1967 Cougar build (over 700 pictures and videos)

[andrewb70]

Those who master technology make cool parts.

Ancient proverb...

Andrew

[andrewb70]

I will just leave this here...



Andrew

[ryeguy2006a]

Love it!

[wfo guy]

Not bad.

[andrewb70]

Last week I took a spare 9" carrier, that I have been dragging around for about 8 years, to a recommended shop to swap out the ring and pinion. This was a Currie nodular 9" carrier that came with a 31 spline True Track diff, but had a useless 4.57 ring and pinion gear.

A while back I purchased a used OEM 2.75 ring and pinion and also a REM polished 2.75 ring and pinion from Quick Performance. I told the guy to use whichever gear set he felt would be the quietest. HE ended up setting up the used OEF Ford gear. I started the carrier swap yesterday and finished it up this afternoon.

I took my first drive and I have to say, that in my opinion, this is the optimal rear axle ratio when using the 8HP70 transmission. The gears are very quiet and I am pretty pleased.

For anyone contemplating the 8HP transmission swap, I would use either a 2.75 or at most a 3.00 gear set, assuming the typical 25.5 to 27 inch tall tires that we all use. With a taller tire, a 3.25 gear would work as well.

Andrew

[Zachalanche]

that 4.7 1st is a deep gear.

- - - Updated - - -

that 4.7 1st is a deep gear.

[CarlC]

For anyone contemplating the 8HP transmission swap, I would use either a 2.75 or at most a 3.00 gear set, assuming the typical 25.5 to 27 inch tall tires that we all use. With a taller tire, a 3.25 gear would work as well.

Andrew

Similar ratios on the late model GM transmissions vs. 8HP where the Gen6 ZL1 diff gear is 3:23:1 but a taller tire.

[andrewb70]

As Thanksgiving and Christmas approach, my tuning business tends to slow down. This isn't entirely unwelcome, as it gives me a little more time to work on my pwn projects.

One thing that has always bothered me a little was the rear ride height and ride quality. Calvert Racing specified the rear spring package from the start, but as always adjustments are often needed. I called them and asked what can be done and they suggested swapping out the rear portion of the leafs. They sent the new springs and it was relatively straightforward to swap them out. The rear was lowered exactly an inch and the ride quality is definitely softer now.



The next project was to make a center console that will cover the shifter. I 3D scanned the area between the seats, capturing the shape of the tunnel and the shifter the best I could. I sent the scan to James and he started to design the console in Solid Works.



3D printing the whole console was going to be cost prohibitive, even if done in pisces, so I opted for "tab and slot" construction. James sliced up the model and I had Send Cut Send laser cut the pieces from 1/8" Hardboard (that's what they call it).




I ordered some CA glue along with some activator and started to glue the pieces together.




The hole in front of the shifter pocket is for a cup holder and the rectangular opening at the very front will accept a 3D printed tray for holding the phone or whatever else is needed.



After the initial glue up, I used some bondo with fiber strands to strengthen the joints.



Then I further strengthened the whole thing by adding fiberglass to all of the joints.



The area around the shifter will also get a trim piece once the console is finished and I add a way to hold it on the tunnel.



The rear plate needs to be rounded off to better fit the shape of the tunnel, but otherwise it fits pretty well.



Andrew

[jaybee]

That's pretty slick. I haven't used Send Cut Send yet, but I'm thoroughly convinced they're a great resource.

[FLYNAVY53]

send cut send is such a brilliant idea.....Ive used them for everything from car parts to making a full wooden lego workbench for my kids

[Vimes]

Looks pretty good, but I'd suggest putting the seats back in for a test fit before going any further, and make sure nothing interferes with actually using the shifter.

[andrewb70]

That's pretty slick. I haven't used Send Cut Send yet, but I'm thoroughly convinced they're a great resource.

I have used them for numerous projects for the GTO, Cougar and Suburban.

send cut send is such a brilliant idea.....Ive used them for everything from car parts to making a full wooden lego workbench for my kids

Awesome idea!

Looks pretty good, but I'd suggest putting the seats back in for a test fit before going any further, and make sure nothing interferes with actually using the shifter.

The shifter placement was determined when the seats were installed and before the console was made. If you look at the picture of the 3D scan, you can see the outline of the seats and the shifter in the scan, with the console modeled around it.

