Yeah, I am still hackin away on this. Not getting much done it seems. EVERY LITTLE THING goes wrong for me, sometimes more than once. Had trouble with--
Hydraulic clutch system
hydroboost lines
oil lines for turbo
tach wheel
driveshaft
etc
etc
etc
Its not that this swap is really harder than anything alse I have done, more like there are forces working against me (if I believed in such things) to make every thing that should be simple, as difficult as possible. Fittings I dont have, fabricating parts, multiple trips to get what I need. I am shure you all know the feeling. The driveshaft shop wanted the rear half of the driveline so they could balance the whole works. I dropped it off on a saturday when they werent open. Just stashed it on one side of the building and would call them Mon and tel them it was there. Girlfriend asked "what if someone steals it??" I told her that the way things were going for me, I fully expected it to get stolen and accepted it was inevitable. It didnt get stolen, it is all prettied up and installed now.
So bad in fact, that a couple of days ago when I decided to pump out the front tank and put fresh fuel in it, that the 24 hour credit card co-op pump wouldnt authorize. I COULDNT EVEN BUY FUEL!!!
Anyhow, enough with the boo-hooing.
Hydraulic clutch setup- initially there was not enough pedal travel. The piston in the master cylinder was bottoming out way before the pedal reached the floor. It would have worked that way, but I wanted the pedal travel to be comparable to other things that I drive. I wanted to put a heim joint in the pushrod anyway, so I removed the original stud from the lever, and drilled a hole higher up on the arm. Also welded a piece of angle iron and drilled it to make it double shear. Clutch pedal was also extremely easy to push, with not enough travel at the clutch fork, in my opinion, so I ordered up a 1 inch master cylinder to replace the 3/4. Seems to be pretty good now, but wont really know untill I try to drive it.
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Picture looks pretty dark on my computer. My apologies if it is that way for everyone. It is a shot of the modified lever and pushrod.
Oil lines for the turbo- supply was metric thread. Nobody in town had anything, so I had to go to Des Moines. the drain line I had all the metal fittings done up, just needed a piece of 7/8 line to connect the gap. Couldnt get that either, so I had to drop back and redo it all for 3/4.
Tach reading wheel- after receiving the sprocket, I came to my senses and decided it was just to heavy to risk hack fabbin it onto the balancer and having it out of balance. Decided to forget about the tach for now, and utilize an aftermarket one with the DT360 flywheel sensor later on. Moved on to putting the front clip on for good, so I could figure up what I needed for intercooler connections. After mocking everything in, it was apparent that there was no room to mount anything on the balancer anyway because of the electric fan shroud in the way. Bottom radiator lines would have been a concern too.
Waiting on getting my injectors back. Should be here Sat or Mon from what I am told. Not far off from a test fire at this point. Got stuff for my intercooler pipes today. No doubt there is stuff I am forgetting. I am losing enthusiasm for this project, but must push on regardless, because I need this rig to tow my buggy out to California early next month for a competition.
My $5 swap meet PS resovoir
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electric fan and shroud my buddy made for me. was easier to use this Crown Vic fan than dual Taurus ones
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As it sits right now
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Also, considering all the trouble I was running into with everything else, I reversed my idea of a remote mount tube/fin oil cooler. For the sake of simplicity and cost, I went ahead and cut the filter head off the original block mounted cooler, tapped the passages, plugged them and put it back on. Maybe later when I find a good deal on a cooler at a swap meet, I will attempt to go through the trouble of mounting one up front.
Only thing that truly has went simply, was the 7.3 upper radiator hose fits perfectly with about an inch cut off the 90 degree end!!