My 67 Cougar Build

[1bad68cat]

I started this build a couple years ago. It is a slow build. And I mean really slow. I have posted some pics of the things I did in other threads but figure I'll include them here.

I started with this:

https://static1.pt-content.com/images/pt/2015/05/nbNCjBo-1.jpg

https://static1.pt-content.com/images/pt/2015/05/xEL0v2j-1.jpg

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[1bad68cat]

As I mentioned before I did some small things here and there. Here are a few pics of the front brakes I will be installing.

https://static1.pt-content.com/images/pt/2015/05/ED8xODt-1.jpg

https://static1.pt-content.com/images/pt/2015/05/VEcDMio-1.jpg

https://static1.pt-content.com/images/pt/2015/05/CClOYH1-1.jpg

[1bad68cat]

I did some prelimnary mock up with the coyote engine.

https://static1.pt-content.com/images/pt/2015/05/OnorvDb-1.jpg

https://static1.pt-content.com/images/pt/2015/05/T29xu1B-1.jpg

Along the way I built an engine lift fixture because I didn't feel comfortable with the lift brackets supplied with the coyote engine. I can see them bend as I lifted the engine. Getting the CG right also proved to be cumbersome with the supplied lift brackets.

https://static1.pt-content.com/images/pt/2015/05/cOuV4CN-1.jpg

https://static1.pt-content.com/images/pt/2015/05/NIiTvS5-1.jpg

https://static1.pt-content.com/images/pt/2015/05/0QyAyzo-1.jpg

[1bad68cat]

To date, I have mostly installed the front suspension. Still need to weld upper control arm mount gussets, top coil over mount, and the down tubes. I'll tie the gussets, coil over mounts, and down tubes together.

https://static1.pt-content.com/images/pt/2015/05/bGDSXht-1.jpg

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[Chev Korbin]

Nice to see another Cougar, hehe. They are popping up a lot lately. Looks like a good start to an awesome build.

[1bad68cat]

Small update. Fabbed and tacked the motor mounts in. Hope to finalize engine placement then install engine and transmission to fab up a transmission cross member.

https://static1.pt-content.com/images/pt/2015/07/SW6MXfu-1.jpg

[DrFraZZy]

Subscibing! I definitely want to drop a COYOTE on a cougar xr7 someday soon!

[1bad68cat]

Another update. Mocked up my hydroboost to see if I can get it to clear the coyote engine. Results look promising. Used a reproduction Boss 429 Mustang brake booster wedge to tilt the hydroboost up. Still need to figure out what to do about the billet hood hinge interference and determine what the brake pedal ratio needs to be. If anyone has a later model mustang with hydroboost perferably the SN-95 (96-2004, prefer 2003-2004) variety would you mind telling me what the pedal ratio is.

https://static1.pt-content.com/images/pt/2015/07/TR9Z03r-1.jpg

https://static1.pt-content.com/images/pt/2015/07/4VUZwRM-1.jpg

[DrFraZZy]

This is definitely has my name written all over it... i am like searching for a clean cougar on the cl!

[1bad68cat]

More updates.

https://static1.pt-content.com/images/pt/2015/09/fPdiqAR-1.jpg

https://static1.pt-content.com/images/pt/2015/09/jYwmTZY-1.jpg

Brake pedal mod for adapting an 03 cobra hydroboost to the cougar pedal support. I replicated the pedal ratio from the cobra.

https://static1.pt-content.com/images/pt/2015/09/fPaM5Iz-1.jpg

Pedal support setup with hydroboost, S197 mustang hydraulic master, and roller bearing converison

[1bad68cat]

Updates continued...

https://static1.pt-content.com/images/pt/2015/09/I4aVXFD-1.jpg

Used parts from the S197 mustang and adapted them to the cougar clutch pedal.

https://static1.pt-content.com/images/pt/2015/09/9Bx9t75-1.jpg

Hydroboost mounted using a reproduction Boss '9 mustang brake booster wedge to clear the coyote engine.

[1bad68cat]

A few updates. Was able to roll the car out of the garage this weekend on it's own suspension. Finished welding in the upper control arm gussets, upper shock mounts, and frame boxing plates. Still need to weld in the down tubes and shock tower delete plates, but I will first fab up the transmission cross member so I can return the coyote motor to my buddy.

https://static1.pt-content.com/images/pt/2016/02/TkZwpeT-1.jpg

https://static1.pt-content.com/images/pt/2016/02/jlCbqTv-1.jpg

Hope the car is not sitting too low once the real wheels and tires are on.

https://static1.pt-content.com/images/pt/2016/02/lgQvbpb-1.jpg

https://static1.pt-content.com/images/pt/2016/02/7kPq9Sb-1.jpg

[DrFraZZy]

Its coming along nicely!