Andrew

[wfo guy]

How are you going to finish it? Paint, upholstery, wrinkle finish?

[andrewb70]

How are you going to finish it? Paint, upholstery, wrinkle finish?

Wrinkle finish sounds like a pretty good idea actually. I was also considering bedliner. I think for either finish to work well with wood, it will have to be primered first.

Andrew

[andrewb70]

This past weekend my buddies BA, Tom, Gary flew in from Alabama and Chicago to get this project knocked out. My neighbor Don and my local buddy Casey also joined the part and everyone's assistance was invaluable.

The goal was to take off the stock LSA supercharger and install a Harror 2650RP. I wont bore you with the details of disassembly, so here we go with the more interesting parts of the installation.

Once we set the new blower on the engine, it was pretty obvious that the front steam crossover was not going to work as I had it configured with the original LSA. Thankfully the crossover was made out of Earl's adapters and some 3/16 NiCopp tubing. I dug out my roll and BA went to work with some scrap tubing to see if we can get that sharp bend done on the driver's side. The old crossover snaked between the water pump and the snout, but the new blower snout was actually touching the water pump a little (more on this later).

BA made a very tidy new tube and I flared the ends and installed new tube sleeves.




Here you can see how tight everything is, but the tube snakes neatly through the available space.



While a couple of guys made a Summit Racing run, we decided this was a good time to see if the Holley low mount AC bracket and compressor would fit in my very limited space. I was afraid the the back of the compressor would hit the engine mount or the dipstick. As it turned out, it cleared both and fits beautifully. This will be a fall or spring project to add AC for next season. Kudos to Holley for making a very tidy compressor mount.







If you look carefully at the driver's side intake gasket, you can clearly see there is a gap. This is because the blower snout hit the water pump. We decided the best course of action was to take a flapper wheel to the water pump casting and give it the clearance that was necessary.

Also, the snout entry is huge, although it uses a standard Gen 4 four bolt throttle body spacing.



The new blower looks basically the same as the old one, except for it being black.



Another thing to note is the new Nick Williams 103mm throttle body. I was really afraid that it would cause issues with my 3D printed air intake box, but the NW throttle body and the blower snout put everything in the same location as before.

The upper pulley is a little bigger than the stock pulley, at 85mm, while I retained the ATI 10% overdriven lower blower pulley. With this combination it is making about 14-15psi.

I will be upgrading a few components before LS Fest, such as a new Harrop reinforced and slightly bigger intercooler brick and Holley LSA fuel rails. I had a length call with Carl Casanova and after doing a little math based on my previous datalogs, he said the current injectors (ID1050x) and fuel pump (525L/hr) will be just enough, even on e85.

Andrew

[ryeguy2006a]

That's an awesome upgrade Andrew! How much boost were you making with the LSA?

[Vimes]

Looking that over, first my mind started Rod Stewart's Do You Think I'm Sexy, and morphed into ZZ Top's Sharp Dressed Man. Looking good.

[wfo guy]

Very cool, very good friends. The common goal is obvious to me.

[andrewb70]

That's an awesome upgrade Andrew! How much boost were you making with the LSA?

Seems to be about 14-15 now compared to 10 before.

Looking that over, first my mind started Rod Stewart's Do You Think I'm Sexy, and morphed into ZZ Top's Sharp Dressed Man. Looking good.

LOL

Very cool, very good friends. The common goal is obvious to me.

They are great friends. It would have taken me 2 weeks to do this. One of them also installed new shocks and rear swaybar on the Suburban. So much better now!

Andrew

[andrewb70]

In order to prevent any issues at LS Fest, I had a chat with Carl Casanova and we decided the injectors and fuel pump were going to work with the added power, but the fuel rails tend to become a restriction at about 750HP.

I didn't want to take any chances, so I ordered some Holley LSA fuel rails.



One thing that Carl was adamant about was using a fuel damper, so I ordered one, from Holley as well, that was designed to screw into the back of the fuel rail. Unfortunately, it was not designed for the LSA rails and the damper hit the side of the blower case.

I needed about a 1.25" extension from the back of the rails.



My buddy TJ came through in a pinch with the help of one of the lathe operators at ICT Billet.



The damper fits perfectly now.



I also made a crossover hose for the front of the rails.

I am waiting for a few more parts and she will be ready to rock at LS Fest.

Andrew