Thanks to Josh-kabob and Bullet Bob for providing the electrical diagrams I needed to complete the wiring on Jose's car.  Hoping to hear it run real soon.

How it looks after Day 13

Looking Good

Typical Mustang Steve job!!!
Very clean and detailed......
6sally6

PS........why is Sherry getting agitated?!  She's gonna drive it?!!

Last edited by 6sally6 (9/26/2021 5:11 PM)

Day FIFTEEN
Monday of Week 3

What a hell of a day!!! Everything we touched went to -oh no I used a word I shouldn't have-!

I checked the coil voltage and only got 9.85 volts. Probably due to the way I bypassed the pink wire under the dash.  I had left about 1”’of pink wire at each end, splicing in a copper wire. So, I reworked that, completely removing the pink sections with new copper wire from the switch to the underhood harness.  Now it gets 11.9 volts while battery has 12.3.  close enough.

Put power steering fluid in. All went well with that.  Installed tranny coolant lines.  Had to make a new crowfoot tube nut tool to get to the lines on the side of the tranny

Then the real fun began.

Went to add coolant to the engine. Major waterfall coming from between the water pump and the timing cover. Appears one of the bolt heads holding the rear cover on the water pump is holding the water pump away from the timing cover. Never seen that one before.  Will delay the water pump removal to another day.  But it will be a long day. Coolant lines, hoses, shroud, radiator, AC and PS and ALTERNATOR brackets must be removed. Then remove water pump and figure out what is causing the problem. I do not like having to rework every single item on this build due to crappy parts.

Tomorrow is another day. Will install and weld up the exhaust system.  Water pump revisit on Wednesday, which is the dey this car was supposed to drive away under its own power.

Stay tuned…

Decided to go to the opposite end and replace the fuel sender. Installed new one.  Note new one has 3/8” tube instead of 5/16” as it should have. Not a deal breaker. The rubber seal felt like a thin rubber band and two attempts to install it resulted in distorted seal (yes, used grease to hold it in place-ain’t my first rodeo). Finally after two attempts and MASS VOLUMES OF SPILLED GASOLINE, I found an old one in my tool box and installed it. Jose had assured me all the gas had been removed from the tank.  NOT!!!
Will place gas in tank tomorrow. Did not want to leave it overnight unsupervised.  Hopefully leak is cured.

Attempted to install Scott Drake 💩 dual exhaust system.  Jury is out if this thing will ever get installed properly. Yes, I could put it in there and the exhaust would go through it, but I like things straight, level and in a workmanlike manner. We’ll see how it turns out. I already determined the 2” GT tips will require an extension to reach the tailpipes. Since we cut off the 1-7/8” diameter rear of the pipes, they are too short to reach the 2” ID tips. Will have to add a section of pipe to make it work.   Hopefully I can get everything to line up and fit correctly.  Nothing worse than seeing the mufflers from the rear of the car and one is at a different angle than the other. Details matter.

Then, the $32 brake light switch installed holds the brake lights on ALL THE TIME. More freaking rework… and not easy rework.

Basically were ten minutes away from firing the engine… then, the LAW kicked in.

So, today was a backwards moving day. Hopefully tomorrow will be better.

About those rear cover bolts on that water pump. They probably have taller heads on them and, no, shorter ones off of the old water pump probably won’t fit.  Different threads.  I’ve experienced this twice in the last few years while using Auto Zone pumps.  I took the first one back as PO’d as you should be and with the second one I was smart enough to check it before I left the store.  I told the manager “I don’t know who you are going to sell this to, cuz it’s not going to fit any small block Ford I know of.”

Last edited by Muzz 66 (9/28/2021 12:48 AM)

I'm sorta happy putting in studs for the front cover and WP.
I always hated trying to keep up with which long one went in which hole.
My only draw back is...I used all-thread for the studs
Shoulda looked for some grade 8 stud material I guess.
6sally6

Day SIXTEEN
TUESDAY of Week 3

Installed the exhaust system today.  Had to go to a muffler pipe and get the rear half of both tailpipes remade so they would work with the Scott drake 2” GT louvered exhaust tips. (Stock was 1-7/8”)
The entire system is level an straight within 1/8” and 100% welded with no clamps used.

