Bringing the '65 back to life

[racecougar]

A pile of plumbing arrived this week, and it started going onto the truck today. All is PTFE lined. Hydroboost lines are -6AN. Fuel feed is -8AN, return is -6AN. Filter is spec'd for gasoline and E85 at 175 GPH and 10 microns (wanted some headroom over the 400 LPH pump). All fittings are steel.

[Ta2Don]

Gonna be sweet!!!

[racecougar]

We bent up a return line from the booster to the pump this morning, then cut a pass-through from the trunk to the underside of the bed for the fuel lines. Dad started whipping up mounting brackets for the fuel filter while I assembled hose ends. We'll pick up next weekend.

[racecougar]

Today we bent up a vent line, made brackets to mount the fuel filter and alcohol sensor (in progress in this photo), and assembled the feed/return hoses from the tank to the filter and alcohol sensor. The brackets received a coat of paint today, so we should be able to reassemble everything tomorrow, then work on the lines to the fuel rail.

[racecougar]

Day 347: Other than the two hose ends at the fuel rail and wiring up the fuel pump relay, the fuel system is complete.

[racecougar]

Knocked out the remainder of the PCM-to-dash integration today (wiring), then stuck the drivers seat in and hopped in to determine the proper angle for the back of the instrument cluster. The factory cluster, as well as the typical aftermarket plates, point the gauges at the drivers chest. The plan is to lay the gauges back to set the gauge faces perpendicular to the driver's line-of-sight.

[racecougar]

Checked quite a few items off the list today. I finished the fuel system, installed the kill switch, and started routing the lead to the starter while Dad knocked out the engine-to-frame ground cables and started making heater block-off plates.

[racecougar]

Block-off panels installed, more ground cables installed, torque-limiter installed, and started playing with plug wires.

[racecougar]

Something old, something new: Used the old cable cutters and the new cable crimper to knock out the battery cable wiring this morning.

[racecougar]

Back from Hot Rod Power Tour and back to work. Knocked out the plug wires and re-routed the fuel tank wiring to tuck it behind the tank today.

[racecougar]

Time to be cool! A really nice Be Cool 35202 radiator showed up last night and was promptly installed today. We whipped up a couple of lower saddle mounts, then sectioned the stock upper mount in three places to properly locate the upper saddles. The fuel pump relay was also wired up today.

[racecougar]

Busy day at the shop today. We installed the radiator into the freshly painted mounts, mocked up the radiator hoses and steam line, measured for the overflow and trans cooler, discussed intake tube options, then turned our efforts back to the instrument cluster.

The cluster is cut to the correct depth and angle, the back panel is cut and fit, the gauge and indicator lamp holes are all drilled...all that's left is a little clean up work, then weld, paint, wire, and install.

[racecougar]

Another busy day. Dad ran the mill all day working on a really nice piece that will be revealed soon. I finished up the radiator fan and coolant overflow mounting he had started (the unpainted steel panel with lightening holes seen on the side of the radiator). We went with a '94-'97 4.6L Thunderbird/Cougar fan, as it fit the core perfectly, has two speeds, and pulls plenty of air.

Need to do a little trimming to fit the upper mount, shoot some paint on the fan mounting plates, and wire up the fan electrical connector before we can check the radiator off the list.

[racecougar]

Yesterday:

Clockwise from top: A sneak peak at the pieces Dad has been working on for the instrument cluster. He turned a sheet of aluminum on the mill for the back plate, and cut a lens that fits between the bezel and the "bucket". We also trimmed the fan to clear the upper radiator mount and installed the transmission cooler this morning.

Today:

Radiator fan is wired, radiator core is grounded, and the transmission cooler lines are made and laid in place. The lines just need to be insulated near the header and clamped/secured to the frame rail.

[racecougar]

Transmission cooler lines are all wrapped up, the intake tube is finished, the MAF is wired, new radiator hoses installed, instrument cluster is assembled with wiring underway...we're getting down to just exhaust, driveshaft, wheels, tires, shocks, and alignment before this thing can hit the road.