[1bad68cat]

Its coming along nicely!

Thanks DrFraZZy. I just wish it was coming along faster.

[Adam Smith]

Looking Good! Maybe it's just the pics, but it looks like you have the motor sitting lower than most coyote swaps I've seen. Does the oil pan hang below the frame very much?

[69CougarXR7]

123725

Your doing better than me.... My 69 has not been touched in over a year now..

Brian

[chunger]

Neat build.

I like your idea of using a S197 master cylinder for the clutch. It looks like you modified the pedal by adding a bit to one side so you could attached the end of the push shaft to it. But it also appears that the other end of the master will protrud past the firewall. Is that right? Are you planning on adding a panel or kickout of some kind to cover it up?

Also, assume this master cylinder would only work with a stock type hydraulic throw out bearing?

Nice work!

[1bad68cat]

Looking Good! Maybe it's just the pics, but it looks like you have the motor sitting lower than most coyote swaps I've seen. Does the oil pan hang below the frame very much?

Thanks Adam. The canton oil pan is just above the bottom of the cross member. As for the engine height, I believe it may be one of the lower ones based on photos I could find.


123725

Your doing better than me.... My 69 has not been touched in over a year now..

Brian

Brian, don't feel too bad, my projects have gone on for far too long. Lol.


Neat build.

I like your idea of using a S197 master cylinder for the clutch. It looks like you modified the pedal by adding a bit to one side so you could attached the end of the push shaft to it. But it also appears that the other end of the master will protrud past the firewall. Is that right? Are you planning on adding a panel or kickout of some kind to cover it up?

Also, assume this master cylinder would only work with a stock type hydraulic throw out bearing?

Nice work!

Thanks Chunger. I only non-stock part is the angle iron I welded to the clutch pedal support to bolt the master to. Everything else is stock 67 or S197 parts just repositioned. The part where the master attached to the pin is part of the original pedal, just cut and clocked differently. The pin came from the S197 clutch pedal. The master protrudes past the firewall where the original clutch rod would pass through. Not sure how I got so lucky. I was expecting to have to make a new hole in the firewall . As for the seal, I'm using the one that came off of the S197 pedal support.

My intention was to use this with a stock type hydraulic throw out bearing so that when I have a failure, I could go to the parts store or dealer and get a new part. As for it working with other clutch hydraulic systems, I'm not sure what it may or may not work with. My other cougar has a CNC hydraulic clutch and the bore sizes appear to measure the same so I would assume it would work with that setup.

[fordsbyjay]

https://static1.pt-content.com/images/pt/2016/02/20150517_094854-1.jpg (http://s1096.photobucket.com/user/ricasas/media/67%20Cougar/20150517_094854.jpg.html)



Are those 14" or 15"?

Makes my 13's look woosie.
https://static1.pt-content.com/images/pt/2010/01/IMGP4170-1.jpg (http://s36.photobucket.com/user/fordsbyjay/media/64%20Falcon/IMGP4170.jpg.html)

[1bad68cat]

Are those 14" or 15"?

Makes my 13's look woosie.
https://static1.pt-content.com/images/pt/2010/01/IMGP4170-1.jpg (http://s36.photobucket.com/user/fordsbyjay/media/64%20Falcon/IMGP4170.jpg.html)

Lol Jason. They are 15".

[1bad68cat]

Fabbed and installed my transmission cross member

https://static1.pt-content.com/images/pt/2016/02/U8wQFuC-1.jpg

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[1bad68cat]

Christmas came early.

https://static1.pt-content.com/images/pt/2016/03/jNMxClx-1.jpg

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[Pt109]

Hey Brian, I had a 69 Eliminator. Still one of my favorites. Hang in there, u will get to it.

[Adam Smith]

I must say, I'm a bit jealous haha. I'm hoping to get the Coyote for my Cougar soon. I just haven't decided if it will arrive on a pallet or with a totalled Mustang wrapped around it. Where did you purchase yours?

[1bad68cat]

I must say, I'm a bit jealous haha. I'm hoping to get the Coyote for my Cougar soon. I just haven't decided if it will arrive on a pallet or with a totalled Mustang wrapped around it. Where did you purchase yours?

