the darkside project.

capri v8 driver · March 10, 2011, 21:59:54

the darkside project.

as most people on this forum know, due circumstances, i had to sell my beloved black capri v8. that really hurt, so bad infact that my darkside took controll (and kickt reason and common sense out off the window) and bought this thing:

anyhow, it needed a new hart, so i gave it one, from a 93 thunderbird with 400 k on the clock (witch i found out later when i found the original clock in the booth). so before i dropped the new engine in, that one needed a rebuild. the only thing i can say, the old owner off the thunderbird did take care off the engine, except for worn crank bearings, everthing was within the stock clearances and looked good. so not much work here. the only upgrades are semi lenght headers, a beter ignition, new sensors, new injectors and fuel pressure regulator and beter cooling with a high volume water pump, 24v radiator and mondeo v6 fans.

i did test drive the donor car and the gearbox shifted nice, so i did not rebuild it. bad mistake, first drive, it let go off all the gears.

the picture shows what happend, a snap ring broke off and the clutch fel apart.

so a rebuild and upgrade off the gearbox is in order.

i replace the AOD internals with the internals off the 4R70 gearbox. i also replaced the valvebody for a bauman valvebody and replace the stock torque convertor for a TCI 2800 rpm convertor.

fixed the stock drum brakes and the electrics and finaly it drives again.

well, no. it drives, but braking and handling are a big adventure and the seats, ohh dear, they are rubbisch, they break your back after 15 minutes off driving.

so first new seats. i found a couple off recardos out a jeep and re-upholstert them to match the rest off the interieur. and while i was at it, i fixed the rest off the interieur as well. took everything out off the car, rewelded the cowl (but needs to be replaced anyhow), cleaned and welded the floor, new sound isolation, new heater box, because the old one was missing, electrics, locks, replaced the single speed wiper motor for a 3 speed wiper motor with interval, but re-used the stock wiper knob, so it looks orginal. painted the sheet metal off the dash and added a new dashcover, power windows, added 3 point seatbelts, new rubber seals for the doors and windows, some new chrome bits and the aircon. the aircon alone was 4 off months work and waiting for the right parts and hoses to hook the original aircon unit back up to the '93 thunderbird aircon pump and the ecu off the engine, so everything works together. most people just remove the aircon or use a aftermarked aircon system. this way i keep the original aircon unit.

the rest will follow tommorow.

Mik · March 10, 2011, 22:42:50

Thats gonna be one nice car once you've finished. Good things to come me thinks.

Mik.

capri v8 driver · March 11, 2011, 11:32:08

did i mention that braking and handling are a big adventure?

here is 1 reason why,

the spring and shock broke off the arm, this stuff is 44 years old and are still the original parts, just like the rest like the brakes, springs. the whole suspension.

maybe it was time to upgrade the suspension and take it to a higher level.

the design is not bad, but ford skipped here by re-using parts that are designed for other cars, so there are "build in" issues. now i could just rebuild the suspension, it will never handle right.

after a lot off time searching for solutions that makes the handling off the car beter, i removed all off the old suspension and steering system, so i could started from scratch and also ad strenght to the floor and body off the mustang.

i was very lucky in terms off rust, as you can see there is very little rust.

putting some more metal in the floor to make it more resistant against body flex, a thing these old stangs are famus for.

made my own subframe connectors.

my version off a torque box. these will not flex. i did not really like the sheetmetal torque box.

here you can see the subframe connectors and torque box in place.

there will be more re enforcements added as soon if i take the car apart again for paint.

my new front suspension, this took alot off time to find out what would solve the "build in" issues and ended up with this set up, its a cpp kit together with roller perches, 620 springs and koni shocks.

replace the old steering setup for a R&P steering from steeriods and added a promotor sport bumpsteerkit, i also added the variable power steering system off a thinderbird.

the chance in handling is dramatic, its steers and handle like a modern car and now cornering is not a big issue. even breaking with the drum disk is not a issue, but disks are beter.

also test fitted the new wheels,

next on the list, brakes and rear suspension.

this is the front set up from wilwood.

as for the rear brakes, it will be the brakes from a mustang cobra/thunderbird.

but i am still not sure what to do with the rear suspension and axle. just upgrade it with new springs and shocks and a 8.8 with lsd or going to independent rear suspension. that will take some time, i guess, to figure out the best suspension upgrade verses cost.

will be continuted.......

TNT · March 11, 2011, 13:25:05

What is the make and model of the new alloys ? They are perfect for the Mustang. Great job !

mk2 cossie · March 11, 2011, 14:06:06

very nice project there Paul

and the torque thrust alloys are surely the only choice for old yanks

certainly dont do a build in half measures do ya

capri v8 driver · March 11, 2011, 14:11:40

the wheels are from Coys, witch i found out later. but they where sold to me as a CIM brand, model 517, 17x7 in the front, 18x8 in the rear. there mistake, saves me money.

