Fox T-Bird/Cougar Forums

General => User Rides => Topic started by: Chuck W on December 17, 2007, 06:04:30 PM

Title: Chuck's '83 TBird
Post by: Chuck W on December 17, 2007, 06:04:30 PM
At least that's the preliminary verdict.  I'll hold the final one until I can heat cycle it up to temp again and see if it decides to smoke.  So far it seems fine.

I actually had it back together yesterday, but held off until today to try and fire it since I needed to get some antifreeze (It will be spending a couple months in a non-heated garage....so just water won't do). 

Of course it's running just in time for all this snow to hit this week :p so it's not going anywhere just yet.

It looks like it will warm up and rain(to clean the roads) this week so maybe next weekend I can get it to it's hibernation spot.  I need to get it a fill tank of happy premium too...

I took it off the road last Oct/Nov to deal with the block issue, then the head issue popped up once I got that back together in the spring/summer, so it's been in the garage a year.

Barring any more shenanigans I'll be able to drive it come spring. Then I'll get into the next bit of mods :hick:
Title: Chuck's '83 TBird
Post by: stuntmannick on December 17, 2007, 06:37:50 PM
still rock'n the 2.3?
Title: Chuck's '83 TBird
Post by: thunderjet302 on December 17, 2007, 06:40:07 PM
Cool just in time for the salt :hick:

Pics ;)
Title: Chuck's '83 TBird
Post by: Chuck W on December 17, 2007, 06:48:28 PM
Quote from: stuntmannick;193275
still rock'n the 2.3?


For right now.  The whole plan for this past spring was to get the car running so I could deal with other things, but it decided not to cooperate.  Still it was cheaper at the time to grab another head and swap that out than to get into the I6 swap and all that will entail.  I'll have a cleared out heated garage to work in this winter, so I'll get into block and head prep on the six.  I'm also rebuilding the rear suspension on my Scorpio, so I needed to room to weld/paint/etc.

thunder...yeah I know... :toilet: It's supposed to warm up and rain here this coming week, so hopefully I can make the 10-15 min trip to the other garage and the roads will be moderately clear.
Title: Chuck's '83 TBird
Post by: thunderjet302 on December 17, 2007, 07:04:40 PM
Quote from: Chuck W;193282


thunder...yeah I know... :toilet: It's supposed to warm up and rain here this coming week, so hopefully I can make the 10-15 min trip to the other garage and the roads will be moderately clear.


One can only hope. Salt is evil :mad:
Title: Chuck's '83 TBird
Post by: gumby on December 17, 2007, 07:21:56 PM
Quote from: Chuck W;193271

Barring any more shenanigans I'll be able to drive it come spring. Then I'll get into the next bit of mods :hick:

wanna drive it to CJ before you tear into it for the I6 conversion? :shakeass:
Title: Chuck's '83 TBird
Post by: P71 on December 17, 2007, 07:43:49 PM
The I6 is going to be really cool. I can't wait for that to go in...
Title: Chuck's '83 TBird
Post by: Chuck W on December 18, 2007, 05:27:17 PM
OK well the final verdict is.......









The '83 lives again!!!

I started it up again this afternoon when I got home from work and ran it up to temp and no smoking. 

The tune is all to pen 15, especially when cold, but I'm not going to really mess with it until it has some fresh gas in it and I have time to drive it and sort it out.
Title: Chuck's '83 TBird
Post by: tc² on December 19, 2007, 12:09:11 AM
So... Twin Turbo I6 or...? :hick:
Title: Chuck's '83 TBird
Post by: Chuck W on December 19, 2007, 10:36:53 AM
Quote from: tc²;193509
So... Twin Turbo I6 or...? :hick:


Probably just a single...
Title: Chuck's '83 TBird
Post by: thunderjet302 on December 19, 2007, 10:44:19 AM
Have the roads cleared enough for you to take a spin yet? We've still got salt all over the roads here. :hick:
Title: Chuck's '83 TBird
Post by: Chuck W on December 19, 2007, 10:48:46 AM
Quote from: thunderjet302;193544
Have the roads cleared enough for you to take a spin yet? We've still got salt all over the roads here. :hick:


The snow is melting, but no rain yet..so it's not going outside on the roads.  Its supposed to rain Sat, so "maybe" on Sun I can make the trip.  I'm fiddling with a couple other things at the moment on it, so it's not an "issue" at the moment.
Title: Chuck's '83 TBird
Post by: thunderjet302 on December 21, 2007, 01:47:09 AM
It's raining here. Any such luck by you?
Title: Chuck's '83 TBird
Post by: Chuck W on December 21, 2007, 07:57:26 AM
Quote from: thunderjet302;193813
It's raining here. Any such luck by you?

Supposedly it's going to dump here Sat, but right now nothing.
Title: Chuck's '83 TBird
Post by: thunderjet302 on December 21, 2007, 02:37:50 PM
In Chicago it's supposed to be 45* tomorrow (Sat) with rain in the afternoon. Then Saturday night into Sunday the temps are going to drop into the 20s with acspoogeulating snow late Saturday night into Sunday. Hopefully that  won't make it out by you :hick:
Title: Chuck's '83 TBird
Post by: HAVI on December 22, 2007, 10:23:02 PM
What I6 are we talking? small or big?
Title: Chuck's '83 TBird
Post by: Chuck W on December 23, 2007, 12:44:47 PM
Quote from: HAVI;194023
What I6 are we talking? small or big?


I've covered it a couple times here.  The plan is for a hybrid US/Aussie engine.  The block will be a US 200 I6 and the head will be an AL Aussie X-Flow EFI head.
Title: Chuck's '83 TBird
Post by: Drewstang on December 23, 2007, 06:32:19 PM
With a big dirty turbo attached to it right?
Title: Chuck's '83 TBird
Post by: HAVI on December 24, 2007, 06:03:31 PM
I guess I missed that.  I s'pose you've already checked out http://www.fordsix.com then?
Title: Chuck's '83 TBird
Post by: Chuck W on December 24, 2007, 06:16:28 PM
Quote from: HAVI;194301
I guess I missed that.  I s'pose you've already checked out http://www.fordsix.com then?

Yup ;)
Title: Chuck's '83 TBird
Post by: Chuck W on December 30, 2007, 10:11:54 AM
Well...it's moved.
(http://www.turbochuck.com/images/Tbird/hibernationmode.jpg)

I had some time and the roads were clear on Sat, so I got things together and drove the car over to it's winter storage spot.

It wasn't w/o issue though. 

The first issue was I had picked up a couple of those band clamps for the exhaust to secure the ler and tailpipe.  They're nice and all, but one thing about them.  If the joint is not PERFECTLY straight (i.e. if there is ANY curvature along the pipes) they do not work.  So for the time being, I put a couple small tack welds on the joints in question and will deal with that come spring.

Then I had the car warming up and I was shuffling the cars out of the drive and I walk back around front and see the car smoking like a chimney ... Are you shiznitting me?!? :beatyoass:  So at this point I have said hell with it and it's going to storage anyway.  So I hop in and drive it to the gas station.  Well after driving it ...the smoking stopped.  So I'm not sure what the issue is.  It may be something with the turbo seals, but the smoking stopped completely after 10-15 mins of driving.  I put some Sta-Bil and fresh gas in the tank.  I was going to fill it up since it was going to be in storage, but as the meter on the gas pump was approaching $50...and it wasn't full yet..I decided that was enough for now :p  The car has the 22gal V8 tank.

I got on it a few times...it's going to be fun when I get the tune sorted :hick:

A couple items I noticed (haven't driven the car in 14 months).  I will be buying new tires come spring..these are done and old.  Also, I need to sort out the clutch pedal.  Currently I has a '79 Mustang pedal assy that I modified to mount a quadrant on (originally it was just a straight pull) and the clutch pedal has WAY too much travel and releases way too high.  I may try and swap in a later assy with a quadrant and see if that helps a bit.  I may have the cable a bit tight too, so I'll fiddle with that come spring as well.  The bell I'm using is one of the early straight pull bells, not one with the small "dog bone" cable.

Anyway, it's out of the garage now and the other projects can commence :D
Title: Chuck's '83 TBird
Post by: Jim_Miller on December 30, 2007, 10:28:24 AM
Grat's Chuck!
Now you should adapt the 88 nose to it and make it look sharp!
Title: Chuck's '83 TBird
Post by: Chuck W on December 30, 2007, 10:58:38 AM
Quote from: Jim_Miller;194989

Now you should adapt the 88 nose to it and make it look sharp!


I sure hope you're not being serious.....:beatyoass:



[SIZE="5"]4-eyes rule,
Aeros drool[/SIZE]

:flip:
Title: Chuck's '83 TBird
Post by: gumby on December 30, 2007, 01:09:17 PM
Quote from: Jim_Miller;194989

Now you should adapt the 88 nose to it and make it look sharp!

OMG!!!! :spit: (http://i25.photobucket.com/albums/c73/gmby23/24.gif)


chuck - glad to hear the smokin stopped. maybe jus some stray oil or a seal that needed some workin in....i hope come spring time she emerges ready to roll!
Title: Chuck's '83 TBird
Post by: Chuck W on December 30, 2007, 01:38:00 PM
Quote from: gumby;195017
OMG!!!! :spit: (http://i25.photobucket.com/albums/c73/gmby23/24.gif)


chuck - glad to hear the smokin stopped. maybe jus some stray oil or a seal that needed some workin in....i hope come spring time she emerges ready to roll!


Yeah, it might have been a remnant of the blow-by caused when the #4 rings went.  It's possible the oil seal in the turbo was out of whack from that and it needed a little boost to get things back in order. 

It did make me wonder if the old head was bad, but it was very evident that there was oil leaking into the #1 exhaust port, so I don't think the head swap was wasted.
Title: Chuck's '83 TBird
Post by: vinnietbird on December 30, 2007, 05:50:33 PM
Aeros don't "drool",Chuck.Well,mine doesn't,anyway..LOL.She rocks !!! Ugly as a pot of stewed a$$holes though right now,but new paint will be coming soon.
Title: Chuck's '83 TBird
Post by: Dogcharmer on December 30, 2007, 09:38:55 PM
Quote from: Jim_Miller;194989

Now you should adapt the 88 nose to it and make it look sharp!


Yeah, yellow headlights kick ass! :rollin:
Title: Chuck's '83 TBird
Post by: turbo83coupe on January 01, 2008, 09:07:52 PM
Quote from: Chuck W;194993
I sure hope you're not being serious.....:beatyoass:



[SIZE="5"]4-eyes rule,
Aeros drool[/SIZE]

:flip:


wow!! I sure hope that was a joke when he siad that :beatyoass: :evilgrin:
Looks good Chuck  ;)
Title: Chuck's '83 TBird
Post by: thunderjet302 on January 02, 2008, 07:29:00 PM
Hey did it snow by you New Years eve? If it did you just beat the new salt wave :hick:
Title: Chuck's '83 TBird
Post by: Chuck W on January 02, 2008, 07:57:26 PM
Quote from: thunderjet302;195491
Hey did it snow by you New Years eve? If it did you just beat the new salt wave :hick:

It rained NY's Eve.  It snowed NY's Day though...and yes, they were not shy with the salt.  All we got was a dusting, so there is more salt on the road than snow.
Title: Chuck's '83 TBird
Post by: thunderjet302 on January 02, 2008, 11:55:37 PM
Quote from: Chuck W;195500
It rained NY's Eve.  It snowed NY's Day though...and yes, they were not shy with the salt.  All we got was a dusting, so there is more salt on the road than snow.


50* and rain here Sunday. Maybe the salt will go away :hick:
Title: Chuck's '83 TBird
Post by: ZondaC12 on January 03, 2008, 12:49:34 AM
Yeah we had a day last week where it rained all friggin night and most of the morning...lightly. Then it poured later. The next day the roads were CLEAN. Took the cougar and the 38 out for a loooong drive. Now both kinds of white stuff are everywhere again. :hick:
 
(sheesh do we OVERUSE the hell out of that icon or what!?)
Title: Chuck's '83 TBird
Post by: daminc on January 03, 2008, 07:45:10 AM
Quote
Yeah we had a day last week where it rained all friggin night and most of the morning...lightly. Then it poured later. The next day the roads were CLEAN. Took the cougar and the 38 out for a loooong drive. Now both kinds of white stuff are everywhere again. 


We had the same thing here, but they started salting in the rain towards evening so it wouldn't freeze in case the temp. dropped

So the next day it was like driving in a salt spray from the car in front of you.

They're crazy with that stuff.
Title: Chuck's '83 TBird
Post by: ZondaC12 on January 03, 2008, 10:43:42 AM
Uh, wow. WTF thaaaaaat's bs. Now I know how bad it is out there. Makes what we deal with here look like nothin! Sheesh.
Title: Chuck's '83 TBird
Post by: Funky Cricket on February 09, 2008, 04:18:50 PM
still sporting the turbo 4 then. I popped over to see if the conversion was complete. I'm still thinking that might be the road I take. I love 4 eyed fords, I love t-birds, I love ford i-6's... can't go wrong! hehe.
Title: Chuck's '83 TBird
Post by: Chuck W on February 09, 2008, 04:24:12 PM
Quote from: Funky Cricket;203161
still sporting the turbo 4 then. I popped over to see if the conversion was complete. I'm still thinking that might be the road I take. I love 4 eyed fords, I love t-birds, I love ford i-6's... can't go wrong! hehe.


Yup, I wanted the car to be running for a bit.  I've gotten as far as stripping the I6 block and getting ready to do the mods on it, but my daily needs rear brakes and the Scorpio needs the rear suspension done before I proceed any further.

I didn't want the car to be down for another year while I messed with the conversion.
Title: Chuck's '83 TBird
Post by: Funky Cricket on February 09, 2008, 04:57:35 PM
it's no fun to not drive your car!
I "carless" at the moment, but I've been thinking on it alot, as I hope to be in a position to buy a toy in 2009. So I want to have a plan in place.

I'm back to thinking a bird with a i6, instead of a capri or falcon.. the birds are just to comfy...

maybe a 250 and then i'll save up for one of mike's heads and then maybe do an EFI multi-port conversion... hmm... that'd be a head turner! Or bring in a falcon 4.0, but then I'd have to ship away for any parts and I don't think the t5 bolts to that without a conversion ring on the bell housing.
Title: Chuck's '83 TBird
Post by: Chuck W on April 13, 2008, 06:10:17 PM
Well a little bit of good and bad today with the Tbird.  I stopped over to remount the wheels after I'd had the new tires installed.
I was greeted by a dent in the hood as I pulled the car cover off of it.  Apparently at some point within the past week or two something was dropped on the hood pretty hard.  There is a 1/2" diameter, 1/8" deep dent/divot down to the metal.  There's a corresponding cut in the cover that was on the car too.

I'm guessing my friend's kid (where the car is stored at the moment) or one of this friends had an "accident".  She asked him and he had no idea.

I'm not sure if they can spot fix it or whether the hood will have to be reshot.  Not much I can really do other than get it fixed.

Other than that issue I fired it up for the first time in 4 months and let it warm up.  The weather has been py the past few days, so it will be another few before I can get it out and drive it.  Of course last weekend was beautiful.
Title: Chuck's '83 TBird
Post by: Chuck W on April 14, 2008, 02:00:44 PM
Well I talked to my paint guy today.  He's saying probably $250-ish to fix it.  Joy.

On a brighter note, the weather looks to be good the next 2-3 days, so I'm planning on going over tomorrow and grabbing the car and drive it, give it a bath and hopefully fiddle with the tune a little.  I'll take it back to storage by Fri though as the rains are supposed to come back.

I do have on order a little item that will add a minor visual tweak that I have been wanting to do for a while and have finally located the proper specimen.  I'll post up picks when I have them in hand and in place.
Title: Chuck's '83 TBird
Post by: Chuck W on April 15, 2008, 10:47:34 AM
Well I stopped and picked up the car today. :D

I need to relearn how to drive it, as the boost comes on like a frieght train at about 2600-2800rpm and just takes off.  Hopefully I'll get some time to fiddle with the tune a bit the next couple days to work on smoothing things out.

I drove the '80 over to stick in it's place thinking I was going to have to fight the carb the whole way...however it decided to behave today. 

Got to drive both the Foxes today :hick:

I'll post up a couple new pics tonight...but the car is FILTHY!
Title: Chuck's '83 TBird
Post by: EricCoolCats on April 15, 2008, 11:23:22 AM
Sucks about the dent but glad to hear you drove it. It's been a long winter...I'm sure it was worth the wait. The atmospheric gods were with you. :)
Title: Chuck's '83 TBird
Post by: Chuck W on April 15, 2008, 11:28:20 AM
Yeah, the air is still a bit cool, but the sun is out and the skies are clear. 

As I was pulling away from the first stop sign, the tires were still slimy from being new.  As soon as the boost came on ever so slightly the car went sideways.  There was some guy coming up behind me in a convert SN-95 V8....he decided to keep his distance. :hick:
Title: Chuck's '83 TBird
Post by: gumby on April 15, 2008, 12:19:20 PM
Quote from: Chuck W;214074

I need to relearn how to drive it, as the boost comes on like a frieght train at about 2600-2800rpm and just takes off. 

you runnin a .48 or .63 hotside on that turbo?


man am i jealous......
Title: Chuck's '83 TBird
Post by: Chuck W on April 15, 2008, 12:23:09 PM
.63 A/R with a GN cold side.

I think the exhaust has a bit to do with that as well.

I was kind of surprised myself.
Title: Chuck's '83 TBird
Post by: chri85tc on April 15, 2008, 12:30:53 PM
I know what you mean about the boost comin on like a freight train, my turbo is set up like yours in my 85.(T3/T4, .63 AR)

I just had to comment because I just got back my turbo today after I blew the rear carbon seal on it
Title: Chuck's '83 TBird
Post by: BCA on April 15, 2008, 04:49:14 PM
Chuck,

Sorry to hear about the hood. Glad you are being able to exercise it though; I too am jealous !

I can't wait to see this "visual tweak" you speak of. 

Brent
:cougarsmily:
Title: Chuck's '83 TBird
Post by: Chuck W on April 15, 2008, 05:57:40 PM
Well just to prove that it is out and getting driven ;)

The pics aren't all that great as it was mid-day and sunny, but at least it's not sitting in the garage.

(http://www.turbochuck.com/webimages/projects/83 TBird/4_08_1_s.jpg)
(http://www.turbochuck.com/webimages/projects/83 TBird/4_08_2_s.jpg)

And here is the chip/dent... :(

(http://www.turbochuck.com/images/Tbird/Chip.JPG)

It got a bath when I got home today, and I'm going to take the laptop with me to work tomorrow to see if I can fiddle with the tune a bit.
Title: Chuck's '83 TBird
Post by: turbo83coupe on April 15, 2008, 09:35:16 PM
such a nice 83  :)
Title: Chuck's '83 TBird
Post by: Chuck W on April 18, 2008, 09:22:30 AM
Well I've driven it every day since Tues and have been slowly working on the tune.  Nothing scientific as I haven't had much time aside from driving back and forth to work, but I have improved the warm-up strategy a bit and worked on a couple flat spots in the VE table.  I got antcy this morning and pushed it to 17psi in 4th...no noises and no smoke...so after a little more VE tuning, I'll get back to adding more spark advance.
The tune is all goofy because as I was trying to tune it the past couple times, it was either running on 3 cylinders, or burning oil...so that never helped matters :p

The rains are supposed to return tonight, so it will go back into storage.  Hopefully it won't get any new dents...
Title: Chuck's '83 TBird
Post by: ivygreen on April 18, 2008, 07:57:45 PM
Man, I really love that car.
Title: Chuck's '83 TBird
Post by: daminc on April 18, 2008, 08:12:09 PM
Beautiful car, Chuck
Any inside shots?
Title: Chuck's '83 TBird
Post by: Chuck W on April 18, 2008, 09:11:33 PM
Just a couple.  Hasn't changed much in there yet.

(http://www.turbochuck.com/images/Tbird/Seats/interior_7_06_1.jpg)
Title: Chuck's '83 TBird
Post by: daminc on April 18, 2008, 09:16:44 PM
I can't believe how small the top of the dash is, in that car.
I like those seats too.
Title: Chuck's '83 TBird
Post by: Chuck W on April 26, 2008, 06:33:09 PM
Ok, well I spent a little time with the car today.  The first task was to work on the tune a bit more.  Made some pretty good improvements in that repsect.
Second I swapped the Pro 5.0 stubby shifter handle for a stocker so I can actually reach the shifter in all 5 gears.
I put quite a few miles on the car today, as opposed to just driving it back and forth to work.

When I got back home again after some errands I did a bit more work on it.

See if you can guess what is different on the front of the car...
(http://www.turbochuck.com/webimages/projects/83 TBird/fogcovers.JPG)

Yes, it's the foglight covers... I have been wanting a set of the white covers for a while now, and I found a set...that came in this...

(http://www.turbochuck.com/images/Tbird/marchals_2.JPG)
(http://www.turbochuck.com/images/Tbird/marchals_1.JPG)

I got them out of France.  The lights are new and unused and basically came complete with a little  "install" kit in a neato plastic package.  The yellow lights will probably wind up on the '80.

I know the cover change on the fogs is a trivial thing, but I always liked them over the later grey covers.

Then I finally did some "real" work and finished off the exhaust with a new stainless tip.

(http://www.turbochuck.com/images/Tbird/Newtip_1.JPG)
(http://www.turbochuck.com/images/Tbird/Newtip_2.JPG)

I found it online and is an 11" long 3-1/2" dia tip with a 3" inlet.  It was the PERFECT length to finish off my Stinger tailpipe. It was also only $20...bonus!

While I had the car up in the air I also snapped a pic of the exhaust that I installed at the end of last year.

(http://www.turbochuck.com/webimages/projects/83 TBird/exhaust.JPG)
Title: Chuck's '83 TBird
Post by: turbo83coupe on April 27, 2008, 01:37:54 AM
looks good!!  :)
Title: Chuck's '83 TBird
Post by: Carpimp1987 on April 27, 2008, 02:10:37 AM
Its about time you got to drive that car and fix it up some more looks good. Keep up the work and i can't wait to see more pics.
Title: Chuck's '83 TBird
Post by: yellow86coogr on April 27, 2008, 03:20:52 AM
Lookin' good chuck W. I like those white covers as well
Title: Chuck's '83 TBird
Post by: gumby on April 27, 2008, 07:09:23 AM
oooooh, pretty tires!

kinda surprised to see a single exit tip on there; looks real good.

now, about that under car shot.....youve got jackin rails and SFCs, but your jack is under the LCA pickup??? :tg:
Title: Chuck's '83 TBird
Post by: Chuck W on April 27, 2008, 09:31:05 AM
Well I thought about the twin tip, as I really like that look.  When it came down to it though this was just much cleaner and easier (and cheaper, as the twin tips I was finding with a 3" inlet were 2-3x's as much as this one was).  This one was perfect though for the install with the Stinger tailpipe.  I cut nothing to install it, just placed it at a slight angle and welded it in.

As far as the jack location...I said the same thing to myself as I jacked it up.  I did place the stand under the JR though :hick:
Title: Chuck's '83 TBird
Post by: 5.0 tbird on April 27, 2008, 01:21:28 PM
^ Drools at those foglights. You wouldn't be interested in selling your old covers would you? I'm missing one.
Title: Chuck's '83 TBird
Post by: 50tbrd88 on April 27, 2008, 05:38:28 PM
Nice work man...I know how it is putting up with these py indiana winters and then finally being able to get the car out.  I've been driving mine quite a bit but it has exposed a few gremlins.  Sweet car.
Title: Chuck's '83 TBird
Post by: Chuck W on April 27, 2008, 08:14:27 PM
Quote from: 5.0 bird;215977
^ Drools at those foglights. You wouldn't be interested in selling your old covers would you? I'm missing one.


