Wow, I didn't realize it's been a couple months since my last post, but with holidays and work I've had only a limited amount of time to work on the Fury, but I have been keeping busy on a bunch of mundane, behind the scenes kind of tasks that must be accomplished before we can move on to the more visible or tangible steps, so here's a brief look at what I've been up to.
A couple of weeks ago Jimmy came over and we finalized the rear housing position (side to side, pinion angle, etc.) and tacked on the billet perches. We then started looking at the coil-over mounts, which from the start Jimmy didn't like; he felt they were far bulkier and space wasting than necessary so he came up with an alternative that will mount the lower end of the shock directly to the aft end of the truck-arms. This solution is actually pretty eloquent and will save a GREAT deal of space for the Watts linkage while also adding about 1 1/2" of shock travel by moving the lower mounting point that much farther below where my original mounts would have. Sorry, there are no pictures of the mounts at this point but once everything comes back from powder-coating I'll get some shots.
Once we got the rear housing done we moved on to the exhaust routing. If anyone ever tells you truck arm suspensions are difficult to package, TRUST THEM! As noted in an earlier post I decided to run the exhaust out the sides, which I would have done whether I ran truck arms or not, but still, packaging is TIGHT! While I worked on the doors (more on that below) Jimmy set about lining working on the headers, tubing, v-band clamps, and cutting the holes in the frame.
The first step was cutting off the flanges of the TTI headers so the ends would be perpendicular to the frame then tacking on a v-band ring and lining up the first piece of exhaust tubing. From there we figured out where we wanted to cut the holes in the frame, which Jimmy did using my handy little plasma cutter. It was the first time Jimmy (a VERY accomplished fabricator) had ever used my cutter and he was stunned at how well it cut, comparing it to his FAR more expensive shop unit. Below are a couple shots of what we ended up with:
View from above through the drivers door:
View from below at about the same location:
Once we get the headers back from coating (we're using this trick looking Titanium colored coating) we'll go ahead and solidly mount the stainless exhaust tubing in the frame, then mate up the mufflers (as shown in an earlier post) and other stainless tubing.
Like everything else I've encountered with this build I end up having to do things in what would seem to be a very strange order, but like any puzzle there's really no alternative other than to work through the steps logically and in order. What I'm talking about are the doors, without which I can't move on to the fender and cowl placement, both of which are upon me, so I've been working diligently to build out both doors, and while on the surface that may sound like a quick transfer of parts from the originals to the glass replacements, it's anything but.
The glass doors are remarkably detailed, and if this was a track only car I could simply bolt on the pieces I need, but since it's a street car I felt the glass was far too weak to simply bolt on the striker, window cranks, door pulls, etc., so I've been dissecting the original doors and sourcing the metal to use in the glass doors. While I wish I could simply use the donor metal as backing material that isn't always possible, so in places like the striker I have to carefully line up the donor metal, remove the fiberglass, then meld the metal into the glass door. It's actually been pretty enjoyable, but just another unforeseen layer in the build.
One thing I found that's really aided in the process is a 2-part structural adhesive from 3M, part number 051135. This stuff has a pretty short pot-life but it seems to be EXTREMELY strong while remaining less than brittle.
Here are some shots of the doors and the work that's had to be done.
Striker area:
Outer Door Handles:
Inner Door Handles:
With all the rust damage I decided to get a replacement cowl (detailed in an earlier post), so we had the replacement cowl blasted and luckily found only minor rust issues which we can easily repair. I began prepping the replacement cowl by removing the inner-most layer of steel (there are 3 layers that make up the entire cowl) because this inner-most layer is the only remaining part of the original left on the car; you can see it in various pictures throughout my post. What I'm hoping is to simply marry the replacement cowls 2 remaining layers right on top of the single layer remaining on the car, finally leaving me with a usable structural mounting point.
One thing I was uncertain about was how far our engine set-back REALLY was, what with the fact there was no cowl, no front sub-frame, no nothing to really gauge things from. Well, I guess pictures are worth a word or two because the pictures below pretty much tell the story: 50/50 weight distribution shouldn't be an issue, especially when you combine the set-back with the fiberglass hood, fenders, and bumper!
Yes, that's the original firewall sitting on top of the intake port for #8 cylinder:
Here's the view from the right side of the car:
And one from head on:
At this point I'm going to massage the replacement cowl and get it to line up nice and sweet, replace the rusted area with a patch panel (already have it), and begin to figure out WTF I'm going to do for a firewall. One idea, believe it or not, came from the Ring Brothers; they suggested using a wheel-barrow! Think about it, what a great contoured shape, it's heavy gauge steel, and if I can find the correct size it might just work, so I'm off to Lowe's to see what they have.
Thanks for all the support and I appreciate your keeping tabs on my progress.