Quotecertainly dont do a build in half measures do ya

maybe it got out off controll again. it will not be a trailer quen, but a daily driver.

to combat the fuel cost, its now fitted with a new LPG system.

KIB · March 11, 2011, 16:21:32

WHAT!!! This is not a Capri!! You bought the wrong car mate... LOL Just kidding.

Nice mustang and I love the modifications you've done.. A bit more stuff to buy "off the shelf" when modifying Mustangs too..

But I'd liked to see you use your skills to adapt this engine to another Capri thou..

Mikey J · March 11, 2011, 18:25:44

Wow, nice project! I like things like this.

Dave2302 · March 11, 2011, 19:54:23

Nice project and nice work Paul, you can't beat the rumble of a V8, like the Yanks say, "there is no substitute for cubic inches"

Keep up the good work fella

Cheers Dave

capri v8 driver · March 11, 2011, 21:02:36

QuoteWHAT!!! This is not a Capri!!

that hurts.......

getting more stuff "off the shelf" is a big advantage. however i still make parts my self. the capri was a nightmare to find the right parts for normal prices. if i had the space, i would buy one again.

its almost the same engine that i had in the black capri, except the engine in the black capri had forced pistons, this one doesn't, but has a beter cam, witch i advanced 4 degrees.

Janspeedcapri · March 11, 2011, 22:38:13

looking good

capri v8 driver · April 16, 2011, 20:41:35

its spring time

sun is shinning, its hot. time to take the stang, fill up the aircon and out for a little drive. again a 44 year old part failed, the engine mount broke, the engine dropt down and put a hole in the aircon pump.

grrrr.......

now, i could go and order a new mount except, i still have a weak rubber mount.

so i build my own version off a decent engine mount that will hold the engine in place.

cost: 20 euro's on metal and bushings. and the mounts are fully adjustable to the side and front to back.

the stock rubber mount: 27 euro for 1. so thats money saved.

and a brand new aircon pump, aircon clutch + filling = 150 euro's

and what have i learned? well, its old, so it will break. with a old mustang, you need to replace almost everything. so a big order for more parts is send out.

more work for me.......

Dave · April 16, 2011, 23:27:09

Good job me mate.

Your certainly throwing some money at it even if you made the engine mounts for half price!

capri v8 driver · April 17, 2011, 07:48:06

with these classic car projects, certainly if it needs to be relaible and save for everyday use, it will cost money. you cant get away with leaving the old stock parts on the car without getting into trouble. so this project is getting very $$$. my best guess would be that this will cost around 35 till 40k in euro's when i am done with it.

capri v8 driver · April 19, 2011, 19:51:42

and they are in.

after some mods,

bolted into place.

since i made them fully adjustable, bringing the engine in the correct position is a breeze now. and i got the 235/45/17 fulda carat and 255/45/18 continental sport contacts tyres for my wheels

very cheap, just 80 euro for all 4.

all with all it was a good day

capri v8 driver · April 22, 2011, 15:06:54

wheels.......

till my suprice, they are not the alcheapo Cim wheels as they where sold to me, but Coys wheels.

the new looks.

after the use off a hamer, they barely fit now, but i still have some work to do to gain alittle bid more clearance. the right side off the car did had a accendent and is fixed the american way, lots off bondo. so that panel needs to be replaced.

from the rear, 255 doesn't look very big.

cossiemk2 · April 22, 2011, 21:53:28

That's a nice Stang there Paul.

Once you get it done the way you want it I'm sure we can see it on a stand at fordfair or the EFE!

(Damn I should have bought a Mustang from the start)

Janspeedcapri · April 22, 2011, 22:54:34

It looks like a devil car

you know...

I think the tyres don't look so wide because we are used to seeing wider tyres on normal cars... I was looking at a brand new vauxhall large hatchback thing today (not intentionally) and it had 235s all round... and a neighbour here has an X5 with bmw wheels with tyres about a foot wide yep thats what it is... that and your mustang itself is very wide so makes the tyres look less so

it'll be awful for me if you finish this before I finish my capri ...that I started 5 years ago

...so flippin slow down please

capri v8 driver · April 25, 2011, 07:25:13

Quote from: Janspeedcapri on April 22, 2011, 22:54:34
it'll be awful for me if you finish this before I finish my capri ...that I started 5 years ago ...so flippin slow down please

there is still alot off work that needs to be done. technical its the brakes, rear axle and suspension that still need to be done. the bodywork will come last.