Sorry, but I need a set of covers for the lights when they go on the '80.  That car "needs" the white ones too, but it will get what I have.

The car is tucked away for another couple days as it looks like rain, but most of the week is supposed to be nice, so it will be back out :D
Title: Chuck's '83 TBird
Post by: BCA on April 28, 2008, 09:27:26 AM
Very cool find Chuck!
Looking good on both ends.

Brent
:cougarsmily:
Title: Chuck's '83 TBird
Post by: rodsterh on April 28, 2008, 12:11:27 PM
You da man Chuck! 

Thanks for the updates. Either color cover looks good on your car...don't think the yellow lenses would work on the 83 tho'

How bout a picture with no covers??  Clear TS lenses, clear fogs...yea man...


Rod
Title: Chuck's '83 TBird
Post by: Chuck W on April 28, 2008, 12:21:09 PM
I'm planning on using the yellows on the '80 most likely.

Next time I take some "real" pics, I'll do some without the covers...but the are sooo cool though :hick:
Title: Chuck's '83 TBird
Post by: nitroracer on April 28, 2008, 11:36:04 PM
Good to know the car is out getting used again!
Title: Chuck's '83 TBird
Post by: Chuck W on July 25, 2009, 04:50:52 PM
Well, nothing too exciting has been going on with the car as I've been busy with a host of other things, but I have been working on a little project lately...the rear bulkhead fit out.

(http://www.turbochuck.com/webimages/projects/83 TBird/reardelete.jpg)

The rear deck and the former seat back are now in place.

It's 1/16" ABS covered with some 18oz carpet I picked up online.  I'm actually going to build a small frame for the ex seat bottom as I want to build in a couple recessed compartments to set things in if I need to.

The headliner is coming out and being replaced (with a darker color) since it's starting to come down a bit.  I just noticed that a couple weeks ago.  Good thing I picked up 2 yards of charcoal material when I bought the stuff to redo the Scorpio headliner.

The carpet is kind of nice in that it doesn't have any backing to it, so it's pretty easy to work with.  I just installed it over the wheel wells there.
Title: Chuck's '83 TBird
Post by: vinnietbird on July 25, 2009, 04:54:39 PM
Nice work,better looking than the Mustang's seat delete kit..I need to figure out how to make an insulated good looking cover for the bottom of the trunk lid.
Title: Chuck's '83 TBird
Post by: gumby on July 25, 2009, 07:31:20 PM
looks good chuck.

are you gonna remove the front or rear glass to get the headliner out, or can you still weasle it out with the cage in there? i need to do sumthin with my headliner as well.
Title: Chuck's '83 TBird
Post by: Clayton on July 25, 2009, 07:36:34 PM
Im definatly going to have to take a look at this thing in person soon.
Title: Chuck's '83 TBird
Post by: massCougarxr7 on July 25, 2009, 08:52:07 PM
Thats pretty B. A. Chuck!1
Title: Chuck's '83 TBird
Post by: DVP on July 25, 2009, 09:32:10 PM
Quote from: gumby;283771
looks good chuck.

are you gonna remove the front or rear glass to get the headliner out, or can you still weasle it out with the cage in there? i need to do sumthin with my headliner as well.


Good point. I think he only has a bar (not extending past the door pillar in my terms :D) so it might be easier.
Title: Chuck's '83 TBird
Post by: Chuck W on July 26, 2009, 07:48:26 PM
Quote from: gumby;283771
looks good chuck.

are you gonna remove the front or rear glass to get the headliner out, or can you still weasle it out with the cage in there? i need to do sumthin with my headliner as well.


 I should be able to wiggle it out.  Good thing I didn't build it with a halo :hick:.  I sure as hell don't want to remove glass...

I also took care of those noisy rod end spacers on the control arms.
Title: Chuck's '83 TBird
Post by: thunderjet302 on July 27, 2009, 06:25:12 PM
How often do you drive this beast?
Title: Chuck's '83 TBird
Post by: Chuck W on July 27, 2009, 08:35:26 PM
Quote from: thunderjet302;284117
How often do you drive this beast?


Not often enough.

I just drove it today, but it had been sitting for a couple weeks before that.
The weather is supposed to be iffy the rest of the week, so I figured I'd better get it out.  My parking situation makes it kind of tedious to get out of the garage, so I need to plan for it so I'm not late for work if I want to drive it in the AM :p
Title: Chuck's '83 TBird
Post by: 86XR7project on July 28, 2009, 09:24:25 AM
Wow Chuck, thats really neat! I bet its real fun.
Title: Chuck's '83 TBird
Post by: 50tbrd88 on July 28, 2009, 07:00:42 PM
I'm just going to get right to the point.  Chuck, your car kicks ass.
Title: Chuck's '83 TBird
Post by: Chuck W on August 02, 2009, 10:26:41 PM
Well I made a little purchase on Fri for the back of the car...

THIS (http://www.steeda.com/products/5link_2rear.php)

I bought it used for a good price (MUCH less than listed here).

I'll need to tweak the P-Hard bar brace a bit and probably lengthen the upper links a bit, but those are no big deal.
Title: Chuck's '83 TBird
Post by: thunderjet302 on August 03, 2009, 09:26:26 PM
Quote from: Chuck W;284134
Not often enough.

I just drove it today, but it had been sitting for a couple weeks before that.
The weather is supposed to be iffy the rest of the week, so I figured I'd better get it out.  My parking situation makes it kind of tedious to get out of the garage, so I need to plan for it so I'm not late for work if I want to drive it in the AM :p



Sounds like you drive it about as much as I drive mine;)
Title: Chuck's '83 TBird
Post by: Chuck W on October 17, 2009, 04:52:09 PM
Well, trying to get a couple pics for the FEP calendar today.  Have had no time and the weather has been py too.

Haven't decided on what two to send off yet, but here are just a couple random ones...

(http://www.turbochuck.com/webimages/projects/83 TBird/10_17_09_1.jpg)

(http://www.turbochuck.com/webimages/projects/83 TBird/10_17_09_2.jpg)
Title: Chuck's '83 TBird
Post by: gumby on October 17, 2009, 05:14:13 PM
you went to speedrome??!!?!?!?? man, the guys i work with now race there all the time!
car is lookin good. makes me jealous....mine is on stands in the garage again.

i didnt even see where you posted about the 5link. any progress on that?
Title: Chuck's '83 TBird
Post by: Chuck W on October 17, 2009, 05:31:48 PM
Well I just used it as a back drop ;)  It's 5-10 minutes from the house.

Not much progress on the 5-link.  Too much time being spent on the new motor mount project. (That, and working 2 jobs...)
Title: Chuck's '83 TBird
Post by: daminc on October 17, 2009, 07:49:41 PM
I like the wheels Chuck. ;)
Title: Chuck's '83 TBird
Post by: jrad235 on October 17, 2009, 10:30:27 PM
Did you lower that car? Or is it just the monster rims filling up the wheel wells?
Title: Chuck's '83 TBird
Post by: Blck85TBirdV8 on October 17, 2009, 11:46:28 PM
That car would look sweet with the moldings painted body color.
Title: Chuck's '83 TBird
Post by: 50tbrd88 on October 18, 2009, 08:36:27 AM
Car is lookin' good as always Chuck!
Title: Chuck's '83 TBird
Post by: Chuck W on October 18, 2009, 10:37:56 AM
Quote from: Blck85TBirdV8;295289
That car would look sweet with the moldings painted body color.


No, it wouldn't ;)
Title: Chuck's '83 TBird
Post by: V8Demon on October 18, 2009, 10:41:52 AM
2nd picture works better ;)
Title: Chuck's '83 TBird
Post by: Ether947 on October 18, 2009, 11:29:14 AM
Quote from: V8Demon;295331
2nd picture works better ;)

X2 - I forgot how good these four-eyed cars look. Nice backdrop. :D
Title: Chuck's '83 TBird
Post by: Chuck W on October 18, 2009, 04:59:12 PM
Quote from: V8Demon;295331
2nd picture works better ;)


New camera, and I was in a rush :)
Title: Chuck's '83 TBird
Post by: Chuck W on October 18, 2009, 05:05:49 PM
A couple more...

(http://www.turbochuck.com/webimages/projects/83 TBird/10_17_09_3.jpg)

(http://www.turbochuck.com/webimages/projects/83 TBird/10_17_09_4.jpg)
Title: Chuck's '83 TBird
Post by: xjeffs on October 19, 2009, 01:47:25 AM
Great lookin' car, Chuck
Title: Chuck's '83 TBird
Post by: BCA on October 19, 2009, 09:38:53 AM
My vote would be for the last one, just because it screams Four-Eye. The only exception might be if you have another shot from that position except moved over just as bit to the right so that you can see the turbo decal and the NACA scoop a little more clearly, that would look even better.

Brent
Title: Chuck's '83 TBird
Post by: V8Demon on October 19, 2009, 10:02:31 AM
Quote
My vote would be for the last one

Agreed.  Great composition!
Title: Chuck's '83 TBird
Post by: 50tbrd88 on October 19, 2009, 07:46:08 PM
I agree the last pic is the best.  Gotta show off the Marchals!!  They are like the crowning touch of your car.
Title: Chuck's '83 TBird
Post by: rodsterh on October 28, 2009, 10:59:24 AM
Sweeeeet! :bowdown:

 Imagine driving down the road and seeing Chuck's car passing you going the other way.:eek:
Title: Chuck's '83 TBird
Post by: Clayton on November 01, 2009, 12:04:09 AM
i live in indy now. i wish i could see it run past me haha
Title: Chuck's '83 TBird
Post by: Chuck W on August 21, 2010, 08:33:42 PM
OK, this poor thing hasn't had much attention the past few months.  It is out and getting driven a bit more, but I haven't turned a wrench on it in a while.

Last time I drove it, the headliner that I'd redone 10 or so years ago, had come pretty loose, and would flap in the wind.  One of my MAJOR peeves.

So, I pulled the headliner and grabbed the material out of the attic I've had for months. 

Went from this...
(http://www.turbochuck.com/webimages/projects/83 TBird/HLbef.jpg)

to this...
(http://www.turbochuck.com/webimages/projects/83 TBird/HLaft.jpg)

The color is actually a better match than the pics show, but that's kind of the case with interiors with all the different materials.

It wasn't too bad getting it in and out with the cage.

Now I really need to get to the many "mechanical" projects that are waiting...
Title: Chuck's '83 TBird
Post by: daminc on August 21, 2010, 08:49:35 PM
Very nice. Is your cage painted or P coated?
Title: Chuck's '83 TBird
Post by: 88turbo on August 21, 2010, 09:05:40 PM
what seats are you using? those dont look like the ones in my 83...
Title: Chuck's '83 TBird
Post by: gumby on August 21, 2010, 09:47:16 PM
Quote from: Chuck W;332928

It wasn't too bad getting it in and out with the cage.

this was my concern. my headliner is in about the same state of sagginess as your before pic, and its driving my crazy.
Quote from: Chuck W;332928

Now I really need to get to the many "mechanical" projects that are waiting...

injectors? intercooler??


when are we gonna put these cars together for some pics?
Title: Chuck's '83 TBird
Post by: Chuck W on August 21, 2010, 10:02:34 PM
Jerry, it's painted.  It was welded to the car when it needed color ;)

The seats are Recaros out of a VW Jetta GLi.

Gumby, yup...those are on the list...as well as the rear suspension.
We just need to figure out a time to do the pics ;)
Title: Chuck's '83 TBird
Post by: gumby on August 21, 2010, 10:07:19 PM
Quote from: Chuck W;332937
as well as the rear suspension.


oh fun! i hadnt heard any updates on that recently
Title: Chuck's '83 TBird
Post by: Chuck W on September 28, 2010, 07:37:45 PM
So, 2 steps forward, 1 step back.

I took some time this evening to finally swap in the larger injectors (75# vs stock 35#).  Made sure the old py laptop was working so I could change the constants in the MegaSquirt, and had at it.

Was tightening down the last bolt on the fuel rail...and busted the boss on the lower intake.  It's rigged in there at the moment, and prob will never go anywhere in the time it will still be in there, but I probably should fix it.  Just not a drop in deal though, as I've modded the lower a bit.

*sigh*
Title: Chuck's '83 TBird
Post by: gumby on September 28, 2010, 08:08:25 PM
pics of the broken boss? is it sumthin i could weld back together for ya?
Title: Chuck's '83 TBird
Post by: Chuck W on September 28, 2010, 08:55:19 PM
Quote from: gumby;337078
pics of the broken boss? is it sumthin i could weld back together for ya?


It's the front boss on the inline intake.  My new welder has a mini-spool gun, so I could weld it up myself I'm sure.  Just need to pull things apart to do it.
Title: Chuck's '83 TBird
Post by: Chuck W on April 24, 2011, 05:23:39 PM
Well, the weather still hasn't decided to behave long enough here, but a couple things have been getting done on the car.

First, I fixed the aforementioned broken fuel rail boss on the intake.  Hooked up the mini-spool to my new welder and built things up, and drilled and tapped a new hole.  That problem solved.

Now yesterday, I was feeling froggy and decided to do this to the car...

(http://www.turbochuck.com/webimages/projects/83 TBird/TB_IC_2.jpg)
(http://www.turbochuck.com/webimages/projects/83 TBird/TB_IC_1.jpg)

Because I was finally getting around to doing this...

(http://www.turbochuck.com/webimages/projects/83 TBird/TB_IC_3.jpg)

You really can't see the bottom of it, because it's obscured by the bumper and oil cooler, but the inlet/outlet are bottom-mounted.

(http://www.turbochuck.com/webimages/projects/83 TBird/TB_IC_4.jpg)
This pic shows how close it is to fitting between the headlight buckets in the header panel.  Somehow I eyeballed the centering placement on it, and there is basically a paper's thickness of room between the IC and the header panel.  I'll probably knock the header panel down a touch when I get ready to remount it again.

Now it's a matter of plumbing things.  I need a bunch of 2-1/2" tubing, and perhaps a couple more couplers.  I have a bunch silicone couplers, 45's and 90's I got cheap a while back, and now will put them to good use.

Being the contrary S.O.B. that I am, I'm not running a rotated intake, so there may be a long run of IC tubing, but it really won't matter when it's all said and done.

Anyway, racing the rain and  weather around here this weekend, so the new mounting brackets are all I got done, but now it means I actually need to finish things so I can drive the car again. :hick:
Title: Chuck's '83 TBird
Post by: vinnietbird on April 24, 2011, 05:42:13 PM
Nice work. Any progress is still progress. As you know, you have to take where you can get it. The weather sucks here, and when it was decent, I had so much other  to do the Sport was left alone. Not cool.
Title: Chuck's '83 TBird
Post by: gumby on April 24, 2011, 06:40:44 PM
Well well, its about  time!
Dodging the rain was quite a task this weekend for sure. Good to see some work on the 83 again.
Title: Chuck's '83 TBird
Post by: Chuck W on April 28, 2011, 10:45:25 AM
Well, I have a pile of 2-1/2" bends and tubing on the way, so after I fix the g/f's Lancer, I'll be making IC tubing.
Title: Chuck's '83 TBird
Post by: Chuck W on May 10, 2011, 09:08:47 PM
Well, I finally had some spare time to work on this.  Got the whole concept scoped out, and just need a couple more bits to be able to do all the finish cuts, etc.

(http://www.turbochuck.com/webimages/projects/83 TBird/TB_IC_5.jpg)

I'll get more pics when I get back to messing with it.
Title: Chuck's '83 TBird
Post by: gumby on May 10, 2011, 10:03:33 PM
You gonna run the compressor outlet over the v/c, or clock the housing and run the pipe low?

Your air filter location ROCKS! same as mine :bowdown:
Title: Chuck's '83 TBird
Post by: Chuck W on May 10, 2011, 11:42:24 PM
Actually the best way it looks to me is to run a silicone "U" off the turbo as it sits.  I looked at clocking it, but it didn't make me happy.

On the driver side, there is a "U" bend that comes out of the intercooler and wraps around the core support, and runs right on top of the lower rad hose brace. It will run low behind the rad, and then shoot up to meet that silicone "U".
Title: Chuck's '83 TBird
Post by: Trinom on May 12, 2011, 04:49:34 PM
Didn't you think about water - air IC? I think it's better for our cars, because you don't have to cut any hole for pipes. There are only relatively thin hoses.
Title: Chuck's '83 TBird
Post by: Chuck W on May 12, 2011, 11:51:14 PM
Quote from: Trinom;359786
Didn't you think about water - air IC? I think it's better for our cars, because you don't have to cut any hole for pipes. There are only relatively thin hoses.

Nope, I didn't have to cut any holes for this.  The addition of a pump, a water tank, etc outweigh any "advantages" over an air-to-air IC for a street car.
Title: Chuck's '83 TBird
Post by: thunderjet302 on May 14, 2011, 05:25:51 PM
Looks cool.

Any idea how much power it will add?
Title: Chuck's '83 TBird
Post by: Chuck W on May 15, 2011, 10:58:14 AM
Don't really know, and not too concerned.  I'll finally be able to work on nailing down my tune better, though.
Title: Chuck's '83 TBird
Post by: Chuck W on June 08, 2011, 11:41:22 PM
Ok, got the final mock-up of the IC tubing done this past weekend.  Had to wait for a couple pieces to show up (they sent me some wrong stuff).

(http://www.turbochuck.com/webimages/projects/83 TBird/TB_IC_6.jpg)
(http://www.turbochuck.com/webimages/projects/83 TBird/TB_IC_7.jpg)

The parts are now off at the powdercoater (for silver) and when I get them back, I'll be able to button this all back up and get the car on the road again.


Other thoughts I was thinking...

I was contemplating removing the existing under-the-floor SFCs I have on the car (from back in '97-98), and using that material I had for the '80 XR-7 to do through-the-floor SFC's.  With the cage and the SFC's and other reinforcements, the car is very stiff as it is.  This would clean things up a bit though, and make things look better overall...as well as make it even more rigid. :hick:
Title: Chuck's '83 TBird
Post by: Chuck W on June 08, 2011, 11:47:58 PM
I added the BOV mount after I mocked things up (and after I took pics).
Title: Chuck's '83 TBird
Post by: 1Bad88tbird on June 09, 2011, 08:36:18 AM
Looks great Chuck. Are you planning on going racing? I'm sure it handles the curves well.
Title: Chuck's '83 TBird
Post by: Chuck W on June 09, 2011, 09:44:47 AM
Probably not much racing.  I'd build a car specific for that if I was going to. I wouldn't mind some HPDE stuff, but I'm more just building a car that I want.  The rear susp and diff need some attention anyway, before I would do anything serious.
Title: Chuck's '83 TBird
Post by: 347Thunder on June 09, 2011, 12:57:44 PM
Quote from: Chuck W;361280
Probably not much racing.  I'd build a car specific for that if I was going to. I wouldn't mind some HPDE stuff, but I'm more just building a car that I want.  The rear susp and diff need some attention anyway, before I would do anything serious.

 
What is the cage for then?? lol Where in the heck did you get those awesome fans, they would give me a lot more room.
Title: Chuck's '83 TBird
Post by: Chuck W on June 09, 2011, 01:15:15 PM
Quote from: 347Thunder;361286
Where in the heck did you get those awesome fans, they would give me a lot more room.

The fan set-up is Derale.
Title: Chuck's '83 TBird
Post by: 347Thunder on June 09, 2011, 05:00:32 PM
very reasonably priced, but the 50amp draw would kill me, my ford contour fans draw 40amps and that hurts my 180 amp powermaster, might have to get the 200amp one.lol God I don't think my car will ever be done.lol
Title: Chuck's '83 TBird
Post by: Chuck W on June 09, 2011, 05:55:53 PM
50A?  It's closer to 25-30A  I only have a 30A fuse in the power wire to it.  I'm only running a 130A 3G alt.

EDIT:  I just looked.  It's the 16812 unit.  I only have a 20A fuse in the power wire.  They don't move massive amounts of air, but they do more than well enough to cool the 2.3T.
Title: Chuck's '83 TBird
Post by: mcb82gt on June 09, 2011, 06:23:55 PM
Quote from: Chuck W;361293
they do more than well enough to cool the 2.3T.

 
Ive very seldom seen a stock fan turn on with the 2.3T engine.  They must cool themselves well or not make much heat??
Title: Chuck's '83 TBird
Post by: Chuck W on June 09, 2011, 08:42:45 PM
Quote from: mcb82gt;361295
Ive very seldom seen a stock fan turn on with the 2.3T engine.  They must cool themselves well or not make much heat??

Well, the stock fan switch is set to about 230*F (or way too ed high).  On mine, the MS controls the fans, and kicks them on at 200* and off at 180*.
Title: Chuck's '83 TBird
Post by: Glocklimited9 on June 21, 2011, 09:32:00 PM
Ive seen this car for years, always been one of my favorite
Title: Chuck's '83 TBird
Post by: Chuck W on June 23, 2011, 11:12:14 PM
Well, I got the intercooler all installed.
(http://www.turbochuck.com/webimages/projects/83 TBird/TB_IC_8.jpg)
(http://www.turbochuck.com/webimages/projects/83 TBird/TB_IC_9.jpg)

I stuck the battery back in it, and fired it up.

Now to bolt the nose back on and fiddle with the tune a bit.
Title: Chuck's '83 TBird
Post by: 50tbrd88 on June 24, 2011, 09:36:04 PM
Everything is looking good as always Chuck.
Title: Chuck's '83 TBird
Post by: Chuck W on June 25, 2011, 04:18:32 PM
Back together and back on the road.  Only a short drive so far, revealing the BOV had transitioned from a quick "PSSSHHHTT!" to a more obnoxious, and amusing flutter.

More when I'm able to get it out and flex it a bit.
Title: Chuck's '83 TBird
Post by: thunderjet302 on June 25, 2011, 07:28:10 PM
I don't think I caught it but how much boost are you pushing?
Title: Chuck's '83 TBird
Post by: DVP on July 08, 2011, 10:31:07 PM
Chuck, what size tires are you running? Ive always loved the stance of your car. C springs IIRC? Wonder how they would sit with 302/351...
Title: Chuck's '83 TBird
Post by: Chuck W on July 08, 2011, 11:25:56 PM
Quote from: DVP;363063
Chuck, what size tires are you running? Ive always loved the stance of your car. C springs IIRC? Wonder how they would sit with 302/351...

245/45 front, 255/45 rear.  Still C Kits in the front.  Haven't gotten around to doing the whole coil-over thing yet.

As far as stance goes, it was the same when the car was a 302/AOD, and the two other's I've lowered this way have been the same.  You might need a 1/8"-1/4"  of spacer on the front springs with the heavier combo, but you can never really tell until it's all on the ground.  I might have some old ride height measurements in one of the log books, but we're talking about 15 years worth of notes.
Title: Chuck's '83 TBird
Post by: daminc on July 08, 2011, 11:41:42 PM
chuck, how do you keep the front wheels from rubbing when you turn  the wheel all the way?
Title: Chuck's '83 TBird
Post by: Chuck W on July 09, 2011, 08:58:55 AM
Quote from: daminc;363067
chuck, how do you keep the front wheels from rubbing when you turn  the wheel all the way?

I don't. :hick: 

Honestly, I don't remember the last time I had it at full lock one way or the other.  There are no limiters on it, and it may rub a bit, but it's such a rare occasion, that I'm not really concerned.
Title: Chuck's '83 TBird
Post by: daminc on July 09, 2011, 09:04:19 AM
Quote from: Chuck W;363083
I don't. :hick: 

Honestly, I don't remember the last time I had it at full lock one way or the other.  There are no limiters on it, and it may rub a bit, but it's such a rare occasion, that I'm not really concerned.