[racecougar]

Day 359: We accomplished a lot today. Instrument cluster is assembled, wired, and installed, along with the headlight switch, wiper switch, ignition switch, and cig lighter. I'm really happy with how it turned out.

Dad painted up the radiator fan brackets and transmission cooler mounts and reinstalled everything. We've decided to forgo painting the front clip for now in an effort to get the truck drive-able in time for a big car/bike cruise I put on every year...and that is just seven weeks away from today.

[racecougar]

Look who has a face again.

[racecougar]

Shocks are installed, coolant reservoir is hooked up, and the exhaust work is underway. We went with KYB Monomax shocks. The exhaust will consist of 3" mandrel bent pipes, Magnaflow 5"x8"x14" mufflers, and will exit the sides just before the rear tires. It's definitely overkill for this engine, but the truck will "grow into it".

[racecougar]

Dad reinstalled the front fenders today and got the front clip all lined up while I worked on the exhaust. Everything from the mufflers forward is completely welded up. The pipes exiting the mufflers are just stuck there temporarily for mockup purposes. We need to pick up a stick of straight tube so that I can make the side exits. After that it just needs hangers and O2 bungs.

[racecougar]

Today we finished up the exhaust and measured for the driveshaft.

[racecougar]

Day 364: This morning we installed the driveshaft, exhaust, battery, fuses, and fluids, then got the cameras out just in case it actually fired up. The first turn of the key in the video is literally the first turn of the key. I really didn't expect it to fire right up. Thus began the cycle of "start it, shut it off, top off fluids, repeat". One cylinder on the passenger side bank has a miss which you can hear in the video. We'll check that out and run diagnostics tomorrow, as this was a plenty good enough result for today.

Video:
https://www.youtube.com/watch?v=Xtn7...ature=youtu.be

[racecougar]

After 365 work days at the shop over the past 4-1/2 years, here's where we stand.

https://www.youtube.com/watch?v=9jDq...ature=youtu.be

This morning we installed the seats, found the plug wire that wasn't seated on the plug, kept topping off fluids, started knocking out nuisance MIL items in the tune file (traction control, fuel tank pressure sensor, etc.), and then discovered a little fuel leak at the pump hat. I'm taking next weekend off, but when I get back to the truck the week after, we'll pull the hat to fix the leak, install a front sway bar, wipers, horn, and other odds and ends, then start working toward wheels/tires/alignment/insurance/registration.

[racecougar]

The truck moved around under its own power for the first time in 25+ years today. As you can see, the rear wheels and tires have been mounted, balanced, and installed. We deliberated over running a 33" bias ply vs. a 31" radial for a bit before deciding to take the hit with regard to stance for the sake of ride/handling quality. Dad also installed the 1-1/4" front sway bar over the weekend. Next up, wheels, tires, and longer wheel studs for the front. We're going to run a taller front tire (compared to what is on there now) and will eventually drop the rear 1". We definitely want to keep it raked, but it's a little ridiculous right now.

[LostMy65]

So cool you're getting close.
.
I'm in minority I'm sure, but I like the hotrod rake.

[racecougar]

I definitely like it raked, too. It's just a bit too much currently.

The list is quickly dwindling. Where to begin...

We ordered a pair of Cragars for the front, however they will not arrive in time for the cruise. We elected to throw a new, appropriately sized, pair of tires onto the wheels we already had. The tires will be transferred over to the new Cragars once they arrive.

Dad also installed a set of 3" wheel studs on the front hubs, cleaned and painted all of the hood hardware, mounted the horns, etc. over the course of the week. Today we knocked out the horn wiring, fixed the wiring to the passenger side taillight, got the low speed radiator fan working correctly, mounted the hood, installed and connected the front turn signal lamps, programmed the tachometer, installed the side mirrors...the list goes on. We took it on a cruise around the farm mid-day. The dogs seemed to approve.