1972 F100 rust pile

[kb426]

Mid-afternoon break at O&S. Today's list includes bolting up the sway bar mounts. Other users have used a bolt that was already in the frame for one mounting hole. I went out and measured the complete frame twice. THat's 2.5" farther forward than Ford intended. So I jacked it up and drilled holes from underneath. Hot metal in the am! I was out of 1/2" nuts so I ran to the hardware store and picked up a couple dozen. The lower control arms are set at the same measurement as the c.v. and bolted up. I did a quick toe -in adjustment and found out the brakes are wore out. The calipers may be alright but the rotors and pads were done. The new power steering and oil cooler lines are installed. The new ac compressor is on. The engine is back in and the front mounts tightened. Next will be exhaust or fuel tank. I need to evaluate my remaining brain power to make a choice.

[Crosley.In.AZ]

Interesting deal with the drive shaft length and the differential spring pad hole for locator stud.  Some folks are more creative than I am

[kb426]

Today added new meaning to O&S! The fuel tank is mounted. It's offset to the right side for clearance on the filler neck. Nothing about it is symmetrical. I used old leftovers to mount it so try not to be too critical. All of this is bolted to the frame. There is a gap for some kind of anti-rub material between the tank and mounting points. The tank will have to come back out for modifications to install the pump assembly so not everything has locking nuts. The 2x2 tubing controls the fore and aft location. If I had an iron worker I would have bent up some nice brackets to do all this stuff. It's going to be hidden by the bed. LOL

[kb426]

I messed with the mufflers for an hour before I cut the stub of the tail pipe off. Now I can make some progress. The rear shocks are in the way of where I wanted to run the tailpipes. I thought I could cut the crown vic pipes in 2 places and make this work. Maybe 4 per side behind the mufflers. Out of brain power.

[kb426]

Anybody up for a little summer shower to make it a little humid? I was working on exhaust. I have removed all the cats and am starting from scratch from the header pipe stubs and working reward.

[kb426]

I'm knee deep in new parts. The front brake parts and the driveshaft stuff has arrived. I'm planning on the next 3 days being very productive. Maybe that was an example of Team Smart:) It's really humid for this area . I won't be going full speed without repercussions. On the list: exhaust, driveline, front brakes, mount radiator and condenser, finish fuel tank and lines maybe get brakelines run to where they would rise to meet the master cylinder. That would leave the rear brake caliper mounts to be fabbed and the chassis would be completed and ready to go outside.

[kb426]

O&S update: I spent way more time on brakes this morning because the calipers had been invaded from sludge falls. All new seals, pads, rotors and lines. I had an idea to make a jig to ensure the ujoints would be in time on the shaft that I shortened. I tacked it and tried my best to line it in my lathe. It was too long. I messed around for at least an hour before I had to get a new idea. I used my line up tools for measurement points. The yoke was machined all the way around so I had 4 points for measurement. It's assembled and in the truck. I installed a new rubber on the carrier bearing and the mount has to be modified. It has to be moved over to center the front drive shaft. The rear shaft will have offset to the side and equal angles up and down. I jacked up the rear and spun the shaft several times and it appears to be ok. After I get the carrier mount in place, I'll dial indicator all the parts. Once again, I didn't get as much done as I wanted. LOL

[Crosley.In.AZ]

1 item that I have never atemtped is to cut & shorten a drive shaft

[kb426]

Tony, that would be the mark of a smart man.
Mid morning break. I made a spacer out of 2 x 4 tubing to fasten the carrier bearing on one side. The pinion angle is off in 2 directions. A simple pinion shim on the springs will correct that.

[kb426]

End of day at O&S. I made up some inserts to replace the rusted originals for the core support. Bolted on the support and spent hours moving and analyzing the radiator placement. This location is around 2" closer to the engine than the c.v. It's higher also. After looking at everything involved, I compromised on height for 2 reasons. No.1, the cooling fan doesn't cover the trans cooler, only road air hits it. No.2, This allows the radiator to completely fill the original radiator opening in the core support. There will be lots of plumbing issues to deal with. The side mounts are roughed in. I will tack them and add plates so there is substantial welded area tomorrow. Lots of thinking, not much finished.

[chimp koose]

Usually lots of thinking results in a much better job . The " drop it in and weld er where she touches " type of job usually shows up with a lot of compromises later in the build . I know I am preaching to the choir but its my way of offering encouragement . You have a build style that needs no excuses .

[kb426]

Thank you, C.K.
Mid-day break. The upper radiator mounts have stiffeners welded on and are bolted on to the core support. In case anybody was wondering, I reused the brackets from the c.v. Tailpipes are welded up. Header pipes are next.

[kb426]

Mid afternoon cool down. I removed the O2 bungs from the old pipes and stuck them in the lathe. Trimmed down and ready for reuse. The right side is close because of the offset rear driveshaft. The last pic is self-explanatory.

[UGLY OLDS]

Why do you have your thermostat set at 100+ degrees  :?:
 Are you sure that you are using enough of that Crown Vic in this build   :?:  
Tex Smith would be proud ....    

Bob...

[kb426]

^^^
Bob is on it!
End of day at really O&S! The left side pipe is done up to the tail pipe. Both tail pipes need to be fitted to the muffler and welded still. That makes me about 50% completion rate for the weekend!