 LOL....Ok, It only happens to me when I forget about it.
Title: Chuck's '83 TBird
Post by: DVP on July 09, 2011, 01:47:45 PM
Awesome. All good news. I don't really like the mystery springs I have on there now. Need to see if I can find a pair. Good to know I can run a taller tire on the front.

Quote from: Chuck W;363066
245/45 front, 255/45 rear.  Still C Kits in the front.  Haven't gotten around to doing the whole coil-over thing yet.

As far as stance goes, it was the same when the car was a 302/AOD, and the two other's I've lowered this way have been the same.  You might need a 1/8"-1/4"  of spacer on the front springs with the heavier combo, but you can never really tell until it's all on the ground.  I might have some old ride height measurements in one of the log books, but we're talking about 15 years worth of notes.
Title: Chuck's '83 TBird
Post by: Chuck W on August 03, 2011, 10:12:17 AM
OK, well the webhost is sorted and I'm working on getting pics uploaded again and links fixed.  Organizing things better this time so I don't have the same issues again.
Title: Chuck's '83 TBird
Post by: rodsterh on August 14, 2011, 10:58:47 AM
Quote from: glocklimited9;361941
ive seen this car for years, always been one of my favorite


+1  :)
Title: Chuck's '83 TBird
Post by: flylear45 on August 15, 2011, 07:40:56 AM
Looking good, Chuck.  How's she running?
Title: Chuck's '83 TBird
Post by: Chuck W on August 15, 2011, 08:31:20 AM
Quote from: flylear45;365169
Looking good, Chuck.  How's she running?

Not too bad.  Been driving it once a week or so, depending on the weather.  I still have yet to get the time to take it out for some revised tuning after the injector and IC install.  It grunts down low (boost starts to come on at about 1800rpm), but it runs out of steam up top.  I've got a new laptop, and once I get a new USB-serial cable, I'm going to let the Tunerstudio auto tune have at it a bit.
Title: Chuck's '83 TBird
Post by: flylear45 on August 15, 2011, 04:24:28 PM
Quote from: Chuck W;365174
Not too bad.  Been driving it once a week or so, depending on the weather.  I still have yet to get the time to take it out for some revised tuning after the injector and IC install.  It grunts down low (boost starts to come on at about 1800rpm), but it runs out of steam up top.  I've got a new laptop, and once I get a new USB-serial cable, I'm going to let the Tunerstudio auto tune have at it a bit.

 

I have been over riding TS autotune under 1300 and in boost. It's paranoid I know, but I think I do a better job in those areas of the curve.

IMHO,  I think anything over (richer than)  12.5 -1 under boost is gonna fall on it's face at higher R's.  Just sayin'. That's the way my TR7 acts. I was too rich at first and was killing the acceleration. A dyno session got me revving the way I should.
Title: Chuck's '83 TBird
Post by: Chuck W on August 16, 2011, 07:19:18 AM
Yeah, I'm thinking it's a bit rich. Not too rich to blow nasty smoke, but rich enough to kill the power.
Title: Chuck's '83 TBird
Post by: EFFalcon on October 16, 2011, 07:23:12 PM
really love the look of this, gives me a few ideas for mine.

I was really surprised to see you were considering an I6 conversion originally! :P
Title: Chuck's '83 TBird
Post by: Chuck W on October 16, 2011, 07:45:02 PM
Quote from: EFFalcon;370291

I was really surprised to see you were considering an I6 conversion originally! :P

The stuff for that conversion is still in the garage, as is another option.  :p
Title: Chuck's '83 TBird
Post by: Chuck W on January 19, 2015, 12:48:29 PM
Dragging this thing out of the past. Loooong time since last posting here. Not even sure where the time goes.

I've been a bad owner, and other than a few drives last season, this old beast hasn't seen much of my attention as of late. Time for that to change!

There are a couple projects that I just haven't addressed, either due to not enough time, not enough money, or just not enough motivation. More of the later, really.

Short list of smaller projects include:

- Rear suspension upgrades, including panhard bar and revised 4-link set-up.
- 8.8 rear with 3.55's
- Coil-overs on the front and perhaps (well, most likely) some different strut mounts.

I've had this old Steeda 5-link stuff for ages.  Time to get it modded/beefed and in place. I've never been happy with the 3.73's I installed in the 7.5, and they've seen better days anyway. I've been wanting to do coil-overs up front for a while now. My Koni's aren't "ideal", but I'm also not planning on going bonkers on spring rates. The strut mounts I made over 15 years ago are probably well past their prime. They were cheap to build, and served their purpose, but they won't work for what I want to do.

The big project is an engine swap. The 2.3T is fine, but it's starting to lose it's appeal to me. Mainly because I've had several cars with them.

I have 2 choices in my garage, and I'm trying to figure out what direction I want to go.

A. SHO V6
B. 200 ci US I6 block with Aussie XF AL EFI head.


Both have the appeal of being "relatively" different, and both would have some sort of turbo attached to them in the end. Option A has the appeal of just being plain shagy. Opening the hood and being able to showcase one of the best-looking engines (IMO) would be sweet. The downside is some serious work is needed to get it into the car. Option B is still unique, and would be cool in its own right. More work needed on the engine itself, mating the head to the block, but it would require very little work to get it into the car.

Seeing as Option A would require more downtime of the car, just to get things together, Option B is slowly winning out. The SHO motor is going to need serious oil pan and K-member work. Even a tubular K-member is probably not going to help things just slide right in. Again, not a huge deal, but means the car is down for a LONG time, while I work out fitment. The option here would be to find a front clip off of a TBird/Cougar and put it on a rolling frame and do mock-ups in the garage. Still kind of tedious.

Anyway, going to get the car situated and get to messing with the rear susp stuff and try and hunt down a 3.55 8.8. That is stuff that's going to be done, regardless of what engine winds up in the bay.
Title: Chuck's '83 TBird
Post by: Aerocoupe on January 19, 2015, 01:15:38 PM
When you get the Steeda 5-link installed I would love to see some pics.

Darren
Title: Chuck's '83 TBird
Post by: thunderjet302 on January 19, 2015, 10:24:51 PM
While the SHO V6 is cool that turbo I6 sounds like it would be cool. A turbo Aussie I6 can make some wicked power.

Why are you considering going from 3.73s to 3.55s? I would think the difference wouldn't be that great between the two.
Title: Chuck's '83 TBird
Post by: Chuck W on January 19, 2015, 10:47:31 PM
Well, it wouldn't be a "full" Aussie I6 (Getting a Barra 4.0 turbo would be hot, though). Still looking into the sum of parts needed to mate the head and block together and make it turbo-ready.

The 3.55's are primarily to stretch the legs a bit. I've never been really happy with the 3.73's. Not much of a change, I know. However, since I'm pulling out what's there, it's a chance to make the change.
Title: Chuck's '83 TBird
Post by: Beau on January 19, 2015, 11:53:08 PM
Chuck, I've the TC 8.8 with the drums I had in my Sport...it's 5 lug, as well as having your 3.55 R&P ratio.

I'm a good little bit from Indy though, but if you were interested and felt up for a drive, we could meet halfway, or however..

Just a thought.. ;)
Title: Chuck's '83 TBird
Post by: Chuck W on January 20, 2015, 10:49:03 AM
Quote from: ThunderbirdSport302;443169
Chuck, I've the TC 8.8 with the drums I had in my Sport...it's 5 lug, as well as having your 3.55 R&P ratio.

I'm a good little bit from Indy though, but if you were interested and felt up for a drive, we could meet halfway, or however..

Just a thought.. ;)

Hrmmm...
Title: Chuck's '83 TBird
Post by: thunderjet302 on January 20, 2015, 03:24:45 PM
Too bad a 300 I6 won't fit. A little heavy but man that would be cool and fun, if turbocharged.
Title: Chuck's '83 TBird
Post by: Thunder Chicken on January 20, 2015, 05:13:07 PM
A 300 will fit. When I was in high school a friend had a '79 Mustang with a 300 swapped in. He used to say his six was only one cubic inch smaller than my V8 (1980 Firebird, 301 V8), therefore it was just as fast. Truthfully, both cars were embarrassingly slow.  The engine was in there, though - it was a backyard swap job, looking like somebody just dumped it out of a front end loader and welded it wherever it landed, but it was in there. He lost that car when he was pulled over for a safety check. It was in really bad shape and was impounded, and he never went back for it.

One engine that has recently gotten my attention is the new 2.7 Ecoboost. That engine would be sweet in a Fox. Of course it's still way too new to be found in junkyards, but it'd be cool...
Title: Chuck's '83 TBird
Post by: Aerocoupe on January 20, 2015, 06:31:37 PM
The early fox Mustangs (79-83 IIRC) came with a factory 200 inch six cylinder in which the K-member was specific to that motor.  If I remember correctly they got the K-member out of the Fairmonts or Granda but I am not 100% sure on that.  Getting a 300 inch six in one and it look good would be a challenge as it is longer, taller, and has the weight of a 302.

Darren
Title: Chuck's '83 TBird
Post by: Chuck W on January 20, 2015, 09:48:55 PM
Yeah...no BB I6 is even on the table. The shortblock I have is a late (83-84) 200ci I6 with the low-mount starter. Basically the lower 2/3's of a SBF bellhousing pattern.

With the AL head, I don't think the weight is going to be more than the 2.3T, even with the extra 2 cylinders.

Looking into pistons/rods/cam stuff at the moment.

'79 Mustangs had the 2.8 V6. The I6 didn't come until '80.
Title: Chuck's '83 TBird
Post by: Beau on January 20, 2015, 10:55:17 PM
Many moons ago, there was a 300/six thread here (technically the EZ board) about what it would require to put a 300" into a Fox. Lots of speculation, I think one thing everyone could agree is that no way in hell a stock hood would cover it.
Title: Chuck's '83 TBird
Post by: gumby on January 20, 2015, 11:39:55 PM
Yay!
Title: Chuck's '83 TBird
Post by: Chuck W on January 25, 2015, 08:23:45 PM
OK, well I had some time to mess with things over the weekend.  Not much, but at least something.

I got the engine drug out.
If only it was as easy as just dropping the head on...
(http://www.turbochuck.com/webimages/projects/83%20TBird/Xflow/AUSssie_1.jpg)
(http://www.turbochuck.com/webimages/projects/83%20TBird/Xflow/AUSssie_2.jpg)

Going to work on getting things torn down while I scope out internal options.

I also messed with test-fitting the panhard bar frame mount. Yeah....Going to have to completely rework the tailpipe. With the revised upper arm location, I should be able to keep a full 3" pipe on there, but it's going to take some work. Gotta remove the tailpipe and mod up the bracket and then go from there.
Title: Chuck's '83 TBird
Post by: Chuck W on December 27, 2018, 05:41:14 PM
(https://turbochuckcom.ipage.com/webimages/Misc/threadnecro.jpg)

THREAD NECRO!!!

I'm embarrassed to even note that it's been almost 4 years since I last posted in this thread. :toilet:

No excuses, other than just "life". I've had some other sizable car and house projects to deal with this year, but I am happy to say that work is FINALLY getting done on this thing.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2018/88_teardown_1.jpg)

Started tearing down the 8.8 to get it cleaned up and ready to put under the car. Along with that will be the install of the 4-link and P-hard bar set-up. This will also require some fiddling with the exhaust after the ler. There is a SLIM chance that I might try and put coil-overs on the rear of this thing, just because it might be easier to deal with in regards to spring rates, etc for a non-stock set-up. Need to look into that, just to see if it's worth it or not.

I also have a headlight upgrade to get installed and I need to at least get the WBO2 installed in the car to finally dial in the tune a bit better on this 2.3T. Engine swaps for this will have to wait, as my project list on the other vehicles is kinda long, but most of those will have to wait for warmer weather, as this is the only car that gets a warm, dry place to sleep currently.  Time is limited, but this thing is on the bench and in my way now. :hick:
Title: Chuck's '83 TBird
Post by: gumby on December 28, 2018, 10:54:32 PM
Quote from: gumby;443232
Yay!

again
Title: Chuck's '83 TBird
Post by: Chuck W on December 29, 2018, 08:40:40 AM
Quote from: gumby;468327
again

I know, right? ;)

Been getting a parts list together for the rear refresh. Gonna stay with the Trac-Loc diff in there, but I know there are a couple tricks that can be done to it.

What are your thoughts on switching to coil-overs in the back of this thing?
Title: Chuck's '83 TBird
Post by: gumby on December 29, 2018, 04:47:49 PM
Quote from: Chuck W;468329
Gonna stay with the Trac-Loc diff in there, but I know there are a couple tricks that can be done to it.
I am a T/L fan. Use the modified stack arrangement and toss in the heavy S-spring. Shim the side gears to preference. I like ~70ftlbs of breakaway torque. Over 100 scrubs the inside tire on the street and feels like a locker at autoX, under 40 starts to spin up the inside tire. I haven't found a justification for the extra cost of CF frictions.

Quote from: Chuck W;468329
What are your thoughts on switching to coil-overs in the back of this thing?
If the lowers in your kit have perches, MM sells MANY different rates of stock location coils. Give them a call, let them know your current front rates, and they should be able to recommend a good spring for the back. Coil-overs are great tools for versatility, but again I find it difficult to justify the extra $$$ in most street applications.

https://www.maximummotorsports.com/Torque-Arm-Springs-C345.aspx

*edit: looked up the kit, stock lowers get re-used.
Title: Chuck's '83 TBird
Post by: Chuck W on December 29, 2018, 07:23:12 PM
Good info on the TL. Still getting everything apart and getting a list together of the parts to buy. Working on getting the housing stripped down so it's slightly easier to maneuver around under the car to get things laid out.

Quote from: gumby;468330
If the lowers in your kit have perches, MM sells MANY different rates of stock location coils. Give them a call, let them know your current front rates, and they should be able to recommend a good spring for the back. Coil-overs are great tools for versatility, but again I find it difficult to justify the extra $$$ in most street applications.

*edit: looked up the kit, stock lowers get re-used.

Yeah, I can reuse my existing lowers, if I want. I may build some new upper links, though. I don't really like what's in the kit (Which needs to be replaced or rehabbed anyway).

I may just wait on screwing with spring rates (and sway bars) until after the car is on the road again. My front suspension set-up isn't stock, and I may need softer out back anyway, when it's all said and done.
Another question I ask myself, is do I keep the old "TracKit" RLCA mount location on the rear axle, or put it back to the stock location? The TK, coupled with my front suspension geometry means I have very minimal dive under braking.



Spent some time in demo mode this afternoon on one side of the housing, getting rid of all of the extra .

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/88_rebuild/extrashiznit.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/88_rebuild/removed_1.jpg)

Once I get the stuff cleaned off, I'm going to get it under the car and get the additional stuff in place, before getting everything cleaned up to coat.

Good thing I'm not going to need these...Just going to pop them out and toss them.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/88_rebuild/bushing.jpg)
Title: Chuck's '83 TBird
Post by: CougarSE on December 31, 2018, 08:11:43 AM
Awesome!  All these updates make me giddy!
Title: Chuck's '83 TBird
Post by: Chuck W on January 05, 2019, 09:26:29 PM
All the bearings, seals, bushings, extra brackets, etc are removed from the housing.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/88_rebuild/stripped88.jpg)

Gotta clean a couple spots up to get the upper arm brackets in place, and then this is ready to get under the car for mock-up.

Gotta pull the 7.5 and a couple other things and then get this in place.

Then it's finish the modification to the p-hard chassis mount and see what needs to be done to make the tailpipe fit.

After that, it's pull it all back out to get cleaned up and coated and the axle rebuild done.
Title: Chuck's '83 TBird
Post by: CougarSE on January 06, 2019, 09:57:55 PM
Interesting, will be fun to watch this.  Hows that I6 coming along?
Title: Chuck's '83 TBird
Post by: Chuck W on January 06, 2019, 10:23:49 PM
Quote from: CougarSE;468444
Interesting, will be fun to watch this.  Hows that I6 coming along?

It's sitting in the corner. WAAAAYY down on the to-do list.
Title: Chuck's '83 TBird
Post by: Chuck W on January 12, 2019, 08:27:11 PM
Plugging along.

Got the 7.5 out of the car and stripped down (some parts are finding new homes, and the housing is going to s)

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/88_rebuild/75out.jpg)

Need to pull the upper arms and put them on the shelf, as they're not going back in the car.

The 8.8 is prepped to get up under the car and begin mocking up the chassis-side panhard bracket bits that need finished.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/88_rebuild/mockupready.jpg)

I'd like to use a nice AL diff cover, but I don't think the panhard bar will clear it. Guess I'll see. Worst case, I'll just get a new one, as this one is super crusty.
Title: Chuck's '83 TBird
Post by: gumby on January 12, 2019, 08:58:51 PM
Hey, those shocks look familiar!
Title: Chuck's '83 TBird
Post by: Chuck W on January 12, 2019, 09:33:20 PM
Quote from: gumby;468498
Hey, those shocks look familiar!

Just standard Koni reds, in proper TBird length. :hick:
Title: Chuck's '83 TBird
Post by: gumby on January 12, 2019, 09:35:19 PM
Would be neat to know the valving differences between your old Tbird Reds, and the Mustang STR.T's like I bought.
Title: Chuck's '83 TBird
Post by: Chuck W on January 13, 2019, 04:08:26 PM
OK, the 8.8 is under the car to begin the investigation of what needs to be done to make this fit.

Driver side looks OK. (Sorry about the lighting. hard to get enough light under the car and not have a shadow from EVERYTHING else)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/5linkds_mock_1.jpg)

Got it raised up to the proper height, but still need to fiddle with the pinion angle. Looking at the pass side.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/5linkps_mock_1.jpg)

Umm.... Look closer

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/5linkps_mock_3.jpg)

Yeah, the pass side upper link bracket is going to foul on the fuel tank mounting bulkhead on that side, if I rotate the housing any more.

The panhard axle mount should clear the tank, however. (I REALLY don't want to put a fuel cell in this thing...) It will be close, though.

I should be able to mod that mounting bulkhead and gain 1-2" of clearance, without much trouble. IIRC, it was also in the way of the panhard bar chassis mount lateral brace tube.


Yuck.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/upperlink.jpg)

I really don't like these upper links. I want to make an adjustable set, which wouldn't be hard to do, but that 30* angle on the leading bearing (These mount to existing RUCA mount locations) is more than I'm going to be able to get with just a rod end or spherical bearing.  Then again, I don't NEED to use the stock upper mounts on the chassis.
Title: Chuck's '83 TBird
Post by: thunderjet302 on January 14, 2019, 03:12:52 PM
I've not seen that panhard setup for a Fox. Who made it?
Title: Chuck's '83 TBird
Post by: Chuck W on January 14, 2019, 09:10:52 PM
Quote from: thunderjet302;468510
I've not seen that panhard setup for a Fox. Who made it?

It's a Steeda 5-Link 2. The jist of it is un-splayed upper links and a panhard bar set-up that will allow for tail pipes (or "pipe", in my case).

Got back under the car for a short bit after work today.

First I rotated the differential to get it to what would be a close position for pinion angle. When I did that, that bracket was in full contact with that gas tank mount.

I then tried to stick one of the upper links in place, to see how things lined up. In doing so, it appeared that the upper arm was WAY too short. Then I looked more closely at the brackets and saw my mistake. While this is a 5-Link 2, I was setting some things up using instructions for a std 5-Link kit, and assumed some things were the same. Like the brackets. They're not.

Once I rotated the brackets to where they SHOULD be for this kit...
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/clearance_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/clearance_2.jpg)

I found at least an 1" worth of clearance between the upper bracket and tank mount.
I'll probably still need to remove some of it, as it's a toss-up on whether the axle will hit the bump stops, or the panhard bar bracket will smash into that mount. Not a huge deal, as it has no need to be that big.
It looks like there is enough clearance for the tank too, so that's a bonus.

Going back to the upper links.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/uplinkinst_1.jpg)

After re-positioning the axle brackets, the upper links still appeared to be too short. Then I remembered that I was working on a TBird and not a Mustang. :hick: Of course they're too short. The TBird uppers are over 1" longer than the Mustang ones (stock).
They're going to get reworked anyway, so longer isn't going to be an issue, but I still need to decide what I want to do about that front connection.

With things in place, I started to try and brain-storm about that lateral brace I need for the panhard chassis bracket. Things are pretty tight through there, and trying to hit the other frame rail might prove to be a little difficult.

Lying there under the car, I got to looking at the lateral brace I's welded in between the rear shock towers a while back, just because.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/crossbrace.jpg).

I think if I weld a mounting bracket it someplace, it would make a great spot to attach that lateral brace. It's 2"x1'x.120" wall rect tubing, welded to the framerails. Should be stout enough...
I just don't want to weld it all in. Just in case I need to get it out of the way for something.


Thinking on the upper arms, do I *really* need to keep the stock front mount locations at this point?

I could easily cut out the old stuff and weld in another cross brace and install 2 brackets that are in line with those on the rearend.
Then I could use something like THIS (https://steinjager.com/shop/index.php?route=product/product&product_id=21380)

That would save a lot of fussing with that odd front angle.

Anyway, just more plugging along.
Title: Chuck's '83 TBird
Post by: gumby on January 15, 2019, 07:56:04 AM
I like the thought of ditching the stock chassis side upper locations. They are proven failure points and they are complicating your install. I see no upside to keeping them. Cutting them out and adding a new lateral tube to hang new mounts will also allow you to incorporate multiple verticle locations for geometry adjustments. This may come in handy especially if you cut down the axle mounts.

As for the lateral brace, weld tabs to the chassis mount and as far to the opposite side of your shock mount rectangle tube as you can get a straight shot at. Then a simple link between the two locations.
https://www.speedwaymotors.com/shop/racing-swedged-tubes~65544-2-18167?suppressautocorrect=false
Easy and removable. You can even get gold anno!
Title: Chuck's '83 TBird
Post by: Chuck W on January 15, 2019, 08:27:13 AM
Yeah, ditching the stock upper chassis side brackets is winning over. I'm not sure if I'll need multiple locations, but I might add at least one. The axle brackets look to be good in their current location, and I think I have enough room above them for clearance on full jounce, so i shouldn't have to trim them down.

The removable lateral link sounds good, but I was thinking of making the whole chassis bracket removable, and welding a lateral support to it, with a removable attachment somewhere along that existing brace I have in there. Probably going to use some 1" x .120" wall square tubing for that piece, so it should be pretty stout.
Title: Chuck's '83 TBird
Post by: thunderjet302 on January 16, 2019, 02:08:20 PM
Quote from: Chuck W;468514
It's a Steeda 5-Link 2. The jist of it is un-splayed upper links and a panhard bar set-up that will allow for tail pipes (or "pipe", in my case).



Ah. I'd never seen one before. Any advantage to it vs. the Maximum Motorsports "ideal" rear suspension of lower control arms, panhard bar, and a torque arm?


/end thread derail
Title: Chuck's '83 TBird
Post by: Chuck W on January 16, 2019, 04:01:43 PM
Quote from: thunderjet302;468526
Ah. I'd never seen one before. Any advantage to it vs. the Maximum Motorsports "ideal" rear suspension of lower control arms, panhard bar, and a torque arm?


You could argue for either, really. Each has their pros/cons.

I paid like $250 for this kit, used, several years ago. Yeah, I need to modify it and it needs to be cleaned up, but seriously...$250. I'd have to modify almost anything to fit this car, so why cut up brand new stuff?

The only downside, for me, with the TA would be the loss of ground clearance. Either is going to do what I need/want for this car.
Title: Chuck's '83 TBird
Post by: thunderjet302 on January 16, 2019, 05:16:14 PM
It all comes down to money :D.