Adam, I got mine through Jegs because they were having a sale. I believe the sale is still going. The kit comes with the crate motor and controls pack for $7K with free shipping.

https://www.jegs.com/webapp/wcs/stores/servlet/KeywordSearchCmd?catalogId=10002&langId=-1&storeId=10001&krypto=9V907oZEpbyHmnZLQhkFDv0uxZJw%2FdyQWM1pVtvP% 2BgpqIqk7%2BnLC%2FvZEuGI0jepGd5vsQzVqktK7%0AaFUfmk j0YQu%2BFeEMqGe6YfCOI8Zjo%2FMrX4BvFVzCqwA%2B614LyV PAQpWzprIU%2FPs%3D&ddkey=http:KeywordSearchCmd

[Josh@Ridetech]

Christmas came early.

https://static1.pt-content.com/images/pt/2016/03/20160330_163809-1.jpg (http://s1096.photobucket.com/user/ricasas/media/67%20Cougar/20160330_163809.jpg.html)

https://static1.pt-content.com/images/pt/2016/03/20160330_170015-1.jpg (http://s1096.photobucket.com/user/ricasas/media/67%20Cougar/20160330_170015.jpg.html)

https://static1.pt-content.com/images/pt/2016/03/20160330_170025-1.jpg (http://s1096.photobucket.com/user/ricasas/media/67%20Cougar/20160330_170025.jpg.html)

I wish that I would've went this route more than anything with my car...

Great build you've got going!

[Adam Smith]

Adam, I got mine through Jegs because they were having a sale. I believe the sale is still going. The kit comes with the crate motor and controls pack for $7K with free shipping.

https://www.jegs.com/webapp/wcs/stores/servlet/KeywordSearchCmd?catalogId=10002&langId=-1&storeId=10001&krypto=9V907oZEpbyHmnZLQhkFDv0uxZJw%2FdyQWM1pVtvP% 2BgpqIqk7%2BnLC%2FvZEuGI0jepGd5vsQzVqktK7%0AaFUfmk j0YQu%2BFeEMqGe6YfCOI8Zjo%2FMrX4BvFVzCqwA%2B614LyV PAQpWzprIU%2FPs%3D&ddkey=http:KeywordSearchCmd

I hadn't seen that kit yet, that's cool! I've been watching salvage auctions for wrecked Mustangs but it's outrageous how much they are going for! ... Brand new motor with a warranty would be awesome!

[69CougarXR7]

Hey Brian, I had a 69 Eliminator. Still one of my favorites. Hang in there, u will get to it.

Biggest problem is $$$... Being the sole provider for a family of 5 really hits the play budget...

I am helping a friend with his project though... Spending his dough is a lot more fun.. LOL..

Brian

[1bad68cat]

Just a small update from the weekend. Decided to cut the firewall out to make clearance for the Charge Motion Control Valves (CMCV) on the back of the intake. I didn't want to move the engine forward for the clearance because it would have created an issue with the steering linkage and oil pan. I figured modifying the firewall would be easier. I just wanted the firewall to remain looking "stockish" after the mod. I think I accomplished it. Still need to complete the metal finishing though.

https://static1.pt-content.com/images/pt/2016/05/23BsRej-1.jpg

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[1bad68cat]

Dressed the welds and retest fit the engine over the weekend.

https://static1.pt-content.com/images/pt/2016/06/CWsqIgD-1.jpg

https://static1.pt-content.com/images/pt/2016/06/w39YmXe-1.jpg

Barely enough clearance. I may massage the area a little more just in case.

https://static1.pt-content.com/images/pt/2016/06/07HPgFy-1.jpg

[1bad68cat]

A few updates. Fabricated the mount for the coyote control pack power distribution block and closeout panels for the shock towers delete. Also picked up a steering wheel along the way.

https://static1.pt-content.com/images/pt/2016/09/ZgywbiB-1.jpg

https://static1.pt-content.com/images/pt/2016/09/BmrqeEF-1.jpg

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[1bad68cat]

New valve covers for the coyote conversion. Machining begins today. Excited what it will look like in person.

https://static1.pt-content.com/images/pt/2016/10/MG57wWG-1.jpg

[Centerforce]

Great progress! Fitting a coyote into most cars is no small task (literally) because of its size, but that just means you have to get creative with things!

[1bad68cat]

Great progress! Fitting a coyote into most cars is no small task (literally) because of its size, but that just means you have to get creative with things!

