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Joined: Sep 2004
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Campfire 'Bwana
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Campfire 'Bwana
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Hi Guys, i haven't posted a build thread for a long time, figured I'd see how it goes. Here's a project we are currently working on.

Customer brought us a pile of components that he had been collecting for a couple of years, needed someone to turn it all into a car. It went a little like this:

[Linked Image]

Frame, which we had to alter quite a lot. The wheelbase was wrong, the 4 bar brackets were out of square by a couple of inches, the mustang II IFS geometry was way wrong... I wish we had started with just the original 1935 frame.

[Linked Image]

Loaded 9" rear end, which we later found to have no outer bearing races at the axle tube ends...

Gen 3 6.4 hemi, brand new factory SRT engine.

[Linked Image]

545 rfe trans

[Linked Image]

big pile of random parts in the front of this trailer.

[Linked Image]

the body was delivered on another trailer.

[Linked Image]


Something clever here.

GB1

Joined: Sep 2004
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Campfire 'Bwana
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Campfire 'Bwana
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Joined: Sep 2004
Posts: 35,293
[Linked Image]

We put the chassis together for the first time to see what we had to work with.

[Linked Image]

This was out first clue that the chassis builder was a crack smoker.

[Linked Image]


Something clever here.

Joined: Sep 2004
Posts: 35,293
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Campfire 'Bwana
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Campfire 'Bwana
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Joined: Sep 2004
Posts: 35,293
lifting the body off the trailer.

[Linked Image]

[Linked Image]

First time joining the body to this frame. This lead to a lot of floor replacement and frame mods for wheelbase corrections and body to frame interface.

[Linked Image]

at this point we are fairly nervous about fitting a 6.4 hemi into a 35 plymouth, no idea where to start, a big shoehorn would have been good.

[Linked Image]


Something clever here.

Joined: Sep 2004
Posts: 35,293
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Campfire 'Bwana
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Campfire 'Bwana
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Joined: Sep 2004
Posts: 35,293
Cutting floors for frame relief, it didn't take long for us to figure out we needed to just build a new trunk floor.

[Linked Image]

we cut and relocated a 4 bar bracket on the frame, along with panhard bar bracket and coil over crossmember.

[Linked Image]

with the wheelbase corrected we continued work on ride height as far as body to frame fitment.

[Linked Image]

cozy mouse home

[Linked Image]


Something clever here.

Joined: Sep 2004
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Campfire 'Bwana
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Campfire 'Bwana
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Joined: Sep 2004
Posts: 35,293
Frame mods for body support.

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]


Something clever here.

IC B2

Joined: Sep 2004
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Campfire 'Bwana
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Campfire 'Bwana
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Joined: Sep 2004
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Had to cut the trunk floor completely out. We found that a 49-51 ford car gas tank would fit between these frame rails, we built a new floor to ride high enough to allow for the tank and also to carry the tank.

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

Building the tank straps and hanging system.

[Linked Image]


Something clever here.

Joined: Sep 2004
Posts: 35,293
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Campfire 'Bwana
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Campfire 'Bwana
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Joined: Sep 2004
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[Linked Image]

[Linked Image]


Something clever here.

Joined: Sep 2004
Posts: 35,293
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Campfire 'Bwana
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Campfire 'Bwana
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Joined: Sep 2004
Posts: 35,293
[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

Building the new driveline tunnel and forward floors.

[Linked Image]

[Linked Image]


Something clever here.

Joined: Sep 2004
Posts: 35,293
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Campfire 'Bwana
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Campfire 'Bwana
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now, in this photo, notice how the upper A arms on the IFS are angled downwards. That's all F'd up. Mustang II lowers should ride close to level and the uppers should reach slightly upwards towards the balljoints. This helps so that the outside wheel pulls inward slightly when loaded on a turn, it's supposed to pitch the tire face to help with any body roll and outward load on turns. This is another example of this chassis being all dicked up. We had to research the correct geometry for this suspension system and correct this by cutting the coil spring hats and lowering them about an inch and a half. e also made mods to the crossmember for engine room, we notched the frame for engine accessory clearance and we did a tricky steering shaft route through an engine mount. We had to relocate the power rack to do this, we went forward with the rack and clocked it so the input shaft laid back.



[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

Test fitting before burning the welds full. notice the boxed clearances at the rack input shaft, near the AC pump on inner frame rail and the alternator area, frame was box clearanced and access sleeves added to be able to change alternator without pulling the engine.


[Linked Image]

[Linked Image]


Something clever here.