I get why you're going the route you are. Makes sense. I'm just trying to learn from what others have and see how it works for their car. Gives me some ideas for improving the rear suspension setup on mine (well above the Maximum Motorsports RLCA).
Title: Chuck's '83 TBird
Post by: Chuck W on January 16, 2019, 08:31:22 PM
OK, back under the car to measure a couple things and scope out that lateral brace.

I have this that I chopped off of the original cross brace
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/PSbracket.jpg)

Sorry for the pic quality. Hard to get a decent shot from under the car like this.

Now I have 2 options on the lateral brace for the panhard chassis bracket. I could go all the way over to the opposite frame rail, but there are a couple issues.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/longbar_1.jpg)

I can't get a clear shot straight at the rail. It hits the PS axle bracket, and is wedged up against that fuel tank mount.
If I want to use that original frame mount bracket, in its intended location, I'll need to chop out more of that tank mount to get it there (This was the primary issue with using the chassis  bracket as-is.)

Meh.

Option 2 (Not going to use that round AL bar, but the piece of square tubing was too long to try and deal with in this instance)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/shortbar_2.jpg)

If I hit a spot on that extra brace I welded i, just this side of the axle bracket, I won't need to cut any extra stuff out on that tank mount. Weld a couple tabs on either side of that frame brace, attach a bolt tube on the end of this lateral piece, and bolt it to those tabs. I would need a slight bend on the tube on the DS to get things lined up properly, but not all that much, really.

If there was a concern about flex in that extra frame brace, I could always weld a support up to the piece that's welded in between the shock towers :hick:
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Xbrace_2.JPG)

I'm kind of liking the shorter, Option 2.

Looking at the RUCA mount
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/RUCA_chassis.jpg)

Basically, my reference point is right in the middle there, of the stock bolt hole location. To line things up with the axle brackets, the inboard tab would need to be about where that exhaust hanger bracket turns up.

I could very easily make mounting tabs and weld them to the floor/frame. If I wanted to brace them frame-to-frame, I'd have to either cut through the floor, or run a smaller tube over the top of the diff/driveshaft hump, just to make sure I had clearance.


I also scoped out the needed length for the upper links (12.25-12.375") so I can get those sourced.
Title: Chuck's '83 TBird
Post by: Tbird232ci on January 17, 2019, 05:42:08 AM
Silly chassis engineers and fabricators.
Title: Chuck's '83 TBird
Post by: Chuck W on January 18, 2019, 09:09:48 PM
Got a little bit of time in the garage this evening. Got a bunch of  from both rear ends that isn't going to be used off of the workbench and got things cleaned up for the next round of work.

Got the DS of the chassis bracket adjusted so the panhard bar mount locations on each side of the car are in line with each other.

Then I chopped up some leftover motor mount bracketry to make the PS mount for the panhard chassis bracket.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/chassisbrkt.jpg)

This will be welded to that extra frame brace under the car, and the lateral brace tube will be welded to that bolt tube.

I'm going to have to make my own upper links, so I ordered some of the bits for that.

This weekend I'm going to try and get that lateral brace tube fabbed and tacked in place and lengthen one of the original links from the kit. I need something to hold the rear in the proper orientation, so I can run it through its full range of motion, to check for clearances, etc.

If I have enough time, I'm going to cut out the DS RUCA chassis mount, in preparation for building the new brackets there.
Title: Chuck's '83 TBird
Post by: CougarSE on January 19, 2019, 11:35:16 AM
I eagerly await your solution Chuck, just make it easy enough that I can duplicate it easily!
Title: Chuck's '83 TBird
Post by: Chuck W on January 19, 2019, 05:37:23 PM
Well, seeing that the weather is marginal around here today, I spent a couple hours in the garage making some headway.

I almost changed my mind about the lateral brace, and seriously thought about taking it over fully to the PS frame rail. I could get a straight shot, but would have to cut out some of the inner bulkhead on that tank mount.

In the end (and after bouncing ideas off Gumby), I went ahead with my plan of using the shorter route.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/PSmount.jpg)

I have this guy, and while not the best for doing a lot of serious bending, it gets the job done for things like this.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/tubebender.jpg)

In the end, I wound up with this.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/chassisbrkt_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/chassisbrkt_2.jpg)

Need to do all of the finish welding, and add a couple of small gussets at the bend.

The attachment on the DS is going to have one bolt through the frame and a bolt into this nut plate dropped into the frame from the trunk.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/framenut.jpg)

I lengthened one of the original upper links from the kit, so now I'll be able to run the suspension throughout its range to see where problems might be, before I get any farther along.
Title: Chuck's '83 TBird
Post by: Chuck W on January 20, 2019, 03:35:30 PM
Got back in the garage for a short bit to check some clearances.

With everything fully compressed, the panhard axle bracket doeshiznit the tank mount, pretty much right as the axle hits the bumpstop.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/fullcomp.jpg)

Shouldn't need too much clearancing. The upper link axle brackets are about 1/4"-3/8" from hitting that crossbar that the panhard chassis bracket is attached to, so I may trim off the top of those brackets, just for a little more breathing room.

The main reason I wanted to do this was to check on how much room I had above the diff/driveshaft.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/RUCAclearance_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/RUCAclearance_2.jpg)

I've got over 3" of room over the snout of the diff, so it looks like I have a reasonable amount of room to weld in that crossbar between the framerails, to allow me a good solid spot to attach my new RUCA chassis mounts. I'm thinking some 1.5" dia, 0.120" wall tubing should be sufficient. I can tuck it right up there where the seat belt mount points are and it looks like a slight bend on each end will take it down to the frame rails. That should also put me right behind where I need to attach the brackets for the RUCA mounts.

The next task is going to be the un-fun process of cutting out that DS RUCA mount, while lying on my back under the car...
Title: Chuck's '83 TBird
Post by: Chuck W on January 27, 2019, 09:48:57 PM
OK, well it was kind of a busy week, so I had limited time in the garage until the weekend.

I did get the panhard chassis bracket all welded up, so that is ready for finishing.

Today I tackled the big PITA of removing the stock DS RUCA bracket. I really wish I had a plasma cutter.

Kinda sucked working around the rear end, etc with the cut-off wheel, but I eventually got it out of there.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/DSRUCAremoved.jpg)

No turning back now...

It would've been easier, had I been able to locate the spot welds, but the paint and other crud just made it impossible to find them.

maybe I'll have better luck when I get to the pass side.

I still need to clean things up a bit, and patch up a couple holes, but that's all cosmetic stuff. The new suspension mounting points won't be attached to the sheetmetal at all.


Still waiting for my upper link parts to show up, so I can get things mocked up and layout the new brackets and crossbar.
Title: Chuck's '83 TBird
Post by: Chuck W on February 03, 2019, 06:44:10 PM
Busy week, having to deal with  weather and then having to fix both of my drivers the past couple days.

Got into the garage for a short bit today.

Mocked up an new upper link, only to find that I had the wrong LH weld bung. Somehow I wound up with one for a 1.125" dia tube and not 1.25".

Still I was able to get the measurement for the tube and lay things out for a look-see.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/newruca_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/newruca_2.jpg)

Going to put the poly end on the chassis side.

I also messed with some s tubing, checking where the new RUCA mounts will be. I have a preliminary plan, but I need that proper LH weld bung to mock things up properly. After that, I need to get the axle out of my way, so I can get the rest of the stock upper bracketry cut out.

Seeing as I got stymied by the wrong parts, I popped the hood to look at the headlight conversion (H4s). The stuff I got from Eric is pretty straight-forward, but I want to re-evaluate my power distribution a bit.

Looking at something like THIS (https://www.kinnettickreations.com/fuse-and-relay-solutions) for a nice contained set-up. I've got about 3 inline fuse holders already that I want to get rid of, and I'll be adding the new headlight circuits, as well as (FINALLY) the foglamp circuit.
Title: Chuck's '83 TBird
Post by: thunderjet302 on February 03, 2019, 10:15:41 PM
Going poly on the chassis end for less noise/vibration?
Title: Chuck's '83 TBird
Post by: Chuck W on February 04, 2019, 08:15:30 AM
Quote from: thunderjet302;468689
Going poly on the chassis end for less noise/vibration?

Pretty much. The lowers are poly on one end, with a (hard) rubber rod end on the other.
Title: Chuck's '83 TBird
Post by: thunderjet302 on February 04, 2019, 03:11:04 PM
Quote from: Chuck W;468692
Pretty much. The lowers are poly on one end, with a (hard) rubber rod end on the other.

The one thing I dislike about my MM RLCA is, with the spherical bushings on each end, that quite a bit of driveline noise makes it to the cabin. In hindsight I should have gone with the version that has poly bushings on the chassis end.
Title: Chuck's '83 TBird
Post by: Chuck W on February 10, 2019, 06:41:32 PM
Not much to report.

Still waiting on parts that were ordered to finish the upper links (The idiots sent them to my old address...even though they JUST sent me an order to my current address a week before) and dealing with the tedium of cutting out the factory RUCA brackets.

I did pick up material to build my new RUCA cross-brace, so that's headway, I guess.
Title: Chuck's '83 TBird
Post by: vinnietbird on February 13, 2019, 08:07:51 AM
At least you are working on the old Bird. I'm waiting til Spring to get back to wrenching.
Title: Chuck's '83 TBird
Post by: Chuck W on February 13, 2019, 09:24:07 PM
Quote from: vinnietbird;468837
At least you are working on the old Bird. I'm waiting til Spring to get back to wrenching.

Well, I haven't done much to it in years. It's due.

Seeing as I'm waiting on parts and tools to do more work on the back of the car, I moved to the front, to start digging into the lighting upgrade.

As you recall, I bought Eric's old H4 Conversion Kit (https://www.foxtbirdcougarforums.com/showthread.php?40636-H4-Headlamp-Conversion-Kit-83-86-FS) earlier last year. My car is still running the original lighting set-up and it's bad enough that I can't run the high-beams w/o overheating the light switch. That's not going to cut it.

So, the easy way to do this was just to unplug the old lights and pull the connectors out of the way, run the new harness, make 4 wiring connections, and be done with it.

That's the easy way. Stupid me has other ideas.

I went ahead and liberated the stock harness from the car.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/lightharness_old.jpg)
 
The plan is to remove the stock wiring for the headlights and replace it with the larger gauge wiring from the new harness.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/Newharness.jpg)

Then I'm going to bundle it all back together.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/newconnections.jpg)

That male connector is what connects to the DS of the stock harness into the original bulb socket. It acts as a trigger for the power relays for each of the Lo and Hi beam circuits.

I will probably replace that connection with a better connector. Like a Weather Pack, or similar.

Those relays are probably fine, as they are, but I've got a new relay/power box coming that is going to house all of the lighting relays, as well as the fan relay, plus a couple other circuits that are currently just with in-line fuses in the engine bay. So, I'll probably run the wiring for the relays into this new distribution box, to clean things up.

More on all of that when it arrives.
Title: Chuck's '83 TBird
Post by: Chuck W on February 18, 2019, 11:15:04 AM
Got the upper links welded over the weekend.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/upperlinks.jpg)
Title: Chuck's '83 TBird
Post by: Chuck W on February 18, 2019, 09:57:05 PM
This should handle those RUCA brackets...

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/grinder.jpg)
Title: Chuck's '83 TBird
Post by: Aerocoupe on February 19, 2019, 12:11:13 PM
Anytime you can do the work yourself you automatically justify adding tools to the garage by the money you "saved"!
Title: Chuck's '83 TBird
Post by: softtouch on February 19, 2019, 04:22:30 PM
I dug out a RotoZip tool I had bought a while back to cut some tiles. I loaned it to my son-in-law to cut off some rusty bolts. He was dismantling the bed of a 50 Dodge pickup he wants to restore. I had never used the metal cutting disks that came with it.
When he finished with it I noticed the disks have an expiration date of 2013.
Who would have thought something like that would have an expiration date.
Title: Chuck's '83 TBird
Post by: Chuck W on February 19, 2019, 09:47:16 PM
This is a nasty, dirty, noisy job...
Title: Re: Chuck's '83 TBird
Post by: Chuck W on February 26, 2019, 09:30:48 PM
So, after much cursing, getting showered in grit and sparks, and then cleaning up a big mess, I finally got the RUCA bracketry out of the way.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/RUCAbrktsout.jpg)

With those finally removed, I was able to layout and bend up the new crossbar that the new upper link mounts will be attached to.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Rupperlinkmount.jpg)
I was able to lay it out, bend it, cut it and clean the ends in one go. It fit up there on the first try. Yay, me!

Knowing I had a certain height needed for the front mount of the RUCAs, I fit everything back in the car and mounted up one of the upper links.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/frontmountheight.jpg)

You can see that the poly rod end contacts the bar, and I'm about a 1/2" lower than I need to be.

You can also see that the cross bar rests on the bosses for the rear seat belt mounts. There is about 1/2-5/8" of clearance to be had there, if I grind the raised side bits, and relocate the brakeline mount.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/bossinterference.jpg)

With a little grinding on the ends, I can also rotate the bottom of the whole thing forward at the sides. This will also allow for more clearance in front of the upper link. With these two changes, I should be able to get all of the room I need to put things where I need them.

I'm going to do all of that and verify clearances. Once I do that, everything is coming out of the car and will be going to get blasted/stripped. While that's away, I can clean up things down here, fill in holes, etc, and get the crossbrace in its proper home and ready for final welding.
Title: Re: Chuck's '83 TBird
Post by: CougarSE on February 27, 2019, 07:04:22 PM
I love it.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on February 27, 2019, 10:36:27 PM
Well, I crawled back under the car after work and made the adjustments to get the crossbar as high up as possible and rotated the sides as far forward as possible.

I'm still 1/4" lower than what I'd like to be.

I have three options:

1. Install a heim joint on the front end of the upper link. I don't really want to do this because I either loose the isolation of the poly rod end, or I have to buy a different poly rod end that's narrower, as the current one won't fit the axle brackets.

2. Cut out the crossbar to allow clearance for the poly rod end. This is really just more fiddly work, as I'll have to fill that section back in.

3. Say "screw it" and run it where it is.
Title: Re: Chuck's '83 TBird
Post by: Mikey97D on February 28, 2019, 10:20:53 AM
Perhaps a dumb question......What if you ran the upper control arms shorter and rotate the bracket you are going to weld on up counterclockwise in the picture?  Have you gone through the geometry to see what would happen?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on February 28, 2019, 10:36:02 AM
Perhaps a dumb question......What if you ran the upper control arms shorter and rotate the bracket you are going to weld on up counterclockwise in the picture?  Have you gone through the geometry to see what would happen?

That's on the list of things to check, once I find my old notes from eons ago on the rear suspension.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 06, 2019, 09:13:57 PM
OK, well after the last post, I messed around with things, and I was able to get the height I needed (and a bit more).

Running some geometry numbers, seeing as the car sits pretty low, it was going to be beneficial to raise the front RUCA mount and (re) lower the rear RLCA mount. I previously had the Kenny Brown TracKit axle brackets on the car, and wasn't planning on using them with this new rear suspension. After looking at the suspension geometry, it looks way better to just leave them there.

Once I had that info and was happy with it, I needed to get some tabs to mount the RUCAs to.

I took some generic ones, and modded them to fit.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/RUCAtabs.jpg)

Then I set about to attach them to the new crossbar.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/RUCAmnts_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/RUCAmnts_2.jpg)

To make sure everything is lined up, I ran some all-thread through all tabs.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/RUCAframe.jpg)

Now that I have these all laid out, I can pull everything apart for clean-up and coating.

I got a bunch of materials to work on the lighting/accy power upgrade, but I'll save all of that for another post when I can detail things a bit more.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 09, 2019, 07:46:57 PM
So I got a couple of hours in the garage this afternoon.

One of the hold-ups I was having on the H4 lighting conversion was trying to figure out how to open up the back of the light holders, to allow for clearance of the H4 bulb connectors/boots.
I knew a 3" holesaw would do it, but without any good way to hold these things, they'd just end up flying around the garage, as soon as the holesaw hit them.
On my ride home from work on Thurs, the idea on how to do it came to me.

I grabbed some s 2x4's and made a little holder jig for them.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/jig_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/itfits.jpg)
A little cleanup and a little paint, and these are ready to go.

I got my relay box the other day
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/relaybox_2.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/relaybox_1.jpg)

I just had it pre-built, as I cost me less than the materials were going to, and I didn't have to chase down proper wires.
The 4 big relays are for the LO-beams, HI-beams, Fogs, and Fan. The smaller relay is also for the fan, and if I decide to put AC back in this thing, it will allow for proper fan control.
There are 6 extra fused circuits, that most of them will replace a couple circuits that are there now being fed by inline fuse holders.
There's a lot of extra wire length that I'm not going to need, but it will be nice spare stuff. Any extra circuits I'm not going to use, I'll just pull the terminals out and remove the extra wires.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/currentdist.jpg)
This is the current situation. I added that small power buss a while back, and that's going to go away.

After thinking about it, I'm also going to get another similar holder and use a couple MAXI fuses to replace those fusible links, just to clean all of that up.
Really, I'm just at the point on this project where I need to start running wiring.

I also took the time to weld up the RUCA brackets on the new crossframe.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/weldedRUCAmnt.jpg)

I really need to be welding more. While the welds are more than functional, they sure look py (IMO). I may add some small gussets to these, but I really doubt that I'm going to need them.



Title: Re: Chuck's '83 TBird
Post by: Tbird232ci on March 11, 2019, 02:31:05 AM
I really dig that relay box. Any guidance as to where I can get one like it?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 11, 2019, 07:47:25 AM
I posted the VENDOR (https://www.kinnettickreations.com/fuse-and-relay-solutions) a few posts back.

I did dig up a couple suppliers for the enclosure/terminal parts, but it was going to be kind of a hassle to try and get it together.

I found another vendor that does similar stuff, and I'll probably get a kit from them for the MAXI fuse box. (Have to post up those details later)

Everything is now out of the back of the car. Parts will be headed to blasting/stripping this week.
Title: Re: Chuck's '83 TBird
Post by: EricCoolCats on March 11, 2019, 09:09:21 AM
Great solution for the light holders, Chuck. I took tin snips to mine, wasn't as elegant but it worked (and I filed down the edges). But what you did is so much better. That fuse solution is pretty awesome as well. Nice progress!
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 11, 2019, 02:19:48 PM
Yeah, the tin snips route was an option I was trying to avoid, if I could help it.

A couple of the holders had been opened up in the past, and looked a bit ratty. This wasn't the original header panel for the car, as that one was cracked, so they came with the replacement one I used when I had the car painted back in '04. (shiznit...it's been THAT long?)
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on March 11, 2019, 02:33:39 PM
I used and air jig saw but ended up having to file the edges as well.  Your solution is simple and one of those " why didn't I think of that".  Sad thing is there is a drill press less than 10' from where my car spends 95% of its time.

I also like that fuse holder solution.  The relays for my headlights and Mark VIII fan are separate and I too have a couple of fuse holders attached at the starter relay so this would clean that "junky" look up.
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on March 11, 2019, 04:21:15 PM
That fuse box should really clean up that jumble of wires by the driver side shock tower. Nice.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 13, 2019, 07:47:09 AM
Dropped parts off for stripping/blasting yesterday.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/offtostripping.jpg)

(The white brace isn't for the TBird ;) )
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 13, 2019, 10:56:16 PM
Ordered my MAXI fuse holder kit (https://ceautoelectricsupply.com/product/gep-6-position-maxi-fuse-waterproof-pdc-kit/) today.

Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on March 18, 2019, 11:25:06 PM
I may have missed this but what differential are you planning on using? You planning on keeping the Traction-Lok or going with something like a True-Track?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 19, 2019, 08:25:20 AM
I may have missed this but what differential are you planning on using? You planning on keeping the Traction-Lok or going with something like a True-Track?
Just going to rebuild the Traction-Loc unit. Gotta start getting together a list of needed parts to redo the rear, but not planning anything fancy.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 19, 2019, 10:10:27 PM
Made a couple brackets and located the relay boxes.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/relaybox_4.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/relaybox_6.jpg)

I need to buy a new tool to do the final crimps for the MAXI fuse terminals, but at this point I'm ready to start cutting down wires and installing connectors, etc.

Still debating on the fog/driving light wiring. If I can find appropriate stuff under the dash for it (which I doubt), I'll use the feed out of (factory) fuse #7 to trigger my driving light relay (it's "hot" when the Lo beams are on). If not, I'll figure out something else.
It's a 2.3 turbo car thing, which this car was NOT from the factory.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 07, 2019, 05:37:09 PM
Been sneaking in time to work on more wiring (and other non-TBird projects), so I haven't had too much new to show.

I was able to pick up the first of the powdercoated parts today, though.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/PC_black_1.jpg)

The housing was pretty pitted, but I'm not too concerned about it being a show car.

They got the black done, but were still waiting on the other powder for the rest of the stuff to show up.
I might be able to get that stuff next week.

Guess I better get back under the car and finish up the prep work there, so I can get that RUCA mount welded in place.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 20, 2019, 01:34:52 PM
So, still running around in circles trying to get a bunch of other things done and still make forward progress on this thing.

The electric fan power/controls was part of the accessory wiring rework, and the last bit on that was to redo the control wiring that comes out from the MegaSquirt ECU. When I originally built it, I'd forgotten to add a diode in the circuit, and in the end just added it out at the relay. That was OK then, but it's not OK now. I'm going to add it inside the ECU case.

I haven't cracked the case on this unit since I got the car running on it 10-12 years ago.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/MS_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/MS_2.jpg)

Keep in mind, this was my first ever major electronics project at the time. If I redo the drivetrain in this car...all of this old MS install will be redone/updated.
It took a second looking at that mess on the protoboard to sort out which was the fan control circuit (There is PWM idle control, TFI circuitry, flyback board stuff for Lo-Z injectors all mixed in there), but I got that sorted out.


Seeing as I never added a WBO2 to the car when I built this, that is on the list for mods this time around as well.

Also, I picked up the rest of my powdercoat today.

Here is a teaser of the new color for the rear susp stuff.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/recoatRLCA.jpg) ;)
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on May 01, 2019, 07:55:19 PM
Is the green you're using for the rear suspension components the same green color you painted the engine?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on May 01, 2019, 11:06:51 PM
The engine is Ford Grey, actually.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on June 30, 2019, 07:56:55 PM
So, things have been busy as hell the past couple of months. Been able to get some parts ordered and things organized, but that's about it, other than a couple minor things.

I finally got some time the past couple of days to make some significant headway though.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/88_rebuild/diff1.jpg)

Picked up the stuff to rebuild the diff and the rear axle.
Got the diff torn down and replaced the bearings, and repacked everything.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/88_rebuild/youresoakinginit.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/88_rebuild/rebuiltTL.jpg)
I went with the "alternative" stack on the diff clutches.
Just need to put the ring gear back on and handle the pinion bearing, then I can put the rear back together.

I also finally got this guy in place.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/rucaframeinstalled.jpg)

After I add a couple smaller gussets, I'll be able to touch up the paint and start getting the links installed and start to put things together.

I also had a helper while I was wrestling around under the car
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/helper1.jpg)

Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on July 01, 2019, 12:57:45 AM
Nice. Glad to see you're still making progress.

I'm a bit surprised you didn't go with the 4700-C kit with the carbon fiber clutches. I've got those in the differential in my car and they grab noticeable better than the regular clutches. But the bigger F-150/GT500 "S-spring" might account for some of that.
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on July 01, 2019, 07:12:29 AM
Second the F150 spring. Made a noticeable difference when I had it installed in the Coupe.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on July 01, 2019, 08:18:50 AM
Looking at the alternative stacking arrangement, things I read said to stay away from the F-150 spring. I'm at a pretty tall stack at the moment (at the upper limit).