Thanks. No kidding. :scared: I always seem to want to learn to do things the hard way. Lol. Because of the front suspension I chose, the alternator doesn't fit in the stock location. I may be forced to reverse mount it. Another is the power steering. I'm hoping the MR2 Spyder power steering pump has sufficient flow and volume to handle the hydroboost and power steering.

[Centerforce]

Thanks. No kidding. :scared: I always seem to want to learn to do things the hard way. Lol. Because of the front suspension I chose, the alternator doesn't fit in the stock location. I may be forced to reverse mount it. Another is the power steering. I'm hoping the MR2 Spyder power steering pump has sufficient flow and volume to handle the hydroboost and power steering.

Those are powerful little pumps! We can't speak to the hydroboost part, but we've seen them used on some pretty beefy tire setups with no issues.

[1bad68cat]

Those are powerful little pumps! We can't speak to the hydroboost part, but we've seen them used on some pretty beefy tire setups with no issues.

That is good to hear. I've been trying to find feedback but usually what I find is that people do the swap because they are switching from gas to electric drive vehicles.

[1bad68cat]

A small update. Machining on custom covers is almost complete.

https://static1.pt-content.com/images/pt/2016/10/iduHqqb-1.jpg

https://static1.pt-content.com/images/pt/2016/10/ui2CnUv-1.jpg

[andrewb70]

Those look great. I would have them media blasted and then hard anodized.

Andrew

[preston]

you could also use a Saturn Vue electric steering motor. Some of the kits online are almost $1500, but I bought the motor and column off ebay for $300 including a little pot for the assist level. I fabricated the attachement to my Ididit column pretty easily. Works real well so far. You'll have to do your own reseach. Try searching for EPAS on corner-carvers.com and that should lead you to the epic vintage mustang thread on the subject. Although if you, like me, are using hydraboost, you are still stuck with needing a pump so moot point I guess.

[1bad68cat]

Those look great. I would have them media blasted and then hard anodized.

Andrew

Thanks Andrew. I was actually thinking about doing that Andrew. I just hadn't decided if I was going to polish the tops. Didn't know how to deal with the cat logo since it has some details machined in. I think I'll figure it out when I get the covers in my hands.

[1bad68cat]

you could also use a Saturn Vue electric steering motor. Some of the kits online are almost $1500, but I bought the motor and column off ebay for $300 including a little pot for the assist level. I fabricated the attachement to my Ididit column pretty easily. Works real well so far. You'll have to do your own reseach. Try searching for EPAS on corner-carvers.com and that should lead you to the epic vintage mustang thread on the subject. Although if you, like me, are using hydraboost, you are still stuck with needing a pump so moot point I guess.

I read that thread of the swap on the vintage mustang forum. It is a great thread. I believe someone also found a way without having to use the Bruno box by using a Prius system. If I didn't already have a power steering rack and also the hydroboost like you mentioned, it would be something I would definitely look into.

[Centerforce]

That is good to hear. I've been trying to find feedback but usually what I find is that people do the swap because they are switching from gas to electric drive vehicles.

They seem to be a popular swap lately for drift, autox, etc. and they all report the steering being super light. If we remember correctly, you can also attach a speed signal input to turn the pump off at higher speeds, which is a nifty little feature.

[1bad68cat]

They seem to be a popular swap lately for drift, autox, etc. and they all report the steering being super light. If we remember correctly, you can also attach a speed signal input to turn the pump off at higher speeds, which is a nifty little feature.

I did read about using the speed signal input. Just haven't found what type of signal it's looking for like pulses, square/sine wave, etc. I figured when I get ready to install the pump I'll look research more.

[1bad68cat]

Some minor updates to my build. I received the custom covers for my coyote conversion. Still need to decide how I want them finished.

https://static1.pt-content.com/images/pt/2016/11/3RySqLE-1.jpg

https://static1.pt-content.com/images/pt/2016/11/Jlayq4F-1.jpg

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[1bad68cat]

I've been lacking on updates because I haven't had much time to work on the car, but the shell is at the body shop now to prep the car for my upcoming engagement photos. Of course it took a major life event to light a fire, but it's getting there.

https://static1.pt-content.com/images/pt/2017/08/4mkVdxf-1.jpg

Car at media blast. It showed good and bad. I was surprised to find out that the car was originally a vinyl top car. The good, the roof wasn't rotted out like other vinyl top cars. The bad, the quarter panel was replaced sometime in it's life, but the repair work is subpar. The body shop will work with it since quarter panels are hard to find.

