Here is the start of my build thread for those that are interested in following my progress. I'm not much of a blogger but I'll write what I can when I can.
I picked up my kit, an MK IV base kit #7832 on 6/30/2012.
I have the body on a buck and have started the build. I still need to finish the inventory (I did inventory the few boxes I needed to start building). That will be tomorrow as well as marking and removing the rest of the aluminum.
I have the upper and lower (FFR tubular) control arms installed as well as the spindles, backing plates and shocks. The shocks are not fully mounted as the springs are backordered.
The steering rack was interesting. I measured several times and decided to temporarily install the rack before making the cuts to the inner tie rods so I could measure everything. Well, the sleeves that were provided in the kit were the wrong size. They were the correct length but the inside diameter was too small. They are supposed to be 1/2" i.d. but the bolt would not fit. The threads would fit but not the shoulder. I had to ream out the sleeves with a 1/2" bit so the bolts would fit. Not sure why that was the case.
Since it's a donor, I am also rebuilding/cleaning/painting/replacing all the parts from the donor as I get to them.
I pulled the rear end apart this week and that will be getting new clutch packs and bearings before going on the car.
All in all, I'm pretty happy with the progress so far.
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MKIV Base #7832, 90 GT Donor, 302 EFI, T5, 3-link, other goodies TBD.
Nothing wrong with that (PS rack seal kit $42 compare to $357 refurbished rack)
Wow! I was going to rebuild the rack I had but the local parts store had rebuilt ones for $75 so I didn't bother. The tie rod ends were almost as much as the rack
I checked out your build site. That's one heck of project you have there. Looks great.
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MKIV Base #7832, 90 GT Donor, 302 EFI, T5, 3-link, other goodies TBD.
Here are some pics of the current status. I have the front end on including the steering rack although something does not look right. I cut the 1.75" off both inner tie rods before the rack was installed and then I installed the FF extensions once the rack was mounted. I don't have the rotors yet but I have the outer tie rods threaded all the way onto the inner tie rods and it still looks like there is toe out. I need to investigate further. Any ideas? frontendlg.jpg
Those outer tie rod ends look very long? Did they give you the wrong ones? Mine are about 6.5 inches long from the end to end, not including the nut, overall length is about 52 inches from grease fitting to grease(Center to center) fitting on the outer tie rods.
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MKIII 5446 Picked up May 06 - Completed May 07.
5.0 EFI-T5- BBK shorties, Edelbrock performer, underdrive pulleys. PS-PB
MK3.1 6707 Picked up July 9,2008 completed May 2009-sold 10/22/09
MKIV ordered 3/5/2010 delivery 4/16/2010 First start 4/29/10 complete 8/23/2010 sold 11/23/2010
"Some people stand around talking about why it can't be done, while others are doing it"
It seems that some of the reman'd racks are a little shy on thread engagement when coupled with the extenders.
Two options:
1) It looks like you have run out of external threads. If your outers are threaded deeply enough internally cut some off of the end so that you can run them on farther.
2) If #1 doesn't work because you are bottoming out inside the outer tie rod ends Breeze offers these:
The concern with these shorter ends is that since you've already cut back the inners you need to assure that you have good thread engagement. Whether cutting back the long ends that you have or going with the short ends you want to see thread engagement equal to 2X the diameter which in this case would be 1".
Yeah, I know, we shouldn't have to be searching out alternative parts when dealing with something that is supposed to be following the "donor concept" however we need to remember, we're causing the problem by adding the extenders but correcting another by using them. This is one of those cases that demonstrates how sometimes by doing things like using these extenders we've modified our donor components to the point that they may not all play happily together afterward.
It seems that some of the reman'd racks are a little shy on thread engagement when coupled with the extenders.
Thanks Jeff, that looks like my issue. I'm bottomed out on the inner tie rods. The outers have about 1.75" of thread and I'm pretty much fully engaged there with plenty of room to go. I'm going to see if I can cut more threads on the inners (need to look again where the flat spots start) and failing that, I'll cut about a 1/2" off the outers and I should be good.
I don't mind (and expect to) doing mods but I wasn't thinking I would have to more mods than what was stated in the directions for this part and wanted to get some feedback to make sure I wasn't missing something.
Thanks again for the feedback.
-Steve
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MKIV Base #7832, 90 GT Donor, 302 EFI, T5, 3-link, other goodies TBD.
Ron, yes, my outer tie rods are the same size as yours. Looks like there is not enough threads on the inners. I cut a 1/2" off the outers today and that did the trick.
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MKIV Base #7832, 90 GT Donor, 302 EFI, T5, 3-link, other goodies TBD.
I got my body buck modified so I can store the body in the garage above the frame. Here is what I started with.
And 3 hours later this.
And tucked away in the garage.
I then started to mock up the power steering booster and make the needed mods. I am using the stock 90 Mustang booster. Here is what it looked like to begin with. You can see where I already started to cut the tube for the mod. It was a little tough to make the first cut into the nice powder coated frame.
I then cut almost all the way through down by the front end. This will just get filled with weld later.
After getting it cut I just pulled it out a bit so I could trial fit the booster and open up the hole in the firewall. The booster and pedal box will be cleaned and painted later but I wanted to get it all mocked up before so I didn't have to worry about the paint. Here is the modifed hole in the firewall.
And the final fitting of the booster and pedal box.
That's all for one day. Next steps will be to cut and weld up the tubing and get the booster and pedal box cleaned and painted as well as the frame. The upper steering shaft is backordered right now so I want to get that installed prior to bolting everything up so I can ensure there are no issues.
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MKIV Base #7832, 90 GT Donor, 302 EFI, T5, 3-link, other goodies TBD.
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