I may need to fine-tune or switch things up in the future, depending on the dynamics of this rear susp set-up.
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on July 01, 2019, 09:21:42 AM
I am running an extra clutch in mine with the F150 "Z" spring.  Was a little chirpy around corners at first but it settled in and has worked great for the last 10 or so years.  Realize I haven't put more than 10,000 miles on it in that time.

The control arm cross mount looks really good.  Be curious to hear your feedback on how the car handles once you get it dialed in.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on July 01, 2019, 11:01:51 AM
We'll see what happens with the diff. I may not ever notice a difference. :p

This car has needed a real rear suspension for years.
I modified the front end geometry almost 20 years ago now...
Title: Re: Chuck's '83 TBird
Post by: Clayton on July 01, 2019, 11:06:52 AM
Better late than never! Just to think I've had my car close to 15 years  :like:
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on July 01, 2019, 03:20:21 PM
This rear suspension is definitely different than any Fox car I have seen which is a few but not 100's or anything like what you have seen over your career.  Maybe I missed it other than you had most of the parts but what is it about this suspension that you like or what you expect out of it?  So hard to quantify suspension performance from one setup to another.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on July 01, 2019, 09:00:44 PM
This rear suspension is definitely different than any Fox car I have seen which is a few but not 100's or anything like what you have seen over your career.  Maybe I missed it other than you had most of the parts but what is it about this suspension that you like or what you expect out of it?  So hard to quantify suspension performance from one setup to another.

I was mainly looking to un-splay the uppers and get a panhard bar on there (or some other way to lower the rear roll center).
I knew I was going to have to modify whatever I started with, and this was cheap.

The uppers in this kit kinda sucked, and seeing as I needed to make new ones, I made them adjustable and took the liberty of moving the attachment points around to help offset how low the car is.
Also, the front roll center is probably lower than it needs to be, but I was playing around and copying what we were doing at KB's on the front susp geometry. Why? Because I could. :toothless:

It's not a perfect set-up by any means, but it should do what I want in respect of trying to balance the car out a bit.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on August 18, 2019, 09:02:00 AM
Been messing around with this thing, as time's allowed between life and other projects.

The diff is ready to go back in, but before I did that, I wanted to deal with the mounting of a couple bits to the axle beforehand.

Since I needed to stay with the lower RCLA rear location, I was re-installing the oold KB axle brackets.

DS went fine.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/dsaxlebrkt.jpg)

PS, not so much.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/psaxlemount_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/psaxlemount_2.jpg)

Needed to make a slight modification to get everything to play nice together.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/psaxlemount_3.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/psaxlemount_4.jpg)

Now to get the diff installed and work on getting the axle bearings and brake stuff mounted.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on September 01, 2019, 10:31:40 PM
OK, well after fighting with getting the pinion bearing preload correct, I was finally able to get the diff installed and that all buttoned up.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/rear_done.jpg)

After that, I decided to dig out the brake parts I've had sitting in the shelf for a while.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/rotors.jpg)
Take a close look at that shipping date...
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/rotordate.jpg)

Yep.

From there I try and bolt the caliper slider brackets on and find them hitting the rotor, on opposite sides.

Looking closer...
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/warpedbracket.jpg)

The hell?!? Yes, the caliper mounting brackets are bent. Both are bent in mirrored images of each other. It's hard to get a picture of, but you can for sure see it when you look at them when unbolted from the axle.

I'm going to see if I can tweak them back in line. If not, I guess I'll need to come up with another set.

I have no idea how they got bent like that. I honestly don't remember where I got them. I've probably had them longer than the brake rotors...
Title: Re: Chuck's '83 TBird
Post by: EricCoolCats on September 02, 2019, 11:31:51 PM
That's messed up. But at least you figured it out before going too crazy.
Title: Re: Chuck's '83 TBird
Post by: Mikey97D on September 03, 2019, 08:23:31 AM
Wow.

Crazy that they are both bent.  Did the fixture slip for welding them on?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on September 03, 2019, 08:47:40 AM
Wow.

Crazy that they are both bent.  Did the fixture slip for welding them on?
The bolt-on brackets for the calipers are both bent. Nothing welded here.
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on September 03, 2019, 09:00:59 AM
Chuck,

Are they the TC or SN95 brackets or custom?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on September 03, 2019, 09:03:53 AM
SN-95, for the Cobra brakes.
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on September 03, 2019, 02:43:22 PM
How did they get bent like that?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on September 03, 2019, 04:02:54 PM
I couldn't tell you. The only thing that I can guess is whatever car they came from was hammered pretty hard.

I spent some time today massaging the brackets with a 20-ton press.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/88_rebuild/straightbracket_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/88_rebuild/straightbracket_2.jpg)

Got both sides straight again.

I may add some thin shim washers between the slider brackets and the axle mounts,just to center things up a little better, but at least the twist is gone.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on October 01, 2019, 10:04:40 AM
So, things have been a little busy the past month. My weekends have been tied up with cyclocross racing since the beginning of Sept, and well, we had our second kid on Sept 1st.  :crazy:

In and around all of that, between house projects, other vehicle projects, etc, I've had limited time to really mess with this.
However, little things are happening here and there.

After sorting out the bent brake caliper brackets, I needed to get a couple more parts and then fab up some brake line brackets.
Grabbed a few bits of s from around the garage, and *insert sounds of cutting, drilling, welding* we have these.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/88_rebuild/brakelinebrkt_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/88_rebuild/brakelinebrkt_2.jpg)

At this point, all I really need to do is seal and install the diff cover, and we're ready to stick the rearend back under the car.

Then I get to try and fit a 3" tail pipe around the rear susp stuff, and see what other things I missed during the mock-up.  :toothless:
Title: Re: Chuck's '83 TBird
Post by: BCA on October 01, 2019, 11:07:27 AM
Nice job on the line bracket and a big congrats on the new addition to the family!
Title: Re: Chuck's '83 TBird
Post by: QUICKSHIFT on October 02, 2019, 07:21:13 PM
Congrats on #2!   Bracket looks good too!
Title: Re: Chuck's '83 TBird
Post by: Mikey97D on October 03, 2019, 08:04:52 AM
Congrats on baby #2!
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on October 03, 2019, 12:38:11 PM
Congrats!

Time to teach baby #1 to weld.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on October 04, 2019, 06:48:03 PM
Oh, hey. Look at this.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/88_rebuild/completed88.jpg)

And it's under the car!

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/installed_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/installed_2.jpg)
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on October 06, 2019, 10:08:12 PM
Looks great!
Title: Re: Chuck's '83 TBird
Post by: 88BlueBird on October 11, 2019, 07:23:34 PM
Nice work fabricating those clamp-on axle brackets!  :bowdown:
Title: Re: Chuck's '83 TBird
Post by: Chuck W on October 11, 2019, 08:01:55 PM
Nice work fabricating those clamp-on axle brackets!  :bowdown:
Wish I could take credit for those, but those are part of that Steeda kit that I cut apart to fit in here.

Not many updates this week. Been wrangling other projects, and time is limited.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on October 27, 2019, 07:58:29 PM
Well, I managed to get the other car projects taken care of and was able to steal away a few hours this week to get some things done on this.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/sortedpwr.jpg)

Got all of the new power stuff and lighting wiring sorted and tucked away. The lone orange wire is for the switch for the fog lights. I need to move a few things around to be able to open the 47'-long doors on this thing to work under the dash before I can finish that.
I'm probably going to make a little cover to hide a bunch of that wiring. There is just A LOT going on there on these cars...and I added more.

Got all of the new lights in place also.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/lights_new.jpg)

Then I went to the back of the car to start to try and fish the tailpipe around everything.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/exhredo_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/exhredo_2.jpg)

There is a bunch of stuff to work around back here...especially with a 3" tailpipe.

I have a plan, but it needed to start with this.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/exhredo_3.jpg)

Probably going to take another whack at the tailpipe and make a few other choice cuts to snake around all of the mess.
Luckily, I have a bunch of tubes on-hand. (This is all for the 240, but I can always buy more ;) )
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/exhredo_4.jpg)

I'm going to need to add a new bung for the WBO2 in the DP, and I think I may work in a couple more v-band clamps to make things easier to remove/fit.

Once it's all redone, I'm hoping my buddy can spray it with some Cerakote, like he did for my 850 exhaust.


Title: Re: Chuck's '83 TBird
Post by: Chuck W on October 28, 2019, 10:44:56 PM
This showed up today.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/spartan2.jpg)

I already have a spare LSU 4.9 sensor in the garage, so I just need to get it into the exhaust and wired up.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 15, 2019, 08:10:18 PM
Well, November disappeared in a flash. Now Dec is half gone due to other obligations and then surgery (snip-snip) recovery this past week have kept me away from doing any work, other than some garage clean up.

However, today I was able to get back to what may prove to be the fruitless attempt to fit a 3" tail pipe around all of this rear suspension stuff.

I stuck the tailpipe up in place to see how far things were off from that end.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/exhredo_5.jpg)
I couldn't even get it lined up properly without hitting the panhard chassis bracket.

I chopped a little bit off of that and got it lined up and secured in place. Then I moved to the front.
After a couple hours, I wound up here.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/exhredo_6.jpg)

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/exhredo_7.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/exhredo_8.jpg)

I basically have a 1/4" of clearance to the frame, upper link, panhard bracket at ride height. I think with some better sorted hangers, I can limit the movement enough.

I realized when I was cleaning up that I probably wanted to raise the ler up a touch, so I'll need to slightly shorten that exit piece from the ler to fit things back together again properly.

Once I fix that, I'll piece together the last bit to the tail pipe, and then move the suspension through its range to see where any problem areas might be. I may wind up have to squeeze a couple tubes here or there, or add clearance dimples, but I think we're pretty close.

After that, I need to sort out the split/assembly locations and tack in the V-band s and basically get things all back in order before final welding.

Then it's off for coating.

Sorry for the pics. It was as hard to get a camera under there as it was that exhaust tubing...
Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 15, 2019, 10:32:33 PM
Another option will be to try and go under the axle.

The old Stinger tailpipe kind of dipped down a bit right after going over the axle and then out to the back. It was kind of low, so that MIGHT be an option, depending on how much droop there is in the system, and whether the over-the-axle just doesn't work.

I am 100% certain that I will NOT be doing a dump on this thing.
Title: Re: Chuck's '83 TBird
Post by: kylesburrell on December 16, 2019, 12:23:36 AM
You could consider oval shaped pipe. Saves you a bit of clearance, if you decide to go under the axle. IDK how much more expensive it is.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 16, 2019, 07:59:08 AM
Yeah, that or I was considering applying appropriate amounts of hydraulically-applied force to "adjust" tubing where needed.
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on December 16, 2019, 05:34:00 PM
3" tail pipe correct?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 16, 2019, 07:34:36 PM
Yup
Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 21, 2019, 03:58:32 PM
I got back under the car this morning and was able to suss out the rest of the tail pipe fitting.

(http://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/exhredo_10.jpg)

(http://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/exhredo_11.jpg)

(http://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/exhredo_12.jpg)

Yup, it's tight, especially at the rear part of the over-axle part. The axle mount for the DS upper link winds up contacting the pipe at any more than 1" of compression over ride height.
I should be able to make things clear if I dimple or squeeze the pipe in that section. Not much more I can do, really. I'll probably also dimple the pipe right there as it goes around the panhard bracket.

I plan on changing ler and tailpipe hangers away from the old double-eyelet type of isolators, to cut down on movement.

I think I'll do something like THIS (https://www.amazon.com/dp/B00HE1FV5W/?coliid=I2KGFOATCB8DGQ&colid=1LJCJB4MYZGHS&psc=1) for the ler, and one of the rear-mounted types for the tailpipe, like what they used on the 99+ Mustangs. That should help control things much better.

I'm planning on adding in 3 more v-band connections (both sides of ler and for tailpipe section) to get away from the slip-fit stuff.

Next steps are to get the v-bands and the hangers and get everything to the ler locked in place. Then I can go back and final fit (tack weld) the bits together to connect to the tailpipe. Then weld it, dimple it, recheck fit. After that, it'll be off to coating.


Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 22, 2019, 06:30:25 PM
Since I'm having to wait for more parts to move ahead on the exhaust, I decided to work on wrapping up the last bit of work on the lighting upgrade.

I needed to run the switch trigger for the fog relay, which meant getting into the car and contorting myself under the dash.

Seeing as this car was never equipped with fogs, the factory power from the headlight switch, through fuse #7 wasn't there. I didn't plan well enough to work this into my new wiring, so I was left with a decision.

Stock set-up for the fogs means that they are only able to be turned on when the headlights are on. I really didn't care about that, nor did I want to hack into new or original wiring for my power source.

Seeing as I had 4 un-used circuits available in my new fuse box, I just put the lead back in for one of the 10A circuits, and ran that into the cabin with the trigger wire.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/addedfuse.jpg)

I just need to wire up the connector and mount the switch.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/fog%20switch.jpg)

I thought there was a dedicated spot for the fog switch, but it looks like it just screws into the plastic on the right side of the DS knee bolster.

I ran out of time to finish the wiring up (Spent too much time fishing the wires into the cabin), so that'll happen in the next day or so.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 23, 2019, 06:18:20 PM
Back to it for about an hour today.

Went ahead and added a connector to the pigtail for the fog switch.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/fogconn.jpg)

Not really needed, but I also added an extra lead off of the fused input, just in case I wanted to add something else small to that circuit. It's a 10A circuit, that's only acting as a trigger for a relay.

I got the switch mounted (Sorry for the grainy pics. Kind of dark in the car]
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/fogswitch_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/fogswitch_2.jpg)

Tucked it in on the lower right side, near the center console.

Just to see how things worked, I connected the battery and tested things out.

Fogs didn't come on. I could hear the relay, but no lights. Pulling the cover off of a light reminded me that I never put bulbs in there... :toothless: Looks like I need to add some H2's to my next parts order.

The other issue is that the HI beams are blowing their 20A (mini) fuse whenever I turn them on. Not using anything crazy for the bulbs, but I may need to step of the fuse to a 25A, as it might be the start that's the issue. Everything else works OK.

Lighting is just about wrapped up.

Title: Re: Chuck's '83 TBird
Post by: QUICKSHIFT on December 23, 2019, 09:05:53 PM




The other issue is that the HI beams are blowing their 20A (mini) fuse whenever I turn them on. Not using anything crazy for the bulbs, but I may need to step of the fuse to a 25A, as it might be the start that's the issue. Everything else works OK.

Lighting is just about wrapped up.


You would be better off doing the relay mod to run the headlights. I did and it's relatively easy.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 23, 2019, 11:54:04 PM
You would be better off doing the relay mod to run the headlights. I did and it's relatively easy.

If you look back on the thread, you'll see that's exactly what I did. Everything is contained in those new boxes. The LO's, HI's, and Fogs all have their own circuit and relay.

I think the HI's pull more of a load than the stockers did, at least initially. The stock headlamp switch is only acting to trigger the relays. No load is going through it now.

If I remember, the wiring that came with these new lights I got from Eric didn't have any fusing in them and just used the stock set-up and added relays. I didn't use any of those connections. I have a whole new distribution box for that stuff.

Looking at details on the MINI vs the ATO fuses, I think the MINIs are a little more susceptible to a higher start current than the ATOs (Less delay). Going to try a slightly higher amperage fuse to get past that.
Title: Re: Chuck's '83 TBird
Post by: EricCoolCats on December 24, 2019, 09:27:33 AM
Looking great Chuck! I like that harness, great idea.

Aren't the headlamps on a circuit breaker from the factory? Is that something the new fuse box has accommodations for?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 24, 2019, 09:48:35 AM
Eric. Nope, the headlights come off of one of the fusible links (Which I've replaced with MAXI fuses) and run straight through the light switch. The HI beams come off of their own, separate 20A fuse and go through the switch on the column.

The only thing I've done here is replace the HI beam fusing with a MINI fuse. Both (Old and new) are 20A, but the stock stuff is the larger ATO type.

I just put the white bulbs back in, and didn't use your blues. I need to double-check what the rating was on those. Perhaps they're a bit aggressive.


Title: Re: Chuck's '83 TBird
Post by: mcb82gt on December 24, 2019, 09:53:22 AM
Very nice work Chuck, I wish I felt more  comfortable with wiring.  LOL  :confused:
Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 24, 2019, 10:45:08 AM
Very nice work Chuck, I wish I felt more  comfortable with wiring.  LOL  :confused:

The only way to get more comfortable is to just read/research/do. ;)
Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 24, 2019, 12:51:10 PM
Welp, there's the problem...

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/H4bulb.jpg)

There are 4 of those trying to work on a 20A circuit.

Guess I didn't REALLY pay attention when I was putting those together.

I dug up a 25A fuse, and they all came on, but I'm not really sure it's a good idea to leave all 4 of those in there.

I tried out the "blue" bulbs, and the light is just more "white" than yellow, so I guess that's OK. Going to run the 60/55W for the LOs and the 100/80W for the HI's. This config should be good with the 20A fusing.
Title: Re: Chuck's '83 TBird
Post by: QUICKSHIFT on December 24, 2019, 02:44:14 PM
You would be better off doing the relay mod to run the headlights. I did and it's relatively easy.

If you look back on the thread, you'll see that's exactly what I did.
My bad. I must have missed that.
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on December 25, 2019, 10:17:20 AM
Those are some bright ass bulbs dude  :grinno: .
Title: Re: Chuck's '83 TBird
Post by: EricCoolCats on December 25, 2019, 10:38:44 AM
Welp, there's the problem...

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/H4bulb.jpg)

Oh yeah...forgot I put those in there. Ooooops. Sorry about that Chuck.  :mullet:
Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 25, 2019, 02:27:01 PM
Would be great if the system could handle it. :)
Still much brighter with the relay mod.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 26, 2019, 11:40:55 AM
Got it all together with the 60/55's and 100/80's. All set there. Now just waiting on the fog bulbs to show up.

Gotta order my exhaust stuff next.

Oh yeah...forgot I put those in there. Ooooops. Sorry about that Chuck.  :mullet:

I don't think that was you. I may have swapped out the other bulbs thinking they may have been too "blue" for my tastes.  :redface: I was wrong. They look fine.
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on December 26, 2019, 03:44:56 PM
Just an FYI:

From CFR, Title 49, Part 571.108: Section 7.3.2 "Type A headlighting system". A Type A headlighting system consists of two Type 1A1 and two Type 2A1 headlamps and associated hardware, which are designed to conform to the following requirements:
(a) SAE Standard J1383 APR85 Performance Requirements for Motor Vehicle Headlamps, with the following exceptions:
(1) Paragraphs 1, 2.1.2, 2.8.2, 3, 4.1.1, 4.1.2, 4.1.3, 4.4, 4.6, 4.8 through 4.18, 5.1.1, 5.1.3, 5.1.5, 5.1.7 through 5.1.16, 5.2.2, 5.3.5, 5.4.1, 5.4.2, and 6 through 6.4 do not apply.
(2) In paragraph 5.3.2, the words “and retaining rings” are omitted.
(3) In paragraphs 4.5.2 and 5.1.6, the words “Figure 28-1 or 28-2 of Motor Vehicle Safety Standard No. 108” are substituted for “Table 3.”
(b) SAE Standard J580 DEC86 Sealed Beam Headlamp Assembly (except paragraphs 3, 4.1.1, 5.1.1.1, 5.1.2.3, and the second sentence of 5.1.6); in 5.2.1, delete the words “and retaining rings;” the correct reference is SAE J1383 Figures 6, 9, 12 and 14.
(c) After a vibration test conducted in accordance with paragraph S8.8, there shall be no evidence of loose or broken parts, other than filaments, visible without magnification.
(d) The maximum wattage at 12.8 volts (design voltage): Single filament headlamp, 55 watts on the upper beam; dual filament headlamp, 43 watts on the upper beam and 65 watts on the lower beam.


Source: https://www.govinfo.gov/content/pkg/CFR-2000-title49-vol5/xml/CFR-2000-title49-vol5.xml

Type 1A1 and 2A1's are the rectangular type headlights like the 83-86 cars have and are defined within this informative article:

https://law.resource.org/pub/us/cfr/ibr/005/sae.j1383.1985.html

So all I am saying here is be careful how much wattage you run as one of our nice folks in uniform with the pretty lights and ticket book may take offense and hence so will your wallet.  I only know all of this due to posting the wattage on the H2 bulbs I originally had in my '83's diamond headlights.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 26, 2019, 04:02:22 PM
Good info.

The HI's will only be run when needed, and the LO's aren't going to be any more bright than a lot of the headlights on newer cars anyway.

I'm not overly concerned. if I feel the need to swap at a later time, I will :)
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on December 26, 2019, 04:52:08 PM
Good deal. Just didn’t want anyone else to try and do the 100 watt / 100 watt setup like I was thinking of running....talk about not smart.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 01, 2020, 10:25:42 PM
Finally got a couple hours between all of the holiday running around to get the fog lights up and working.

Got some standard H2 bulbs
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/fogbulb_1.jpg)

read a bunch of reviews that they didn't fit in the holders like mine. Can confirm.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/fogbulb_2.jpg)

However, it wasn't anything a little time with a file couldn't fix.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/fogbulb_3.jpg)

After that, the car has working fog lights for the first time ever.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/workingfogs.jpg)

Just waiting on exhaust stuff to show up.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 04, 2020, 08:26:45 PM
Getting into the wiring on this thing.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/WBO2/sptn2.jpg)

Wishing I'd planned ahead better on my power distribution and accounted better for it. To keep things simple, I'm probably just going to use the (5A) in-line fuse holder, even though I'd rather work something into the new set-up. It'll all be hidden under the dash, anyway.
If I ever pull everything out and redo things, I'll dig in deeper.

Need to figure out where to mount the sensor status LED. I mounted it in the dash console on my 240 install...and  it was bright. :nonchalance: I want to be able to see it, but not have it blind me at night.

Also decided to swap the older stereo for a not-as-old-stereo while I was in there.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/stereoswap.jpg)
Nothing wrong with the 9801, but I wanted to USB capability and a front-mounted AUX input (Instead of the cable from the back).
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 05, 2020, 08:27:09 PM
*sigh*
Couldn't get into the garage today, so I spent some time updating the firmware on the MS and making sure the current tune was in order, so I can get this reinstalled.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/WBO2/tuner.jpg)
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on January 06, 2020, 03:48:24 PM
Finally got a couple hours between all of the holiday running around to get the fog lights up and working.

Got some standard H2 bulbs
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/fogbulb_1.jpg)

read a bunch of reviews that they didn't fit in the holders like mine. Can confirm.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/fogbulb_2.jpg)

However, it wasn't anything a little time with a file couldn't fix.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/fogbulb_3.jpg)

After that, the car has working fog lights for the first time ever.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/workingfogs.jpg)

Just waiting on exhaust stuff to show up.


Marchal Fog Lights are just so  cool and era specific. They look awesome on your car.

I wish there was a way to put them on 87-88 Thunderbirds where they didn't look tacky.
Title: Re: Chuck's '83 TBird
Post by: mcb82gt on January 06, 2020, 04:00:36 PM
Quote


I wish there was a way to put them on 87-88 "Cougars" where they didn't look tacky.


I added my .02$ also.

What about the Mark VII?  They look pretty tacky on there. 
Title: Re: Chuck's '83 TBird
Post by: EricCoolCats on January 06, 2020, 04:22:28 PM
If the slimmer Marchal 150's (1988.5-90 Escort GT) would fit in the smaller air ducts on either side of the 1987-88 T-Bird bumper cover, that would be a great option. I think they're still too big though. I've seen just generic aftermarket slim fog lamps in those slots and they look decent, but they aren't Marchals by any stretch.
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on January 06, 2020, 07:31:32 PM
Quote


I wish there was a way to put them on 87-88 "Cougars" where they didn't look tacky.