https://static1.pt-content.com/images/pt/2017/08/ZOZBa4F-1.jpg

https://static1.pt-content.com/images/pt/2017/08/PwauZts-1.jpg

Car after epoxy showed even more dings I didn't see when the car was out in the light.

https://static1.pt-content.com/images/pt/2017/08/t81qL4T-1.jpg

https://static1.pt-content.com/images/pt/2017/08/pm4dzhh-1.jpg

One of the subtle changes. Added a GT-E "esque" cougar hood scoop. It will look similar the g-force cougar hood scoop.

https://static1.pt-content.com/images/pt/2017/08/VYorEIV-1.jpg

I also managed to find 18" wheels that fit my car and clear the monster 15" rotors from the gt500 brakes I'm using.

[1bad68cat]

Added some color. Still need to mask for stripes.

https://static1.pt-content.com/images/pt/2017/09/X2ANStp-1.jpg

[andrewb70]

Making progress!

Andrew

[Motown 454]

It's coming along nice!

[1bad68cat]

A few more updates. Body shop laid out the stripes, painted them, and cleared the car.

https://static1.pt-content.com/images/pt/2017/09/URvhrf5-1.jpg

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[andrewb70]

Looking really sharp!

Andrew

[1968CamaroSS_Sam]

Looking good. Love the colors.

[1bad68cat]

A few updates. Still needs to be cut and buffed.

https://static1.pt-content.com/images/pt/2017/10/65hFdBU-1.jpg

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[USAZR1]

That's going to be a killer ride,when done. Nice work!

[roffutt]

More updates please!!! I know I saw your engagement photos a while back and the car is looking great! I'm loving those wheels and stance.

-Robbie

[Project Bike Truck]

I am wondering what you did with the rear suspension?

[1bad68cat]

More updates please!!! I know I saw your engagement photos a while back and the car is looking great! I'm loving those wheels and stance.

-Robbie

Robbie, unfortunately I haven't touched the car since the engagement photos. I was completing the build on my brother's 66 mustang so I could use it in the wedding. His car was a lot closer to finishing than my cougar was. Plus I needed a red car for the wedding.

https://static1.pt-content.com/images/pt/2018/08/HBGUbLp-1.jpg


I am wondering what you did with the rear suspension?

It will be a custom 3-link with watts link for the rear suspension.

[67cougnut]

any updates?

[1bad68cat]

any updates?

No updates unfortunately Haven't had the time to work on it

[jcsexton2]

I am sure you have answered tis at some point in this thread, but what independent front suspension kit did you use on this setup? Is this a Total cost involved setup?

[langleylad]

I am sure you have answered tis at some point in this thread, but what independent front suspension kit did you use on this setup? Is this a Total cost involved setup?

It's not the TCI kit , I used it in my build .

[1bad68cat]

I am sure you have answered tis at some point in this thread, but what independent front suspension kit did you use on this setup? Is this a Total cost involved setup?


It's not the TCI kit , I used it in my build .

I am using an Art Morrison Sport IFS kit. It was not specifically made for the cougar/mustang, but they have a kit that is close to the same frame width as them. I made modifications so I could remove the lower crossmember for any engine service/repair(i.e. oil pan) that may be needed in the future without having to remove the engine. Also, the major mods are in my sig. :)

[Tsaints1115]

If I may ask, what all was involved to run those 15" brakes? Are those the S197 setup from the GT 500?

[1bad68cat]

If I may ask, what all was involved to run those 15" brakes? Are those the S197 setup from the GT 500?

The brakes are from the S197 GT500 as you mentioned, specifically a 2014. My front suspension uses the Wilwood Pro 2in drop spindle. I coupled it with a MBM mutil-pattern rotor hub, PN GM689. I then designed a caliper bracket to attach the 6 piston brembo calipers.

[Tsaints1115]

Gotcha, Thanks

[Lockdown]

Could you post more pictures of the hydraulic master clutch modification on the pedal bracket and clutch assembly?

I'm in the process of doing the exact same thing but wanted to see how you fabricated it.

[1bad68cat]

Could you post more pictures of the hydraulic master clutch modification on the pedal bracket and clutch assembly?

I'm in the process of doing the exact same thing but wanted to see how you fabricated it.

Sorry Lockdown. I just saw this. Is there a specific picture you're looking for? The clutch master is mounted on angle iron than I welded directly to the pedal support.