Janspeedcapri · April 25, 2011, 08:57:12

are you really going to pull the bondo job apart? doesn't notice in the pictures

fordrwd4ever · April 25, 2011, 15:49:13

Really nice Mustang you got there

Makes me wonder if i should get one too(oldtimer offcourse).....
Get it finished, so it can go on FordFair or EFE

capri v8 driver · April 25, 2011, 19:26:20

Quote from: Janspeedcapri on April 25, 2011, 08:57:12
are you really going to pull the bondo job apart? doesn't notice in the pictures

it does not show on the pictures, but yes, i will cut the complet panel and inner wing out off the car and replace it. the americans did not bother to straighten the sheet metal, they coverd the complet panel with bondo. to clean it, weld the rust spot, that will be under the bondo and straighten the outer and inner panel out would take days, if not 1 or 2 weeks. a new inner, outer and rear panel is 180 pounds, so its cheaper to replace it.

together with the cowl 1 door and maybe 1 fender, those 4 will be the most off the panel work that needs to be fixed.

i also will replace the stock 8 inch rear axle for a shortend 8.8 inch axle with a lsd and 3.73 gear. more on that next month, when the parts arrive.

QuoteDamn I should have bought a Mustang from the start

they are nice cars, when everything is fixed and upgraded

technical, these cars are rubbish to start with. to make a decent driver out off it, its best to replace everything. there is one +, you can get every part for it.

capri v8 driver · June 13, 2011, 19:29:59

as promised, the rear axle.

this rear axle is from a thunderbird s/c witch a friend bought, took apart and never botherd to put it back together.

i cut off the brackets and cleaned it.

there where some problems with it, it was a 4 lug and i need a 5 lug axle and it was very wide.

time to do some work, after i cleaned it and put some primer on it. then its time to find the right inner axle's for it. after 4 weeks the first set of axles arrived, but they where wrong, someone in india put the wrong numbers on the axle's, so i ended up with to long axles. after a other 4 weeks, i finaly got the right axle's (but also with the wrong numbers on it) so now it was time to measure and measure and measure again before i did the first cut.

as you can see i cut the housing ends off instead off cutting the axle in the middle and take a piece out of it and weld it back together. the reason, strenght.

my plan, use the lathe and make the orginal housing ends to size, so they fit insite the axle tube.

speed it up a little bid (because i know you dont have time to read this)

and you end up with this

now i can slide it into the tube

carefull measuring to ensure the housing end sits straight in the tube and welded together. first one small weld to weld everything and one extra weld over it to make it stronger. that was not such a good idea. why? well, i want disk brake on it and i had 2 sets one from a thunderbird and 1 from a 94 gt mustang.

with the shorter axles, the distance between the hub and the flange was 1/2 inch to narrow and the brake caliper now sits on top off the brake bracket. now there are several solutions for it witch all cost time and money. i could make a new bracket, but i was lazy today and did not want to spend $200,- for new brackets. so how to solve it, well simpel, put the bracked on the rear off the flange. i just cut a little piece out off the bracket and slide it over the axle tube and mounth it to the rear off the flange. and there i got in trouble, that extra weld.

after making some clearance and grind down the extra weld, it now fits.

next to do, weld the spring brackets into place, and some braces for the brake hoses and lines and paint it.

there you have it, 1 lesson in shortening a 8.8 axle and fitting brakes on it.

66 restomod · June 13, 2011, 20:29:58

Looks great Paul

i like the homebuild modifications a lot

Tonie

Lemon-Ade · June 14, 2011, 23:21:48

Love all the fab work on this Paul

Top notch mate.

capri v8 driver · July 13, 2011, 14:48:57

after waiting for some more parts, i finaly could finish the rear axle.

sorry for the crap quality picture.

first i needed to weld new spring pershes to the axle. first thing i did was fabricating a jigg to hold the perches to the correct distance for the springs.

positioning and center the pershes, thanks to the jigg thats very easy now.

and make sure they are in the right angle, so the geonomotry is spot on.

than is time to weld them on the axle, first tacking them into place.

and than weld them. this has to be done carefully, to much heat and the axle tube bends. so small welds at a time.

some paint and start putting the axle back together.

than its time for the brakes. first thing to do, make 2 spacers for the disk and axle hub, so disk's are centered.

i made the center rings a bid longer so they also center the wheels.

made new brake lines

and this is the finished axle.

next, the rear suspension.... still waiting for these parts.

Lemon-Ade · July 13, 2011, 22:15:09

Pics look fine to me Paul, that is looking really good

. The extra Bracket is that for a panhard rod ?

Ade

capri v8 driver · July 14, 2011, 08:38:53

the extra bracked is for the panhard bar.

Janspeedcapri · July 14, 2011, 09:35:19

Quote from: capri v8 driver on July 13, 2011, 14:48:57
positioning and center the pershes, thanks to the jigg thats very easy now.

Thats pretty much how I did the manual rack mounts on my 2.8 x member - only i tacked the mounts to the jig cos tightening bolts seemed to distort the positions - tacking just freezes things where they are.

Is that chrome on the cover? ...looks nice

Dave · July 14, 2011, 10:05:07

Top Job Paul all coming together nicely.

Them disk's will look so much better behind them alloys than the drums!

the darkside project.

Janspeedcapri

Janspeedcapri

Janspeedcapri

66 restomod

Janspeedcapri