I added my .02$ also.

What about the Mark VII?  They look pretty tacky on there. 

I always loved them on my Mark VII LSC. Never though they looked tacky on a Mark VII.
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on January 06, 2020, 07:34:21 PM
If the slimmer Marchal 150's (1988.5-90 Escort GT) would fit in the smaller air ducts on either side of the 1987-88 T-Bird bumper cover, that would be a great option. I think they're still too big though. I've seen just generic aftermarket slim fog lamps in those slots and they look decent, but they aren't Marchals by any stretch.

Any idea on dimensions of the 150's?
Title: Re: Chuck's '83 TBird
Post by: EricCoolCats on January 06, 2020, 10:56:43 PM
Approx. 6" wide x 3" high. I remember them being as wide as a headlamp or regular Marchal 750 lens but about half as tall.
Title: Re: Chuck's '83 TBird
Post by: mcb82gt on January 07, 2020, 09:56:40 AM
Quote


I wish there was a way to put them on 87-88 "Cougars" where they didn't look tacky.


I added my .02$ also.

What about the Mark VII?  They look pretty tacky on there. 

I always loved them on my Mark VII LSC. Never though they looked tacky on a Mark VII.

They are "ok".  Seems like just hanging out front on that bracket.  Looks odd at some angles.  Not smooth and tucked in like the Mustangs and TC XR7.

I have a small escort marchal at home.  I snagged it at a yard, thought it was cool.  I'll look for it tonight.
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on January 08, 2020, 03:08:43 PM
Approx. 6" wide x 3" high. I remember them being as wide as a headlamp or regular Marchal 750 lens but about half as tall.

Hole in the standard 87-88 Thunderbird bumper cover is approximately 2" high by 7" wide. So too short for the 150s.
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on January 08, 2020, 05:04:55 PM
So I believe the original 87-88 TC fog lights were Hella and the part number on the lens is 301-960-515.  Appears it was used on multiple vehicles but I would bet the mounting brackets for the 87-88 TC's will be vehicle specific.  Some guy has a set of the87-88 TC specific ones on ebay for $175 but one of the lenses is gone.  A person might be able to offer him less to get the brackets and then seek out some good lenses.

I have a full set of the Marchal's for my '83 that I spent many an hour restoring brackets and all.  Brackets and housings are powder coated and the lenses have been polished.  So yes, I am going to put a TC bumper cover on the car as I really liked the nose of the '85 TC that I owned way back in the day.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 08, 2020, 06:17:07 PM
Looks like I need to get back in the garage and get some work done to reclaim my thread. ;)

This is really what it's all about though.  8)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/10_17_09_4.jpg)
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 09, 2020, 04:27:35 PM
OK, well I had a jury duty summons today. The case we were there for got cancelled, so that meant...heading home for the rest of the day!

Had to tend to a couple things, but then I took a couple hours to get into the garage for a bit.

First I raised the car up a bit more, to make the exhaust and other work a bit more bearable.

After that, I pulled the mocked-up tail pipe, and then got the exhaust out of the car for rework.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_1.jpg)

I'd picked up a couple more 3" V-bands, that actually nested into each other, so I was going to use them on the ler.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_2.jpg)

A little clean-up on the inlet side
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_3.jpg)

And then a little adjustment and clean-up on the outlet side (To keep things in the same spot back there)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_4.jpg)

I'm not going to pull the downpipe to install the WB O2 sensor bung until I pull everything out to go get coated. Just saving a bit of rework.

I should have some time this weekend to get the exhaust and ler back under the car and start to get the ler hanger sorted out. From there we start to piece together the tailpipe again and get it tacked together for final fitment.
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on January 10, 2020, 10:44:05 AM
What color are you planning on having the exhaust powder coated?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 10, 2020, 11:00:16 AM
What color are you planning on having the exhaust powder coated?

The Cerakote my buddy uses is black. We'll just leave the tip and the V-band s uncoated.

(https://turbochuckcom.ipage.com/webimages/projects/97%20Volvo%20854T5/2019/ex_cerakote.jpg)
Title: Re: Chuck's '83 TBird
Post by: fusseli on January 19, 2020, 12:22:04 AM
Nice car and nice exhaust setup!  You have a lot of hangers on it, I had heard all that's needed is on at the ler and the down pipe, supporting the whole system if the cat is deleted.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 19, 2020, 08:26:35 AM
Nice car and nice exhaust setup!  You have a lot of hangers on it, I had heard all that's needed is on at the ler and the down pipe, supporting the whole system if the cat is deleted.
Well, that set-up is from another car. It was just to show the coating that I'll be using.

I'm going to have 4 hangers on the TBird system, because I need it to not move around a lot.

Update coming later.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 19, 2020, 04:33:27 PM
Time has been limited but I was able to get a little time on Sat to tend to this.

I need to sort out 2 hanger locations for the ler. I don't *need* all of them, but I need the exhaust to be held pretty securely.

Laying under the car and looking up at the floor pan, I found the perfect spot for a front mount location. Originally there was a small bracket of some sort, but that had been removed long ago. There is a small backing bracket under the carpet for it, which I made use of.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_5.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_6.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_7.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_8.jpg)

Then I was able to tack together the ler side of things.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_9.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_10.jpg)

I still need to do the rear mount, and that I'll have to add some sort of mounting bracket.
However, with the ler location locked, I was able to finally piece together the rest of the exhaust.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_11.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_12.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_13.jpg)

Yup, that's a full 3" pipe around all of that mess. Looks like I'll just need a small dimple/squeeze to get it to clear the frame rail, and maybe a couple more small ones to clear a couple things. All worth it for not having to do a turn-down on the car.
Just need to get the rear two hangers in place, and we're all set to weld/dimple/coat.

Earlier in the week I was able to spend some time messing with the WBO2 wiring. Have the plan sorted, just need to get it all done.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/WBO2/sptnwiring.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/WBO2/led.jpg)

Working on a house project now, but may get a few moments tonight after the kids are in bed.
Title: Re: Chuck's '83 TBird
Post by: BCA on January 22, 2020, 08:47:50 PM
What are the brakes on the bench from?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 22, 2020, 08:53:55 PM
What are the brakes on the bench from?
I was wondering when someone was going to ask about those.  ;)

Those are 13" Brembos from an 04-09 Volvo S60/V70R. That configuration is being adapted for my '97 850 Turbo. (I also have a set of the fronts for my Volvo 240 project).

Doing some layout for an adapter.
Title: Re: Chuck's '83 TBird
Post by: BCA on January 23, 2020, 08:13:01 PM
I was wondering when someone was going to ask about those.  ;)

Those are 13" Brembos from an 04-09 Volvo S60/V70R. That configuration is being adapted for my '97 850 Turbo. (I also have a set of the fronts for my Volvo 240 project).

Doing some layout for an adapter.

Darn.
Cool for the Volvo project, but I was hoping you had figured out a way to get them on the '83.   8)
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 23, 2020, 08:53:01 PM

Darn.
Cool for the Volvo project, but I was hoping you had figured out a way to get them on the '83.   8)


Oh, I probably could. If I really wanted to.  :toothless:

I had a set of EVO Brembos a while back, but never moved forward on the possible install and sold them off.

The Cobra brakes will suffice for the time being on the TBird. ;)
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 25, 2020, 08:13:00 PM
So. Much. Going. On.

Was finally able to get back into the garage to get the last of the exhaust hangers in place.
For the rear mount of the ler, I did something similar to the front mount.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_14.jpg)

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_15.jpg)

Then I got out back and hung the tailpipe.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_16.jpg)

I need to splice in the tailpipe v-band connection and then pull it all out and weld it and "clearance" the couple spots that need it. Then off for coating.
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on January 27, 2020, 02:37:17 PM
Mounts look pretty good. Did someone leave a white wig in the car  :grinno:
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 27, 2020, 03:19:31 PM
Heh. That was something attached to the original seat base that wound up stuck to the factory sound deadening. I've just never bothered to se it out of there.
Title: Re: Chuck's '83 TBird
Post by: vinnietbird on January 29, 2020, 06:39:58 AM
Nice work, Chuck. I had to do some clearancing as well when I raised my pipes and put the tips in the notched bumper cover. I always love seeing your progress.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 29, 2020, 09:13:27 AM
Thanks, Vin.

Wish I was making faster progress, but things are starting to wrap up here and there.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on February 01, 2020, 04:11:15 PM
Exhaust is all welded up.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_17.jpg)
Title: Re: Chuck's '83 TBird
Post by: Chuck W on February 16, 2020, 10:32:44 PM
Well, while the exhaust is off getting coated, I have a couple other things I can wrap up while I wait.

Got the rear brakes all closed up and bled today and mucked around more with the WBO2 wiring.

Nothing really pic worthy, though. Just more things crossed off the list.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on February 23, 2020, 08:08:51 PM
Picking this up on Tues!
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhaustsneakpeek.jpg)
Title: Re: Chuck's '83 TBird
Post by: Chuck W on February 29, 2020, 08:56:49 PM
Picked this up earlier in the week and got it installed. (Hard to get good lighting under the car...)

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_18.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_19.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_21.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/5link/Exhaust/exhrebuild_20.jpg)

Now to get all of the rear suspension tightened up.
Title: Re: Chuck's '83 TBird
Post by: Clayton on February 29, 2020, 09:38:46 PM
Looks good! I'm going to have to so some witchcraft under the passenger side of mine to get the tail pipe around the PHB mount and gas tank. DS wont be bad at all cause there's tons of room
Title: Re: Chuck's '83 TBird
Post by: Tbird232ci on March 01, 2020, 03:04:16 AM
It's a shame that the driveshaft is the ugliest thing under the car now. Time for an aluminum one.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 01, 2020, 08:33:13 AM
It's a shame that the driveshaft is the ugliest thing under the car now. Time for an aluminum one.
It's a possibility, but right now getting the car back together to be able to drive it is the main priority. Besides, there's lots of other ugly under the car to keep the DS company. ;)

Just a handful of things to do now, and most of it just involves the time to get it done.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 08, 2020, 11:43:01 PM
So, I was able to get a few things done this week.

I've got the WBO2 all wired up.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/sptn2installed.jpg)
While I was messing around with wiring for that, I swapped out a newer head unit from the older Alpine I had in there. Not much change, aside from having actual AUX and USB inputs (The old one had the cable AUX adapter from the backside of the unit).
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/newradio.jpg)

With the WBO2 all installed, I'm basically at the point where I could fire up the engine. However, I don't want to do that until I get the fuel filter situation sorted.
I want to ditch the tedious Aeromotive one I have on there for a stock-type replacement (Not necc Ford stock-type), that isn't a huge messy hassle to regularly replace. Having to unscrew things to replace an element is just too much of a hassle.

I've got AL fuel lines under the car currently and am going to make remove a section where I currently have fittings and install some nylon sections and a new filter/bracket.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/newfuelfilter.jpg)
Will be MUCH easier and more conducive to me regularly replacing the filters. Just waiting on a couple of fittings to arrive.

I've got the rear suspension *mostly* installed/tightened up. I need to deal with the mounting on the DS of the panhard chassis bracket and get the pinion angle all set.
This is where I ran into a couple problems.
As I was checking the driveline angles,I remembered that I was going to replace the motor mount isolators. I didn't want to set that all up, only to have new bushings mess things up (raise the engine)
Good thing I stopped to check
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/deadmount.jpg)

This is why I stopped using that secondary supplier for the bushings and went back to the Energy Suspension ones. This was one of the dual-durometer lowers. The soft grey stuff just collapses and the stiffer black material just disintegrates...
Going to swap those out before I set the pinion angle. I'll need to adjust it a bit, as it is pretty close now with the engine sitting a little low.

I did run into an "oops" when I was attempting to fit the panhard bar in place.
Evidently I didn't put enough bend in the chassis brace, and it hits the panhard bar...
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/phard.jpg)

Examining a couple options.
I might be able to slide the DS of the bracket rearward a bit (with a couple adjustments) and adjusting the pinion may change the orientation of things slightly, that the PS mount on the axle will move forward a bit. That may get me some of the clearance I need.

I could put a bend in the bar, which isn't a big deal, aside from losing the ability to easily adjust the bar length and center things up by just turning the bar.
To get around that, I could add a jackscrew into the PS section of the bar, to make things adjustable again.
I'm not concerned about the bar having a bend, the Phard bar on my Volvo 240 has a bend in it (stock), and I added a jackscrew in it to make it adjustable without issue.
(https://turbochuckcom.ipage.com/webimages/projects/80%20Volvo%20264/Adjph_2.jpg)

Just would like to try to avoid cutting up the bar, if at all possible.

Just one of those things I thought I verified, but evidently not well enough. :shakehead:




Title: Re: Chuck's '83 TBird
Post by: Mikey97D on March 09, 2020, 12:00:03 PM
My 2 cents on the last option that no one asked for:  I don't see a picture of it but you are using rod end bearings on the end of the panhard bar?  If so I would suggest using both right hand threads to save some money and then drill and pin the threads so they don't unscrew while adjusting.  In my head I would put the jackscrew on the end easiest accessible end of the panhard bar closest to the rod end.  Perhaps you could have the rod end thread into the one side of the jackscrew?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 09, 2020, 12:34:14 PM
The current bar is LH/RH threaded on the ends. If I need to mod things, I'll probably put the jackscrew on the PS and have one end into the bar, and the other into a female rod end.

Going to see how things wind up after getting everything in the proper orientation and get the pinion angle set right before I start cutting things apart.
Title: Re: Chuck's '83 TBird
Post by: Mikey97D on March 09, 2020, 01:22:44 PM
Sorry, what is the PS acronym?  My brain keeps going Power Steering.  LOL
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 09, 2020, 02:24:19 PM
Sorry, what is the PS acronym?  My brain keeps going Power Steering.  LOL
Passenger side. ;)
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 09, 2020, 08:19:20 PM
Had a few moments to get the PS bushing out after work.

 :nonchalance:

(Hint: There is supposed to be about a 1/2" of black material between that grey stuff and the upper bracket)

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/deadbushing_1.jpg)

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/deadbushing_2.jpg)

Junk.
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on March 09, 2020, 11:52:07 PM
Well that might change how the motor sits  :toothless: .
Title: Re: Chuck's '83 TBird
Post by: Tbird232ci on March 10, 2020, 04:18:17 AM
Had a few moments to get the PS bushing out after work.

 :nonchalance:

(Hint: There is supposed to be about a 1/2" of black material between that grey stuff and the upper bracket)


Junk.

I know a guy who makes motor mounts.

;)
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 10, 2020, 10:24:10 AM

I know a guy who makes motor mounts.

;)

I know a guy how used to make them. ;)

I have a set of ES bushings sitting here. Just need to install them.

These are an OLD set of my Type 1's. Like original batch zinc-plated stuff.
Title: Re: Chuck's '83 TBird
Post by: Tbird232ci on March 11, 2020, 05:10:25 AM
I know a guy how used to make them. ;)

That guy sure was a prick.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 11, 2020, 05:46:57 AM
Was?

 :giggle:
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 14, 2020, 08:49:18 PM
Well, new motor mount bushings are in place.

Also took the time to wrap up the fuel filter situation.

I was originally going to remove the Aeromotive filter that I had on the car, and go with a more OE set-up, but after some thinking I decided to keep it.

First I prepped some nylon fuel line.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/Fuel%20System/boilboil.jpg)

Then I popped a couple new fittings into it.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/Fuel%20System/fuelline.jpg)

I picked up a quick-disconnect fitting for the filter and shortened my hardline to put the new flex section in place.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/Fuel%20System/newconfig.jpg)

Now to get the pinion angle set, etc and see where I am on whether I need to mod my panhard bar.
Title: Re: Chuck's '83 TBird
Post by: Clayton on March 14, 2020, 10:37:01 PM
Saucy :toothless:
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on March 15, 2020, 09:53:45 AM
How to make Chucks magic fuel line end prep sauce:

https://thumbs.gfycat.com/PoisedPeriodicBinturong-size_restricted.gif

If I was smart I could figure out how to get the  gif to work without clicking on it....
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 15, 2020, 11:07:39 AM
I guess for clarification, that is a drink heater element giving me boiling water in the jar. Fairly mobile, and quick to heat up.  :giggle:
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on March 15, 2020, 09:31:22 PM
I guess for clarification, that is a drink heater element giving me boiling water in the jar. Fairly mobile, and quick to heat up.  :giggle:

That's a pretty good idea.
Title: Re: Chuck's '83 TBird
Post by: bodyman on March 15, 2020, 10:09:52 PM
How to make Chucks magic fuel line end prep sauce:

https://thumbs.gfycat.com/PoisedPeriodicBinturong-size_restricted.gif

If I was smart I could figure out how to get the  gif to work without clicking on it....
It was worth the click... here you go

(https://i1060.photobucket.com/albums/t456/bodymann/50B482F9-FDD8-4D8C-A041-2AC38494FD76_zpsgwb6l531.gif) (https://s1060.photobucket.com/user/bodymann/media/50B482F9-FDD8-4D8C-A041-2AC38494FD76_zpsgwb6l531.gif.html)
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 16, 2020, 12:46:43 AM
Pinion set...I still need to mod the panhard bar.  :nonchalance:

*derp*

Upside. I may actually try and get the car started this week, as all of that is buttoned up.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 16, 2020, 09:30:01 AM

It was worth the click... here you go

(https://i1060.photobucket.com/albums/t456/bodymann/50B482F9-FDD8-4D8C-A041-2AC38494FD76_zpsgwb6l531.gif) (https://s1060.photobucket.com/user/bodymann/media/50B482F9-FDD8-4D8C-A041-2AC38494FD76_zpsgwb6l531.gif.html)

What makes this funnier is if you see the rest of the vehicles in the stable.

Title: Re: Chuck's '83 TBird
Post by: Clayton on March 16, 2020, 06:55:57 PM
The Swedish chef and a bunch of Volvos  :giggle:. Still amazing work man. I knew what you were up to when I posted Saucy I just saw the classico jar and lost it
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 17, 2020, 08:02:05 PM
THIS (https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/firststart.mp4) happened today.

Ran it for several minutes. Fiddled with a couple settings, but the bulk of things will need to wait until I can actually get it out on the road. It has a full tank of gas that's been sitting for over 2 years. It's had Stabil 360 in it, and didn't smell too bad when I was doing the fuel filter stuff, but I'm sure it would be much happier with some fresh juice.

The green light on the side of the center console is the  WBO2 status indicator (at operating temp). The kit comes with a blue LED, but I bought a bunch of LEDs off Amazon to get a green one to match the dash lighting.

So far it seems to run OK. I'll mess with Warm-up settings again when the engine is cold. It currently isn't happy at idle unless the AFR is around 13.0-13.5. I'll double-check to see if there's any offset in the AFR in the WB, and make any adjustments needed there.

It's the old tune that was in the car when I parked it. However, I changed the spark map to a much more aggressive version (similar to the PE) from what was in there, and the firmware was updated. I never had a WBO2 in it previously, so the tune should get dialed in much better now.





Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 18, 2020, 02:55:19 PM
Got a few moments to get a bend in the panhard bar.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/Phardtweak.jpg)

Planning on ordering parts this weekend for the adjuster.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 21, 2020, 08:20:07 PM
While I'm waiting on panhard bar parts to show up, I took care of a couple other details that needed attention.

Got the panhard chassis bracket all fastened down.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/phchassisdone.jpg)
Inserted a nut plate behind the upper of the two side mounting bolts (It supposed to line up with an existing quad-shock mount) and ran the lower bolt through the frame. I didn't weld it, as I *may* revisit the chassis brace at some point, and didn't want to mess with cutting things out.

I went to install my non-power lock door plates, only to find that the DS one has gone missing at some point...
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/PSinstalled.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/DSmissing.jpg)

New floor mats ordered and on the next round of parts buying in a couple weeks, I'm going to pick up one of THESE (http://scottrodfab.com/shop/index.php?id_product=186&controller=product#/rtb-with_latch/color-satin_black) to tidy up things under the hood a bit and help aid in airflow management.
Title: Re: Chuck's '83 TBird
Post by: mcb82gt on March 23, 2020, 09:56:35 AM
That radiator piece is cool!  Thank Chuck.

Are you going to rivet it in?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 23, 2020, 10:31:46 AM
Not sure yet. I may do some small riv-nuts, as I'd rather be able to easily get it out of there if I need to more easily access anything with the IC or oil cooler.
Title: Re: Chuck's '83 TBird
Post by: mcb82gt on March 23, 2020, 11:10:45 AM
I agreed, would be nice to easily take off.  Let me know what you go with, thanks.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 26, 2020, 03:35:57 PM
The panhard parts showed up today.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/phadjparts.jpg)

Hoping to test fit things and get this together by the end of the weekend. Floor mats are supposed to arrive tomorrow.
Title: Re: Chuck's '83 TBird
Post by: Mikey97D on March 27, 2020, 09:12:23 AM
How is that insert being attached to the bar?  I see a chamfer, welded?  Will you be running a tap through it afterward?
Title: Re: Chuck's '83 TBird
Post by: BCA on March 27, 2020, 09:30:39 AM
So is the EVTM the inspiration for the green color?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 27, 2020, 09:32:18 AM
It'll be welded. I had no issues with the panhard bar I modded on my 240 using these parts. Same with the new upper links I built for this car with the weld-in bungs.

I have the car down, suspension loaded. I'm going to mock up the original bar to see what length the car wants for everything to be centered. Then I'll cut off the section to allow for me to insert the new parts to allow for some adjustment around that point.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 27, 2020, 09:33:14 AM
So is the EVTM the inspiration for the green color?

Heh.

Nope, just wanted something different.
Title: Re: Chuck's '83 TBird
Post by: BCA on March 27, 2020, 09:37:19 AM

Heh.

Nope, just wanted something different.

I can respect that.
It's why we own what we do and not another cookie cutter Mustang.  :smile:
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on March 27, 2020, 09:11:37 PM
Looking good. Can't wait to see it move under its own power again.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 29, 2020, 08:36:03 PM
Well, I started to make some progress today.

Got the rear centered under the car and mocked up what I needed the nominal length of the panhard bar to be.
Then I cut the LH threaded end off and cut it to fit the new adjuster parts in for the correct length.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/phardmock.jpg)

Then I grabbed the other weld bung from the package to weld it in. After it cooled a bit, I was test-fitting the jackscrew and it wouldn't thread in. So, I gave it a dirty look and grabbed the 5/8-18 bolt that was sitting on the bench...and that threaded in.

 :beatyoass:

I was sent a mis-made part. See that scribe line in the weld bung? That means LH threaded, as BOTH of them in the package should've been.  This one was RH threaded.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/pharddone_1.jpg)

So, instead of having the car done and on the ground today, I'm having to wait for a LH rod end to make this all work now.  :bs:


Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 03, 2020, 08:49:18 PM
Finally got a couple moments to get the panhard installed this evening.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/phardinstalled_2.jpg)

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/phardinstalled_1.jpg)

I may need to pop it back out quick and clearance the PS side of things. It's not super happy with the female rod end in there.

It is however ready to come down off the stands.

This weekend I'll be buying that fill piece for the front of the engine bay and getting the remaining bits to reconnect the heater.

I disconnected it waaaaay back when not because the core was leaking, but because I'd deleted the coolant passage out of the intake, and needed to figure out different coolant tubes, and never got around to it. Getting around to it now.

Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 04, 2020, 08:25:32 PM
I spent a little more time making myself feel better about the panhard bar. I needed to do a little clearancing of the rod end spacers to get things to be happier in the bracket.