We installed a brand new brake light switch designed for power brakes.  Of course, it makes the brake lights stay on 100% of the time.   MORE REWORK to file the booster for clearance or special order another switch.  Gotta love aftermarket parts.

Still waiting for that driveshaft that was supposed to be delivered Monday, according to FedEx.

Tomorrow I will rework that water pump, removing everything starting at the radiator. That is one downside of installing a tight-fitting fan shroud.  It requires that you disassemble everything to get to the pump.
A/C, P/S, Alternator, all those fancy billet brackets.

It would have been finished today if not for the water pump issue.

Praying for no more problems.

Day SEVENTEEN
Wednesday of week 3

Turned out the water pump leak was caused by incorrect gasket that was supplied with the pump. The port openings were larger on the gasket and overlapped mid air.  This was all my fault for not verifying fit more closely.  At least it was working on all clean, new parts.  It did not take too long since we were already pretty well practiced at removing the radiator and shroud.  That part is fixed.
I made a custom 5/16” steel tube for the radiator overflow.  You want pics?  Just come to the mini bash and see it in person.
Bring your camera.

We put gas in the tank and, of course, the new seal leaked worse than the other new seal.  I talked to the owner at Alamo Classic Ponies in San Antonio about a seal and sender. He said they always had problems with the replacement seals but NEVER has a problem with Ford Original type seals. He said Ford still stocks them and he has some in stock.   Jose will be at his place when they open in the morning to get three of the Ford seals, a new sending unit with 5/16” tube, unlike the existing new one with 3/8” hose, a new filler hose and body seal and maybe a new gas tank.  I hope he gets the new tank, but I am concerned about quality.

The brake light switch was repaired by grinding a small amount off the activation plate. Did not take much at all.  Just a big pain getting the switch out and back in place.

The car is ready to run once we get it to stop leaking gas tomorrow.

Forgot to mention.  Monday’s driveshaft delivery has still not occurred.

Last edited by MS (9/29/2021 9:34 PM)

Day EIGHTEEN
Thursday of Week 3

The new drive shaft finally showed up, three days late, from CJPony.  Installed the Maverick C4 yoke on it and installed it in the car with no issues.

We started the car today.  This is the smoothest, quietest engine ever. The Summit 500 cfm carb started as soon as gas got to it.  I adjusted idle speed and mixture. All appears to be fine. Checked the timing with a light and got it at 10 degrees BTDC, just as I had set it up when I stabbed the distributor.  The Scott Drake Hipo 2” exhaust system is really quiet. Stock Explorer roller cam runs smooth with zero valvetrain noise.
Slight tranny leak from the shifter selector shaft seal, but the tranny was installed “as purchased”.
Borgeson steering using saginaw pump make zero noise and works well.  Not road tested yet.

Battled leaking fuel pickup again.  Install it, watch it leak, drain tank.  Cuss alot. Repeat, repeat, repeat. The owner of Alamo Classic Ponies in San Antonio swore by Ford replacement seals, so we bought four.  NONE OF THEM would fit in the groove in the tank because the diameter of the seal was 1/8” to 1/4” too large.  And, if it won’t fit in the groove, there is no way it can seal. The guy suggested using Ultra Grey RTV on it, so he lost credibility with me really fast.
Finally found a used seal in my parts that fit in the groove and was able to get it to seal.
FIVE TRIES for somebody that knows how to do it to get it to seal. 

Anybody that wants to manufacture a correct size seal has a great opportunity to make some money. The ones that come with the reproduction senders do not fit right, either.

So, the car has been started, now awaiting the hood to be installed and a new, non-melted speedo cable and some gauges for oil and temp.  Tried to get gauges to work, installed new CVU, still not right. 
Ordered autometer oil and temp gauges. Gas gauge worked, but apparently no longer does. Maybe just need to add more gas since it only has under three gallons in it.

Took Friday off to celebrate Sherry’s birthday.

Hope to drive it Saturday

Outstanding.
3 days late from CJP is on time.

Wrong way to bypass pink wire.