Joined: Sep 2004
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Campfire 'Bwana
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Campfire 'Bwana
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Joined: Sep 2004
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[Linked Image]

[Linked Image]

upper A arms now reaching upwards like they are supposed to.

[Linked Image]


Something clever here.

IC B3

Joined: Sep 2004
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Campfire 'Bwana
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Campfire 'Bwana
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Joined: Sep 2004
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[Linked Image]

[Linked Image]

[Linked Image]

Starting some steering column/input work here.

[Linked Image]


Something clever here.

Joined: Sep 2004
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Campfire 'Bwana
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Campfire 'Bwana
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Joined: Sep 2004
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we routed the shaft between the exhaust manifold and the engine block, had to run it through the engine mount.

[Linked Image]

[Linked Image]

[Linked Image]


Something clever here.

Joined: Mar 2007
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Campfire Tracker
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Joined: Mar 2007
Posts: 5,082
I envy your talent.


Stupidity is expensive
If you find yourself in a fair fight, your tactics suck!
Joined: Feb 2003
Posts: 15,551
Campfire Ranger
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Campfire Ranger
Joined: Feb 2003
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Absolutely amazing Dave. I can’t begin to imagine what goes into fabricating/building that ride up. I can’t wait to see the final product.


"I Birn Quhil I Se" MacLeod of Lewis
I Burn While I See
Hold Fast MacLeod of Harris
Joined: Sep 2004
Posts: 35,293
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Campfire 'Bwana
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Campfire 'Bwana
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Joined: Sep 2004
Posts: 35,293
The 1935 body originally had external door hinges, our customer wanted them removed and replaced with internal hidden hinges. This is fairly common with street rods but it's an extra challenge with a 4 door with rear suicide doors like this car has.

[Linked Image]

It might not look it, but that was a bunch of work per door.

[Linked Image]

This was also the day that we pulled the rear axles out of frustration due to the car being difficult to roll around in the shop. The axle builder pressed bearings on the axle shafts but they never put the outer races in the axle tube ends. So, we once again stop our progress to correct something another shop F'd up.

[Linked Image]

[Linked Image]


Something clever here.

Joined: Sep 2004
Posts: 35,293
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Campfire 'Bwana
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Campfire 'Bwana
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Joined: Sep 2004
Posts: 35,293
with new bearings pressed on, we get back on track with the door mods.

[Linked Image]

[Linked Image]

[Linked Image]

The guys that sold us the hinge plate kits said it couldn't be done (to the rear doors). We said "just send us another kit for the front doors and we'll cut em up and make em work" (we had to cut up the first kit they sent anyways so this wasn't a huge step)

[Linked Image]

[Linked Image]


Something clever here.

Joined: Sep 2004
Posts: 35,293
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Campfire 'Bwana
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Campfire 'Bwana
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Joined: Sep 2004
Posts: 35,293
We ordered a bare set of bucket seats from procar and we built our own riser boxes that located the seats at the correct ride height.

[Linked Image]

I'm jumping all over the place here but in this picture we have our custom 3" mandrel bent exhaust all cut and fit the way we want it. We made this in house with various sections of straight and mandrel bent tube sections cut to fit and clocked correctly for the routing we wanted.

[Linked Image]

That exhaust is bad ass. Stainless Borla mufflers, our hanger system is clean, looks nice and these pipes are rock solid.

[Linked Image]

Fitting shifter, under dash AC, locating our AGM optima battery, engine module and related electrical under passenger seat.

[Linked Image]

We string some wires, plum some fluids and she's a runner soon.

[Linked Image]


Something clever here.

Joined: Sep 2011
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Campfire Kahuna
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Good to see you posting pictures Sir David. Two thoughts, WOW!!, and $$$$$$$$$$$$$$$$$$$$$$$$$$


These premises insured by a Sheltie in Training ,--- and Cooey.o
"May the Good Lord take a likin' to you"
Joined: Sep 2006
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Campfire Tracker
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Joined: Sep 2006
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Very cool! I feel lazy.


I like to do my hunting BEFORE I pull the trigger!
There is only one kind of dead, but there are many different kinds of wounded.
Joined: Jan 2005
Posts: 38,867
Campfire 'Bwana
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Campfire 'Bwana
Joined: Jan 2005
Posts: 38,867

Absolutely amazing!

Too bad that this can't be made into something that could be easily shown to all of those who say, "Nothing can be done about, best to just junk it and buy a new vehicle," when asked about some (compared to this) minor problem.


Not a real member - just an ordinary guy who appreciates being able to hang around and say something once in awhile.

Happily Trapped In the Past (Thanks, Joe)

Not only a less than minimally educated person, but stupid and out of touch as well.
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