Then we got to this point.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/ontheground.jpg)



Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 09, 2020, 07:19:13 PM
Got around to installing the ScottRodFab front cover this afternoon.

I wound up having to mod it a bit.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/Nosecover/cover_1.jpg)
The panels were marked
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/Nosecover/cover_2.jpg)
But they weren't correct for me. Found that out after I had started to drill the first one.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/Nosecover/cover_3.jpg)

A little cutting/fitting
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/Nosecover/cover_4.jpg)
And we're in place
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/Nosecover/cover_5.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/Nosecover/cover_6.jpg)

Yes, I kept the prop rod and radiator hold-downs, because this was more for airflow, than being pretty.

I just need a couple rivets to finish things up, but the rest of the original hardware holds everything down.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 10, 2020, 06:44:26 PM
Up next, heater hoses.

Some 5/8" SS tubing I've had sitting around for 12 years, just for this purpose, and a bunch of silicone elbows.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/heater%20hoses/htrhoseparts.jpg)

All mocked up, waiting on clamps and a couple tubing separators. (Thought I had enough clamps, and can't find my OE coolant hose clamp (that attaches to the valve cover).

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/heater%20hoses/hhmockup.jpg)

Once this is done, it'll be time to be eyeing the weather to see when I can spring this thing from the garage and take it for a test drive.
Title: Re: Chuck's '83 TBird
Post by: Clayton on April 10, 2020, 11:56:58 PM
I bet it'll be real nice to have it out and about again. I cant wait to see some new action shots!
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 12, 2020, 05:48:26 PM
I bet it'll be real nice to have it out and about again. I cant wait to see some new action shots!
Yeah, it hasn't been out of the garage in 2 years, at least.

The biggest thing will be seeing how much I screwed up the rear susp. :P That, and hoping I set up the 8.8 properly.

More things planned for the future, but right now I want to be able to drive it for a bit.
Title: Re: Chuck's '83 TBird
Post by: ISTLCRUZ on April 12, 2020, 06:44:50 PM
Hey Chuck, when you finally take her for a road test take some pictures of the ol’ bird & post em up.Always been a fan of your car. The Cobra wheels look like it should have left the factory with them. Awesome car!
Title: Re: Chuck's '83 TBird
Post by: Clayton on April 12, 2020, 07:10:39 PM
Yeah, it hasn't been out of the garage in 2 years, at least.

The biggest thing will be seeing how much I screwed up the rear susp. :P That, and hoping I set up the 8.8 properly.

More things planned for the future, but right now I want to be able to drive it for a bit.

Eh I have an feeling you're gonna be ok lol
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 18, 2020, 06:16:35 PM
It was a momentous day!

It got the heater hoses all sorted out and installed on Friday, which was the last thing to do on the list.

This afternoon, I got everything situated and fired the car up to get it out of the garage. Fire it up, make a couple adjustments in the tune while it's warming up, and then back that sucker out of the garage.

I toss the toddler in the car, and we go for a short trip around the block as a shakedown. No odd noises, no weird smells, seems good. Get back home, drop the kid off and go out for about a 5-6 mile drive. The car runs great. So far no noises from the suspension. Absolutely NO exhaust rattling on anything. Car feels good.

I get home and give it its first bath in probably 3-4 years.

Right after I take these pics and go to pull it back into the garage...Something has gone wrong. I have no FP prime and the car won't start. :disappointed:

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/out_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/out_2.jpg)

I only had a little time left to mess with it today, but it's acting weird. I get no FP prime when I should and the ECU acts like it's powered up, even when the key is off.  :dunno: Looking under the seat at it, one of the LEDs on the MS is flashing, like it has power.
It was also about this time that I realized that I forgot to tighten the main connector on the ECU. I'd just plugged it in when I reinstalled it in the car, but never got back to snugging the screws down. Reseating and tightening things down makes no difference.
The only car-side change was getting rid of the fusible link that powered this system with the fuse, but all is good there.

I'm going to pull the ECU tomorrow and check it out on the bench to see if anything looks amiss there.

*sigh* SO close.

Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on April 18, 2020, 07:16:34 PM
Ugh. So close. But the car looks great. I love the stance and those wheels. One day when I get off my ass and do a SN95 brake swap I'm going with those 94-98 Cobra wheels. They just look perfect on these cars.

Notice any difference with the pan hard setup?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 18, 2020, 07:31:33 PM
I didn't get enough time to really check it out. Didn't want to get on it too much right off the bat. ;)

Felt pretty good on the couple higher speed twisties I was able to get to, though.
Title: Re: Chuck's '83 TBird
Post by: ISTLCRUZ on April 18, 2020, 09:21:17 PM
That’s one nice 4-eye. How long have you owned it ? Any pics of before all the work ?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 18, 2020, 09:46:07 PM
I've had it since '96.

I didn't have a digital camera until '03-'04. I suppose I could go back through the thread and fix broken links from when my old host server folded, but I just haven't put in the effort.

Title: Re: Chuck's '83 TBird
Post by: Clayton on April 19, 2020, 04:08:46 PM
Little speed bumps pave the way unfortunately but, that's half the fun. They like to tease us.

Car looks phenomenal as always, glad to see it got some street time. Even if it was only a few miles.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 19, 2020, 06:24:05 PM
Well, I found the culprit. The new fan control relay trigger wiring is back-feeding into the ECU and affecting the injector circuitry.

When I pulled Fuse #1 HERE (https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2019/Lighting/Relay%20box%20wiring.pdf), the issue went away. Things should be the same, as all I did was pull a diode into the ECU case, instead of having it out at the relay on the old set-up. 

Can't drive it w/o a working fan, so I need to sort that issue out.

Simple enough fix though.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 20, 2020, 10:49:49 PM
Situation corrected. I needed to move the diode on the fan control circuit back out to the engine bay. That was the easier route vs. trying to feed another wire back into the cabin.

The car is ready to rock.
Title: Re: Chuck's '83 TBird
Post by: BCA on April 21, 2020, 08:51:10 AM
Glad you got that sorted. Good to see the bird back out in the sunlight, looking amazing as always.  8)

Looking forward to hear your impressions of the new rear suspension. 
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 24, 2020, 06:26:52 PM
Put about 15 miles on it today, doing a little more shakedown and tuning.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/042420_1.jpg)

Messed with some more warmup parameters, made sure the fan worked and went out. When I put it all back together, I'd messed with the spark map a bit (It had always been a little soft under boost). Need to pull a couple degrees back out under boost, but so far, so good.

Going to do a bolt check on the rear suspension this weekend, but other than that, we're ready for duty.  :mullet:
Title: Re: Chuck's '83 TBird
Post by: bodyman on April 25, 2020, 01:15:58 AM
Me  :like: your :ford:  :birdsmily:   :headbang:  on



Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on April 30, 2020, 12:22:30 AM
Let us know how it feels with all the rear suspension updates. Looking good  :biggrin:
Title: Re: Chuck's '83 TBird
Post by: Chuck W on May 07, 2020, 06:27:01 PM
Weather and schedule haven't been kind to getting this out and about much lately.

I'd forgotten about swapping the speedo gear (went from 3.73's to 3.55's), so I took care of that.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/speedogear.jpg)

After my last drive, I noticed that the AFR targets were off. I've just been letting TunerStudio Autotune deal with making adjustments around town, but I saw it was running a bit rich down low.
I corrected that and was able to drive the car to work today (Been WFH mostly, and it's been raining on the other days I've gone in).

I was able to get a couple more pics of it out and about on a couple of errands (and NOT in my garage or driveway)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/050720_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/050720_2.jpg)

Want to get some more miles on it before I decide what I think about the suspension. Had it up to about 70-80mph today, but didn't find too many twisties to feel things out.
With the big Cobra rear sway bar (the big solid one), I'm not sure if I'm going to need to increase the rear spring rate or not. I
could also drop the panhard down a bit too. My roll center in the front is kinda low, so that messes with the overall roll axis.

I do need to roll the front fenders a bit. I get some rub on the pass side on bumps. It's done that since I redid things a while back, so I just need to get around to it.

Looking forward to more good weather!
Title: Re: Chuck's '83 TBird
Post by: Chuck W on May 14, 2020, 06:40:39 PM
Well, I bought one of these to deal with the tire rub situation.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/fendroller_1.jpg)(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/fendroller_2.jpg)

It worked OK, so we'll see if that helps when I can get back on the road (supposed to rain all weekend...)

I'll probably do the driver side for good measure.

I also noticed that the pass side front is a little lower than the driver's, so that probably isn't helping.
Looks like I need to some up with a spring shim to raise it up a touch. (*Goes to dig through the stash in the garage*)
Title: Re: Chuck's '83 TBird
Post by: Chuck W on June 20, 2020, 05:18:31 PM
Not much has been happening with this, other than driving it a bit.

I did take care of the slight PS ride height issue yesterday by adding in another one of the spring shims I had.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/PSspring.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/spacer_1.jpg)

I did a bolt check on the rear suspension, and only found one fastener loose (One of the jam nuts on the PS upperlink), so that's nice.

I did have a loud bang a couple of times while driving it over the past couple of weeks, after hitting kind of a sharp bump in the road. Couldn't see any contact on anything when I checked it out at that time, but I think I found the culprit.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/closephard.jpg)

The bolt axle mount for the panhard bar was sticking out about 1/2" or so from the nut and looked like it fouls on the plastic gas tank cover. It causes it to bang against the tank, which can be kind of loud. There's no risk of it hitting the gas tank during the suspension travel, just that cover that is spaced out about 1" from the front of the tank.

I flipped the bolt around, so the shorter bolt head was facing rearward, and it looks like that should solve that problem.


Title: Re: Chuck's '83 TBird
Post by: Chuck W on June 20, 2020, 08:38:12 PM
Looking back at that first pic, I need to hit the front suspension with some Simple Green and the power washer...

I originally was worried that the panhard axle mount would bang against the fuel tank strap mounting boss on the frame, but it looks like the axle will hit the bumpstop a good 3/4" before that happens.

I still think I want to look into some stiffer rear springs.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on July 15, 2020, 10:37:35 AM
Dealing with an odd failure. The last couple of times I've driven the car, it's seemed "off". I've been chasing around the detonation under boost issue and had just dropped a new  tune for the drive to work on Mon.

Seemed better, but still was rattling a bit. Took it easy the rest of the drives to and from work. When leaving work, and getting home and letting it idle, heard the unmistakable sound of a 2.3T running on 3 cylinders.

Getting out and pulling plug wires as it was running, #4 was unresponsive. I set out swapping plugs, wires, injectors and everything was pointing to #4 being "dead". Which is NOT what I wanted right now. (The car would've been shoved back into storage until I felt like messing with it again.)

The one thing I noticed was that I seemed to be getting no spark at all out on #4. Every other wire I pulled would result in the audible "ticking" or spark jumping to ground. It's still a TFI ignition, so it's pretty "dumb" on what cylinders is getting spark. I checked the cap, but saw no issues. The rest of the dist looked fine.

Chatting with Gumby, he suggested to check the cap again or do a compression check. I headed back out and completely pulled the cap out. Upon inspection, I noticed that the center (coil) post was loose. Testing it with a multimeter confirmed that it would occasionally lose continuity when it was moved.

So, basically what was happening was there was enough play in the coil terminal, that as the spring-loaded contact on the rotor would spin, it would move the post just enough to break contact just as it rotated to the #4 terminal to fire. :nonchalance:

New cap and rotor are on the way...

Title: Re: Chuck's '83 TBird
Post by: Mikey97D on July 15, 2020, 01:55:54 PM
Glad you found the culprit and you didn't have to do a compression test.  Bizarre failure.
Title: Re: Chuck's '83 TBird
Post by: thunderjet302 on July 16, 2020, 12:23:25 AM
That's just odd, but an easy fix.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on July 16, 2020, 03:48:34 PM
Welp. New cap/rotor and fresh plug wires did not fix the problem. #4 is still not sparking.

Could be a bad distributor or TFI module.  :dunno:
Title: Re: Chuck's '83 TBird
Post by: softtouch on July 16, 2020, 05:29:31 PM
Try disconnecting the SPOUT wire to shift the timing to basic.
The rotor and cap plug wire posts alignment may be off.
If you are operating on the hairy edge, moving the timing may make it better or worse.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on July 16, 2020, 06:08:00 PM
It's possible that the dist/aux gear are wearing a bit and causing an alignment issue. There is a little rotational "slop" in the assembly, but I need to see what spec is,

Title: Re: Chuck's '83 TBird
Post by: Chuck W on July 18, 2020, 06:12:04 PM
And the 2.3T Achilles's Heel strikes again.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/dist/distgearworn.jpg)

Need to source an aux shaft, but I have several dist gears here to use.

Might as well replace the timing belt while I'm at it.
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on July 18, 2020, 08:15:53 PM
Do the 2.3’s have the bushing in the body of the distributor like the 5.0’s? Only ask is the bushing in the original distributor I had for my Coupe was the cause of the high rpm misfires. It was just worn out to the point the shaft would wobble in the body under load. Got a reman unit and transferred all my electronics over to it and it’s been good for 15 years.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on July 18, 2020, 09:02:43 PM
Not sure. I don't sense any "wobble". I do have 2-3 other dists in the garage. Just probably need to swap the aux shaft anyway, just to be safe.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on July 19, 2020, 03:49:51 PM
Well, I got back to it today, and detected the very slightest bit of radial play in the distributor.

So, I grabbed my stash of 2.3 distributors I still had.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/dist/diststash.jpg)

I had one, never-used, refurbished unit, but the gear was damaged, and one of the dummy dists for the DIS/EDIS cars with a good gear.

The "new" dist also had the wrong style rotor mount and I wanted to reuse the factory Hall sensor from the current unit, so I swapped everything over.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/dist/rotormounts.jpg)

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2020/dist/refurbeddist.jpg)

Now to find an aux shaft.
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on July 19, 2020, 05:03:22 PM
What is the aux shaft you are needing? Is this something 2.3L specific?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on July 19, 2020, 05:13:51 PM
What is the aux shaft you are needing? Is this something 2.3L specific?

Yeah. It's the shaft that turns the dist and drives the oil pump. Driven by the timing belt.

I've got a line on a used one.

I could get stupid and go billet, etc, but this particular engine isn't worth any of that. Priority is making the car driveable.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on August 14, 2020, 07:32:01 PM
I got this all together a couple of weeks ago. Things are good again.

Just haven't had much chance to drive it though. :nonchalance:
Title: Re: Chuck's '83 TBird
Post by: Chuck W on August 24, 2020, 08:32:12 AM
Driven it a bit and needless to say, it's fixed. I can slam my foot into it and it just goes, with no detonation.  :toothless:

Looks like I might need to replace my old Serial->USB adapter on my MS unit. I keep having connectivity drops. It *is* 15-ish years old, so it's probably due for replacement.
I want to sort that out before I up the boost a bit.
Title: Re: Chuck's '83 TBird
Post by: Tbird232ci on August 25, 2020, 05:08:40 AM
Serial adapter? I haven't seen one of those in years!
Title: Re: Chuck's '83 TBird
Post by: Chuck W on August 25, 2020, 08:01:46 AM
Serial adapter? I haven't seen one of those in years!
I built this MS back in '04-'05...
Title: Re: Chuck's '83 TBird
Post by: Tbird232ci on August 26, 2020, 05:34:10 AM

I actually remember you building it. That was before I could solder circuit boards, and I remember seeing you doing that and saying hell no.

Have you considered going to an MS3? It has much better processing speeds and better resolution. Would it benefit you? Who knows.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on August 26, 2020, 07:43:23 AM

I actually remember you building it. That was before I could solder circuit boards, and I remember seeing you doing that and saying hell no.

Have you considered going to an MS3? It has much better processing speeds and better resolution. Would it benefit you? Who knows.

It was actually my first electronics project. :giggle:

Unless this ECU totally shiznits the bed, I don't plan on swapping engine management in this thing until it gets a new motor. The old MS1 with the Extra Code runs this old tractor lump just fine.

What I would use depends on the project, really. I've got a MaxxECU Sport unit sitting here next to my desk for my Volvo 240 project. I looked at MS3 for that project, but it wasn't going to do what I wanted it to.
Title: Re: Chuck's '83 TBird
Post by: Tbird232ci on August 27, 2020, 05:35:42 AM
I have a MS3 sitting in the garage that will eventually find it's way into my car.

Did you pretty much ditch the factory harness other than the stuff like gauges and lights?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on August 27, 2020, 07:15:06 AM
I built my own engine harness when I did this one. I'd do it MUCH differently if I were to do it now. It's not worth tearing it all apart now. (And dospoogeent things better. I've lost all of my old notes...)

Dash harness is still the same, and I just redid all of the main lighting power wiring recently.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on November 24, 2020, 04:20:02 PM
Welp, it looks like we're tucked away for winter now.

Pulled the battery out of it yesterday and have some StaBil in the tank.

The only thing I have planned for it over the winter is to pull the MegaSquirt out and replace the old serial connector on it with a Serial-to-USB port.
I've been having my connection drop on me while trying to tune/log and I think either the old in-line adapter is starting to fail, or the serial connector on the board is getting flaky after 15 years.
Title: Re: Chuck's '83 TBird
Post by: Mikey97D on November 25, 2020, 10:24:00 AM
I need to put the car away over the weekend too.

I am not a big fan of the StaBil fuel additive.  When I have taken the carbs apart on small engine equipment that had Stabil in it then began having problems I always found a milky white residue.

I found from the snowmobile groups use Star Tron because it isn't as ratio dependent and has a better shelf life in the tank for protection.  Since switching I haven't had to clean the carbs.  Thought I would pass it along for next year.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on November 25, 2020, 11:15:04 AM
I've had the StaBil 360 in there for a couple years, and haven't seen an issue. I'm FI and not carbed though. I didn't see anything odd when I had the system cracked open a couple times this past year.

Thanks for the info, though.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 18, 2021, 06:13:12 PM
Took apart the MS unit the other day to swap out the old serial port with the USB/serial adapter.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2021/MS/MS_2.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2021/MS/MS_1.jpg)

Checked out the ECU to make sure it connected to the laptop fine, and reinstalled the ECU and the battery.

Got it fired up a couple days ago, but haven't had a chance to get it out for a drive yet, but that's coming soon.

Ready for a new season.  :smile:
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on May 24, 2022, 03:01:18 PM
Okay, its been a year so I am hoping you have had some drive time.  What is the verdict on the rear suspension?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on May 24, 2022, 06:14:42 PM
Funny you should bring it up. I tried to drive it to work this morning, but the clutch was acting weird, so I turned around and took another vehicle. Either the cable needs to be adjusted, or it's getting ready to snap again. Overly grumbly about going into gear. Especially first when coming to a stop. Pedal feel felt a little "off", so I'm guessing the cable is about to go. Now I have to dig up what one I used 15 years ago or so when it snapped the last time  :crazy:

As far as the suspension goes. I like it. It does need a bit more roll stiffness in the rear, so I'm probably going to look into the MM rear springs they do for their TorqueArm installs. Other than that, I have a "clank!" on the passenger rear when going over bumps when loaded at speed, but I haven't found the culprit yet.
A few more minor niggling things, but nothing that really detracts from the drive.

My goal this year was just to drive it, and not do too much other than a couple of minor fixes and maybe try and dial the tune in a bit better, now that I finally have a WBO2 in it.

Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on May 25, 2022, 11:46:45 AM
Well that sucks on the clutch cable and hopefully its just that and an easy fix and you get some quality time with the mistress (at least that is what mine gets called).
Title: Re: Chuck's '83 TBird
Post by: Chuck W on June 04, 2022, 06:09:30 PM
Well, I took a few minutes today to look over the clutch cable and it all appears to be fine.
It did look a little "loose" so I tightened it a couple turns.  It's got a straight-pull bellhousing on it (so no silly dog-bine cable) and it's using the Ford Motorsport AL quadrant and firewall adjuster, with the adjustable cable.

Took it out for a drive around the neighborhood. Clutch felt better, but it gets really noisy is I try and downshift to 1st too soon. I don't remember it doing that before and all other shifts are fine, so perhaps it's a combination of T5 manners and a slightly snarky syncro.

Good enough for me for the moment. Means I can get back to driving it once in a while.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on June 24, 2022, 09:00:51 AM
Drove this a couple times over the past week and found new things to fix.

I've noticed the past couple of times that the car has run hotter than usual and has struggled to cool down at idle/low speeds.
I've heard the fan(s) running, but yesterday I discovered only 1 was operating. That explains that. Need to see if the fan motor itself is dead, or a bad connection. Put it in a long while back, so it may be time for an upgrade.

Yesterday I also noticed that the clutch is starting to slip a bit. Hasn't been an issue around town, but on the interstate, cruising around 70 in 5th, when I put my foot into it to pass someone, once the boost comes up to around 12psi, the clutch starts to slip and the revs take off.
I think I have an extra clutch in the garage, so I need to dig that out.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on July 09, 2022, 05:26:42 PM
Got the old fans out today and sure enough, the DS one is dead.

I have a bunch of Volvo fans here, so I thought I'd test fit the shroud to see if one of those would work. Actually would fit pretty nice...if the IC tubing wasn't so close to the bottom of the core support. Looks like I'll need to sort another option.
(Plus side, it looks like this Volvo fan set I have will fit the LTS, seeing as there is no IC plumbing in the way)

I'll see what I can dig up, but probably won't mess with it much the next couple of weeks, as we're heading on vacation next Friday.
Title: Re: Chuck's '83 TBird
Post by: Pro SC on July 31, 2022, 07:16:37 AM
Car is looking good Chuck, glad to see you are still up to your old tricks.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on September 02, 2022, 06:27:09 PM
I kind of drug the fan replacement out a bit, as I was working on other stuff.

I wound up picking up a Contour fan setup, and went the easy route with the LMR installation brackets.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2022/Cooling%20Fan/fanbracket.jpg)

I had it all installed a couple weeks back, but didn't get to the wiring until today.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2022/Cooling%20Fan/wiredalmost.jpg)

And then I ran into a snag.

Firstly, these fans pull WAY more amperage than my old dual fan set did (It was running on a 20A circuit) and pops the fuse upon start-up.

40A appears to be the max draw, which leads to the second problem. The current wiring and relays I have built in are not enough to handle that much. The relay is a 35A unit and the wiring is maybe 14ga out of the distribution box.

I could possibly separate the fans each to their own power/relay, but I don't have enough room in the distribution box for a second (well 6th) relay, and the 50A 280 type relays are too big to fit in place of the 35A ones. I do have 2 other un-used 20A circuits in there though.
I do have enough room in the MAXI fuse box for another circuit (40A), but then I would need to add an external relay...which kind of bugs me, now that everything is all contained currently.

Additionally, it now seems like the trigger circuit out of the MS box is acting up, so I need to investigate that as well.

Need to dig into it and decide the route I want to take to get it functional again.

Upside, I did find my extra clutch in the garage, so I don't need to buy one.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2022/Drivetrain/Clutch/clutchassy.jpg)
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 25, 2023, 07:53:45 PM
OK, got the work on the 850 done, so it was time to stick the Tbird in the garage to get a couple things done.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2022/Cooling%20Fan/inthebay.jpg)

Gotta rework my fuse/relay boxes a bit so I can add a new power lead to the fans and add a larger relay.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2022/Cooling%20Fan/fuserelaybox.jpg)

I have to shuffle a couple things around, but I think I can get it all to fit.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 27, 2023, 06:50:04 PM
Well, I decided to take the day off work, seeing as I was in a lull waiting on parts for about 3 projects and the wife and kids were gone for the day.

