainless hose from turning with the coupling nut as I tighten it to the fitting body. I followed Mark's (Breeze) installation instructions, and it clearly states to tighten the coupling nut to the fitting body, i.e. fitting body remains stationary during the tightening process. I have used my bench vise to hold the fitting body, as well as an adjustable wrench. Either way, the hose twists with the coupling nut. It does, however, tighten just fine, and I'm left with a small gap (<1/16") when complete.
I've watched several 06AN installation videos on stainless hose and it doesn't seem like the hose twists with the coupling nut. Is this normal? Am I doing something wrong?
Question answered: Later this evening....I believe I answered my own question. I watched (and re-watched) a couple videos (one by Aeromotive) for installing 06AN on PFTE with stainless braided jacket. These videos do not demonstrate what I stated above: the tube nut side is put into the vice, and the fitting body is threaded into the tube nut, not the other way around. This makes sense to me. I'm going to proceed with this procedure. Not sure what Mark is describing in his instructions (weird, because his products and directions have been otherwise solid). Also, I need to reopen the connections I completed to verify the PFTE is seated all the way in to the lip on the ferule.
Moving on, but always welcome advice and comments from the forum.
Fuel Lines Complete (continued)
Attached to the diagonal cross support above the rear UCA, and headed toward the tank and filter. The Ham-let Let-lok adapter on the front of the fuel filter is partially visible.
https://thefactoryfiveforum.com/atta...0&d=1620356241
And, connections to the fuel filter and return on the tank. I followed Mark's recommendation to go with the longer rubber hose in the unlikely scenario I need to drop the tank. This should make that task easier.
https://thefactoryfiveforum.com/atta...1&d=1620356274
Close-up view of the return connection/adapter, and the pinched off 1/4" return line--using the recommended 3/8" return line instead.
https://thefactoryfiveforum.com/atta...2&d=1620356289
Here's a close-up of the protective tube I slid on over the stainless braided line where it makes contact with the cross support tube under the PS floor.
https://thefactoryfiveforum.com/atta...3&d=1620356329
It was good to complete this portion of the build. If I ever have the opportunity to try it again, I would like to try hard lines (Ni-Copp).
P.S. I forgot to mention I opened up the 3/8" ends on the fuel filter (both sides) and the 3/8" supply on the fuel pump. The manufacturers taper these ends, and by opening them up with a 19/64" drill bit I increased the openings 10% - 20%. Pretty substantial.
Wheels/Tires Arrived! (And a Question)
Today was a fun day, as my long-awaited wheels and tires arrived. I ordered them Feb. 20, and after too many weeks of no improvement on the delivery date, I found very similar wheels at a different online vendor for about the same price. Ordered them last week. One of the front and one of the rear arrived this afternoon. The other two should arrive by day's end per FedEx.
As I mentioned, I wanted something other than the Halibrand replica look. According to the vendor's website (LMR) this style wheel was available on the 2003-2004 Mustang: they are Cobra style wheels. Has a good ring to it.
I didn't waste any time getting them on to check fit, and see how they look. I'm prepared to make an adjustment to the power steering rack if necessary (add rack spacers) if contact with the F-panel is an issue. I don't have my rough alignment done yet, so can't really tell yet if this will be an issue. I suspect it will based upon other forum members' experience with this size wheel/tire combo in the front.
Rear: 315/35/R17 | 17X9 wheel
Front: 275/40/R17 | 17X10.5 wheel
Rear wheel
https://thefactoryfiveforum.com/atta...4&d=1621381872
Rear wheel has a decent lip. The fronts are flush. Here's the rear:
https://thefactoryfiveforum.com/atta...5&d=1621381883
I think I have a roller.
https://thefactoryfiveforum.com/atta...6&d=1621381895
Noobie question for the forum: is it the wheel that secures the brake disc to the hub? While awaiting for the wheels to arrive I've had them secured with a nut. The calipers hold them loosely in place, but it seems kind of odd to me there isn't something else that secures the disc to the hub besides the lug nuts? Am I missing something?
H2O Temp Guage Converted to Fahrenheit
Today, I received my water temp. gauge back from Speedhut. I ordered the vintage guage set with my complete kit from F5. I'm sure most of you know these are Speedhut gauges. The water temp guage comes from F5 in degrees Celsius.
I recently saw Fman get his converted to Fahrenheit. I prefer deg. in Fahrenheit as well, so followed suit. As Fman stated, it's $14 for the conversion; about twice that for shipping round trip. Anyway, one more thing to check off my list. Speedhut took about one week to turn it around. I thought it was pretty fast.
The white specs are dust/debris from packaging, and my picture turned out a bit fuzzy, but you get the idea.
https://thefactoryfiveforum.com/atta...0&d=1621910407
Brake lines installed (part 2)
Then came off the T fitting, across the front of the X-tubes and over to the PS front.
https://thefactoryfiveforum.com/atta...0&d=1622172508
https://thefactoryfiveforum.com/atta...1&d=1622172526
For the rear brake line run I followed Edwardb and Shark92651 and ran it down inside the footbox, along the 3/4" tube.
https://thefactoryfiveforum.com/atta...5&d=1622172355
In my goodie bag I happened to have a couple rubber boots of sorts, and a cylinder shaped rubber piece to slide on to the line, and push it up into the boot. This centered the line in the boot, and protected it as it went through a hole I drilled in the accelerator bracket, as well as protecting/sealing the line where it exits the footbox floor. Here's what they look like:
https://thefactoryfiveforum.com/atta...0&d=1622172060
https://thefactoryfiveforum.com/atta...4&d=1622172334
Out of the footbox.
https://thefactoryfiveforum.com/atta...2&d=1622172538
Down the 4" chassis tube to the rear. I ended up with one coupling nut. You can see it here. For the rest of the lines I was able to avoid couplers and go direct.
https://thefactoryfiveforum.com/atta...3&d=1622172550
Brake lines installed (part 3)
Then up the 2" tube.
https://thefactoryfiveforum.com/atta...1&d=1622172156
Over to the T at the DS rear.
https://thefactoryfiveforum.com/atta...2&d=1622172285
Then out of the T and across to the PS rear.
https://thefactoryfiveforum.com/atta...3&d=1622172300
Really glad to have this part of the build behind me. I hope the bleed process goes okay. That will be another first for me.
Figured it's a good time to rivet and silicone the inner wall of the DS footbox, so took care of that as well. The reservoir on the firewall is for the clutch. I also installed the Wilwood 0.81" MC that came with the hydraulic clutch kit from Forte.
https://thefactoryfiveforum.com/atta...4&d=1622172564
Still having a lot of fun, and always welcome feedback from the forum.