Got into the fan wiring rework today.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2022/Cooling%20Fan/fanrewire_1.jpg)

I figured out the plan on what needed to move where and what needed to possibly be removed.

I originally thought I was going to replace my MAXI fuse box feed with a new 4-circuit one, but then I realized that the lugs, etc that I had wouldn't allow me to do that, so I opted to make a 2nd 3-circuit lead for the box.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2022/Cooling%20Fan/fanrewire_2.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2022/Cooling%20Fan/fanrewire_3.jpg)

The box rework wasn't too terrible in the end.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2022/Cooling%20Fan/fanrewire_4.jpg)

You can see how much larger the 50A relay is vs the 30A. The pin-out was the same between the two, but the terminals were in the middle of the larger relay, so it wouldn't fit in the corner. I needed to move the sockets in the box down a row. This necessitated moving that 10A fuse location off to the left side. Easy enough to move the lead.

The smaller relay was one that the supplier had added to allow for fan control with AC (which this car doesn't currently have). It wasn't being used, so it could be removed, but I needed to relocate a terminal to an unused slot under the new relay.

Since I was no longer using the rightmost 20A fuse to feed the fans, I could remove that feed, but I still needed the 12V for the coil side of the relay (it gets triggered by the MS), so I left part of the circuit in place and just stuck a small (5A) fuse in there for now.

The new feed from the MAXI box now feeds the power to the fan relay, and a new larger feed out to the fans was made up.

Everything there should be good to go now.

Next project is to replace the clutch. Need to get a new TO bearing and rear main seal, but I should have everything else I need to tackle that.

Need to grab a couple door strikes too. The plastic sleeve is gone from both, and the doors require more effort to close (and make a bit of noise). I'd forgotten about needing those until I moved the car into the garage.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 28, 2023, 10:36:52 AM
So, I was getting the Bird up on stands and found this on the roof...

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Body/fckers.jpg)

Probably from some idiot's NYE celebrations.

Glad it wasn't one of us, but this is ridiculous.
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on January 28, 2023, 11:07:05 AM
As in the roof of your garage?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 28, 2023, 11:24:14 AM
The roof of the Tbird.

It was in the carport until about a week ago.

There is a corresponding hole in the top of the (fabric) carport.

Didn't come through the headliner, so the sheetmetal took out most of the energy.
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on January 28, 2023, 01:50:38 PM
Holy …man that sucks the big one.  That’s literally metal work and repainting the top of the car. mofookie’s that do that BS don’t care about anything until it happens to them and them.

Hopefully you can get it fixed for a reasonable amount.
Title: Re: Chuck's '83 TBird
Post by: jrad235 on January 28, 2023, 08:59:26 PM
Holy shiznit that sucks!
Title: Re: Chuck's '83 TBird
Post by: Mikey97D on January 30, 2023, 09:58:32 AM
Yikes!

Thank the big Guy that didn't hit anyone.
Title: Re: Chuck's '83 TBird
Post by: mcb82gt on January 30, 2023, 10:27:44 AM
Whoa!!!  That is rediculous.   What size hole?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 30, 2023, 12:38:14 PM
Whoa!!!  That is rediculous.   What size hole?

About 9mm.

The metal's also pushed down about 1/4" around the hole.

Title: Re: Chuck's '83 TBird
Post by: Chuck W on January 31, 2023, 08:38:03 PM
Had an hour after work to get the T5 out.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Drivetrain/transout.jpg)

I need to drop the starter so I can get the bell off and remove the clutch and flywheel.

Still fuming about the hole in the top of the car... :beatyoass:
Title: Re: Chuck's '83 TBird
Post by: Beau on February 04, 2023, 01:10:25 PM
Still fuming about the hole in the top of the car... :beatyoass:
 Yeh...goes without the need to be said...idots WITH guns far outweigh those owners who are responsible.
Thankfully none of yous were hurt. Too bad you can't find the little ass hat(s) that did it... and: :beatyoass:
Title: Re: Chuck's '83 TBird
Post by: Chuck W on February 04, 2023, 02:38:36 PM
Got out on the car again for a bit this afternoon.

Got the rest of the clutch bits removed.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Drivetrain/removed.jpg)

The old clutch doesn't "look" too bad, I know it was slipping.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Drivetrain/oldclutch.jpg)

Very slight leak at the rear main, so that's going to get replaced while I'm in here.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Drivetrain/rearmain.jpg)

Next I turned my attention to the interior, so I can have access to work on the hole.

Wrestled this thing out. Not very easy with the cage.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Body/headlinerout.jpg)

Here's the hole from the inside. Haven't found the slug yet, but did see where it impacted/scuffed the headliner board.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Body/holeinside.jpg)

Spent a little time knocking it back up a bit. Going to zap that hole closed and smooth things out.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Body/holerepair_1.jpg)

I'm probably just going to do the best I can to recoat this and blend it. I don't have the time or inclination to have the whole roof of the car repainted right now.

After trying to contort my mid-50's body around in the back seat area to get interior panels loose, I'm about 75% decided that I'm going to gut and rework the rear of the cage and get the rear seat back in this. This cage is dumb. :p
Title: Re: Chuck's '83 TBird
Post by: Chuck W on February 12, 2023, 02:40:08 PM
Got the clutch replacement all wrapped up today. Nothing exciting to look at, so no pics.

With this, the fan wiring, and the door strikers done, this original scope of this project is completed.

Now, I have to deal with "Part 2".

This is going to include:
- Fixing roof hole
- Reworking rear cage bars and reinstalling the rear seat.
- Relocating battery to trunk from the rear seat area.
- Fix driver window, as it looks like one of the attachments of the glass to its holder has broken, so it tips around a bit.

Time to start hacking and grinding...
Title: Re: Chuck's '83 TBird
Post by: Chuck W on February 18, 2023, 02:14:27 PM
Started to tackle the cage stuff today, as I wound up with some extra time I wasn't planning on.

Wrestled the driver side rear interior panels out (Man, I didn't leave myself a lot of working room when I did this originally...) and this is what I'm starting with.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/start_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/start_2.jpg)
Why, oh why?
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/shouldyou.jpg)

Broke out the saw-zall and took the first step.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/firstcut_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/firstcut_2.jpg)

Gotta do a couple more things before I chop out the rest and then get to grinding things smooth, but we're underway.

Title: Re: Chuck's '83 TBird
Post by: Chuck W on February 19, 2023, 05:17:28 PM
Before I do any more cutting on the cage, I figured I'd pause and get the car resting on it's suspension.

I wanted it up off of the ground a bit, so I threw together a set of wheel cribs from a bunch of lumber I had sitting around.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/whcribs_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/whcribs_2.jpg)

This will make working around it a bit easier.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on February 26, 2023, 05:50:54 PM
Back in action with the saw today for a bit.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/alltubesout.jpg)

All unneeded tubes out and now for the really nasty bit of grinding things smooth.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/tubeless.jpg)

Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 02, 2023, 06:57:05 PM
Ugh. Grinding in a cardboard copuppies kinda sucks.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/grind_1.jpg)

Only 3 more spots to do...
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on March 02, 2023, 09:47:16 PM
Looks good and pretty soon it will be one left then prep for paint, paint, and done.
Title: Re: Chuck's '83 TBird
Post by: Mikey97D on March 03, 2023, 07:50:54 AM
That is cleaning up nice. 

Look on the bright side, at least it isn't 90°+ outside and humid.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 04, 2023, 05:04:07 PM
OK, I decided that I was going to get this stuff ground down today.  :beatyoass:

I first went through with the cut-off wheel to get as much of the tubing bits out of the way, so I was mainly just dealing with weld clean-up.
Enclosed myself in a bunch of cardboard and had at it.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/grind_2.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/grind_3.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/grind_4.jpg)

I then went back with the flapper disc to smooth things up a bit

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/grind_5.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/grind_6.jpg)

Then I spent the next 20 minutes or so dealing with clean-up of all of the metal dust... :tard:

Once I get the new tubes sorted, I'm going to come back in and make another smoothing pass at things before paint.

Glad that bits over.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 11, 2023, 06:26:41 PM
OK, so I think this is where the rear bars are going to wind up.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/rearbars_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/rearbars_2.jpg)

They will wind up covered in high-density foam, and my wife is going to make up some covers to match the interior. I'll probably also put some around the top of the main hoop.

I wanted to limit any crazy modifications to the interior panels, and didn't want to make them any more difficult to get back in. It was a fight to get them out with all of the old bars in place. Especially the upper section.

I was limited on how much I could bend the tubes with my low-budget bender. I wanted to turn it down a little tighter in the trunk, but just couldn't without smashing the tubes. It's like 3 small bends to get it angled down and reduce the slash cut. (4 bends in total on the bar).
Gotta notch the front and get things cleaned up for the base plate in the back.

Need to sort out the trunk battery mount and get the couple bits I need to do the relocation from the back seat.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 18, 2023, 01:09:12 PM
Got the passenger-side tube bent up today.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/reartubes.jpg)

Just need to cut the rear to mate to the floor and notch the front. Then I'll get the foot plates welded up and then prep them for painting. I'm going to paint them out of the car, and then touch up the areas around the welds afterwards.

After talking to a couple people, I think the plan for the roof is to get it sealed up and smoothed out and wrap the roof of the car for the time being. I have a buddy who does it, so I just need to make sure things are prepped properly.
Some may not like the idea, but I want the car back on the road. I have other projects to work on.
Title: Re: Chuck's '83 TBird
Post by: Ductape91 on March 18, 2023, 08:56:01 PM
Are you wrapping just the top, upper half(two tone) or the whole car?
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 18, 2023, 09:46:52 PM
Are you wrapping just the top, upper half(two tone) or the whole car?

Just the roof.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 26, 2023, 06:21:28 PM
*sigh*
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Body/brokenglass.jpg)

Not sure how I managed to do it, but I shattered the DS door glass while trying to fix the loose mount.
Luckily I had a spare in one of the doors I have in storage. Just need to get it pulled and transferred.

Been bouncing back and forth between this and Sadie's Bug the past week or so.

Got the rear cage bars fabbed up. Just need to get the paint and get them into the car. Just going to pick up some of the 2K aerosol stuff in the 1Q paint code.

Need to get my battery relocation stuff ordered so I can wrap that up. I thought about moving it back under the hood, but I just don't have a place for it now.

Speaking of wrap, I need to also finish up the bullet hole patching so I can get with my buddy to have the top of the car wrapped.
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on March 26, 2023, 06:32:13 PM
Well that sucks man. I’ve had to replace one window in my 83 and one in the 85 TC (long ago sold) and both were from thieves that didn’t believe the red blinking led in the dash.

Are the door glass on these cars no longer made? Only ask is I know where a 85/86 car is that I could pull the windows out of if needed.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 26, 2023, 06:54:22 PM
I'm not sure if they're still made or not.

I have 4 doors, 3 fenders, a hood and header panel sitting in my storage shed at the other property. I know one set of the doors was a vent-window car, but I wasn't sure about the other.

The set of silver 83-84 doors I have has the regular full glass in them. Drug the DS door home a little while ago.  Man, these doors are heavy...

Title: Re: Chuck's '83 TBird
Post by: Mikey97D on March 27, 2023, 10:16:41 AM
Sorry to see that Chuck.

Glad you have a backup though.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 27, 2023, 11:22:39 AM

I've had door glass in and out of the cars multiple times over the past 25-30 years...this is the first one that has exploded on me.

Got the battery relocation stuff ordered last night, so that's on the way.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on March 27, 2023, 06:26:56 PM
Had a bonus hour available today.

Replacement glass installed.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Body/newglass.jpg)
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 01, 2023, 05:13:10 PM
The battery relocation kit showed up today.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Battery%20Relocate/relocatekit.jpg)

My current set-up that is in the rear seat area is just using a mega-fuse as protection, but I opted to go with the dual circuit-breakers this time. It should also allow me an easier battery disconnect when the car sits for a little bit, but I plan to be driving it more moving forward.

I bought a battery box, which is kind of over-kill for the smaller Odyssey battery I have, but was trying to sort out packaging it and a full-size spare tire in the trunk.

Option 1 - Spare in the stock location and battery up on the frame
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Battery%20Relocate/option_1_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Battery%20Relocate/option_1_2.jpg)

Option 2 - Spare relocated and battery in the well
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Battery%20Relocate/option_2_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Battery%20Relocate/option_2_2.jpg)

Option 3 - Spare in the stock location and Odyssey up on the frame with no box
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Battery%20Relocate/option_3.jpg)
I can just cut my current Odyssey mount from the rear sear area and weld it down in the trunk.

With the box, I was going to mount the C.B. circuitry on the side of the box, but with the Odyssey, I'll mount them on a board in an accessible location.

I'm leaning towards Option 3 and saving the box for another project at the moment, as I really don't *need* a box for the Odyssey.

Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 02, 2023, 06:24:13 PM
Got the battery base cut out from the old location to try out in the new one.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Battery%20Relocate/odysseymount.jpg)

I think I'm going to run with Option 3 for now.

Paint is ordered and talked with my buddy about the wrap for the top.
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on April 02, 2023, 07:29:20 PM
100% agree with Option 3.
Title: Re: Chuck's '83 TBird
Post by: mcb82gt on April 03, 2023, 11:25:15 AM
I think all 3 look fine lol

Cant go wrong.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 04, 2023, 08:28:21 PM
Got the C.B.'s mounted on their board.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Battery%20Relocate/cbboard.jpg)

Welded the battery tray down and mocked up the location of the C.B.'s. Should be well enough out of the way.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Battery%20Relocate/layout.jpg)
Title: Re: Chuck's '83 TBird
Post by: Mikey97D on April 05, 2023, 08:21:52 AM
What is the reasoning for running the circuit breakers in parallel?  In case one goes bad you have a backup?

Thanks!
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 05, 2023, 12:39:31 PM
It was recommended by the supplier of the kit. There are arguments for and against it.
Considering I had nothing in place with the original set-up (Oops), so anything is an improvement. The battery spent most of the time disconnected, but I never had any issues.

I may also move the starter solenoid to the back, but I don't think it's overly needed in the application.
Title: Re: Chuck's '83 TBird
Post by: softtouch on April 05, 2023, 01:54:07 PM
The parallel CBs will split the load. You can draw up to 300 amps . Maybe 150 amps is not enough for the cold cranking  draw for some engines.  
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 05, 2023, 01:58:28 PM
The parallel CBs will split the load. You can draw up to 300 amps . Maybe 150 amps is not enough for the cold cranking  draw for some engines.  

In theory, yes. The arguments against it say otherwise.  It's more than needed for my application and any potential future use.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on April 23, 2023, 08:55:59 PM
Battery relocation is done and wiring all run.

The welding is done on the cage bars and the hole is filled in the roof.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/welded_1.jpg)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/welded_2.jpg)

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/topweld.jpg)

Need to prep all of the needed spots on the cage for paint and get the roof spot smoothed and sealed up.

I also now need to find some rear seat belts for this. I looked in my storage shed and all of my TBird parts bins and they are nowhere to be found. It's highly possible that they got "yeeted" as I didn't think I was going to need them. :giggle:
Title: Re: Chuck's '83 TBird
Post by: Mikey97D on April 24, 2023, 10:14:33 AM
Looking Good!

I think LMR has the repo Mustang belts in a bunch of colors if you want something close to original.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on May 06, 2023, 07:12:46 PM
OK, almost had a successful day on the TBird.

Got the interior all in the car and ready to go. (Sorry about the lousy pic...hard to get good lighting in the garage)
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Cage%20rework/rearseat_in.jpg)

Then I flip the breakers on the power and go to start the car...and I hear no FP prime. Ugh.

Looks like there is an issue between my MS relay board and the FP relay. The wiring runs down the pass side rocker, so I might've messed up something mucking around with the battery cable run, etc.
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on May 06, 2023, 09:16:03 PM
Looks good man! Must have been a fuel thing today. Helped my buddy on his 69 Mustang and it ended up being a $8 filter…ugh.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on May 06, 2023, 11:27:10 PM
Yeah, I just spent the day getting all of the parts that belong INSIDE the car back in their spots. It was nice to get that sorted.

Sucks I need to pull some of it back out to track down the issue.
I know what the issue is, but I did this MS install so long ago, I'm going to have to dig into where the break is.

When I did the install, I removed the old EC power relay but kept the stock FP relay. The MS relay board has relays for both the ECU and the FP. Basically I'm double-relay-ing the FP, as I'm using the relay board FP repay to trigger the stock one in the trunk. Kind of redundant, but it works, and I'm not "planning" on any major changes to the engine management wiring for now. (Even though it needs it, honestly) I would do things A LOT differently now than 17 years ago.

I wired up my 240 differently 10 years ago when I did the MS install on that with no relay board. I wish I hadn't used it on the Tbird, but didn't know better and doubted my abilities a bit more at the time and though it would be "easier" with it.
We'll see where I wind up after I dig into the wires.

I also need to investigate the oil pressure gauge. I noticed it was dead when I pulled the car into the garage. It doesn't "jump" when the key is turned like the H2O temp gauge, so perhaps I have a bad sender.

The cage looks OK as long as you don't look closely at the cut/ground areas. I didn't have it in me to really smooth those out as well as they needed to be. Most of it's going to be covered with the padding anyway.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on May 06, 2023, 11:44:14 PM
OK, well call off the search for why the FP wasn't kicking on.

Evidently the inertia switch had gotten triggered somehow. I stuck my finger in and pushed on the button and it reset.  The car started just fine. Glad I figured that out before I tore everything apart.

Gonna leave all of that as-is for now. Redundant? yes, but it has worked for 17 years, If/when I do any drivetrain changes, I'll rewire all of this stuff then.

Oil pressure gauge is next on the list as is smoothing out the roof spot a bit.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on May 08, 2023, 07:11:20 PM
Did a quick test of the oil pressure gauge by grounding the sender lead. It went fill sweep.

Time for a new sending unit.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on May 17, 2023, 05:47:55 PM
Got the oil pressure sender yesterday and got it swapped out today.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/oilsender.jpg)

We now have a working gauge again.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/oilpressure.jpg)

Going to try and do the finish sand on the primered spot on the roof this weekend and get some paint on it.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Body/primedforpaint.jpg)

I have some 2K paint, so not going to activate that until I'm ready for it. The weather is supposed to be nice this weekend, so hopefully that will all be wrapped up.
Title: Re: Chuck's '83 TBird
Post by: mcb82gt on May 18, 2023, 09:43:40 AM
I never understood the premium sound ON/OFF switch, why the hell would you ever turn it OFF??  !!!   lol
Title: Re: Chuck's '83 TBird
Post by: Chuck W on May 18, 2023, 10:06:43 AM
Yeah. That would make more sense in a dealer demo or something. Not in a road-going production vehicle.

I don't remember why I left the switch in place when I modded the panel for the gauges (I mean, it's probably been almost 20 years since I did that...)
Title: Re: Chuck's '83 TBird
Post by: softtouch on May 20, 2023, 12:51:03 AM
Looks like the "Premium Sound Switch" turns on an additional amplifier to put it in "Boost Mode".
In the EVTM it's called the "Amplifier Switch"
I guess it's used if you want to rattle the neighbor's windows.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on May 20, 2023, 08:12:58 AM
Yeah. Just one of those odd 80's redundancies. Just install the amp and such and there's no need for an ON/OFF switch. It's not like we're talking about 500W of extra power or anything...  :giggle:
Title: Re: Chuck's '83 TBird
Post by: Beau on May 20, 2023, 12:39:36 PM
Personally, I think it'd make a great idea for a kill switch for the ignition. Nobody would ever suspect it.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on May 21, 2023, 10:46:18 PM
Well, the paint is on the car.

(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Body/painted.jpg)

I'm going to wet sand it here in the next day or so to get rid of the over-spray and a couple runs. Then I'll give it a quick polish pass.

The color is off, but the spot is covered and will be covered by vinyl, so I'm not stressing it. I want the car available to drive.

The 1K stuff I bought for the cage bits matched better than this 2K product did. This car doesn't sit out in the sun/weather at all, so it's not faded paint contrast, just a bad mix. It seems like good solid stuff, if I was repainting a whole panel, fender, etc though.
Title: Re: Chuck's '83 TBird
Post by: Ductape91 on May 29, 2023, 09:00:49 PM
That is very off, you wouldve been better off painting the whole roof if you werent going to cover it.
I heard silver paint is hard to get right regardless.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on May 29, 2023, 09:15:44 PM
That is very off, you wouldve been better off painting the whole roof if you werent going to cover it.

That may be the plan in the future when the wrap wears out.

It could've been more due to the 2K configuration vs the 1K I used on the cage bits.

The wife's Bug is on the ground and running now, so I can at least get it out of the garage for the sanding I need to do.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on June 04, 2023, 08:43:32 PM
Well, I should've just done the 1K paint on top as well.
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Body/polished%20out.jpg)

I spent a couple hours wet sanding and polishing the roof out, and if it weren't for the poor paint match (and the evidently too heavy application by me, resulting in runs that wound up darker after I sanded) it wouldn't look too bad. There is an ever-so-slight ripple in area of the patch, but you really need to be looking hard for it. The wrap will hide the color issues and you won't be able to see the ripple.
I spent a couple hours wet sanding down to about 3000 grit and then hit it with the polisher. Got rid of all of the over-spray, and I polished the whole roof for uniformity's sake.
It is what it is for now.

I was thinking about driving it to work on Monday, so I took it for a little drive today on a couple errands. Good thing too, as the fans aren't kicking on. The wiring looks to be fine, but the relay isn't triggering.
The relay I'm using has a flyback diode in it, so I removed the original one I had in there.
I ran out of time to connect the laptop to it and make sure it's sending the trigger (It was before I did all of this work) and I probably should open up the MS unit and make sure the fan control circuitry didn't get damaged somehow.

The clutch feels fine but it is now evident that the 1st gear syncros are bad. Not a huge deal, but still annoying.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on June 09, 2023, 06:06:59 PM
The fans are fixed. The transistor in my MS fan circuit had died. Swapped that out and we're good to go.

I have the fans running on LO speed, as the 2.3 doesn't need both at full speed AND it totally pulls down the 130A alternator and bogs the engine when both run on HI.

Planning on driving it a bit tomorrow to meet up with some buddies. It will also be the first time the kiddos get to ride in it.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on June 11, 2023, 04:20:36 PM
Drive went well. Fans worked as they should and the clutch felt fine. Still have to be mindful of the 2-1 shift, but that's no biggie. I can rebuild the trans later.

As long as it dries up, I'm probably going to drive it to work tomorrow. I'll be able to test the clutch for slippage in 5th on the way there.
Title: Re: Chuck's '83 TBird
Post by: Aerocoupe on June 11, 2023, 05:12:19 PM
Glad you have it back together man. I’ve been battling my Mustang for the last six months just reworking all kinds of  that have over time been neglected. Hope to get it squared up here in the next couple of weeks and then drive the brakes off it this summer as it’s getting a MSPNP over the winter.  Once I get that installed and dialed in I’m getting back on the Bird. It runs and drives but there is a list of  I want to rework as I have the time and money now.

I want at least one of them running and driving so I don’t get withdrawals.
Title: Re: Chuck's '83 TBird
Post by: Chuck W on December 05, 2023, 08:12:59 PM
So, I forgot to post this up when I found it a couple weeks ago, but this is the slug that put the hole in the top of the car.
NOT a handgun round...
(https://turbochuckcom.ipage.com/webimages/projects/83%20TBird/2023/Body/slug.jpg)

Evidently it didn't enter the cabin, but just ricocheted out after it hit the car. I found it while I was cleaning up the spot while putting a new carport up.

I'm hoping to get with my buddy on the roof wrap before things get wintery around here. If not it'll have to wait until spring and the roads are clear of the inevitable salt coating they're sure to get.