XR7-4.6's disjointed Build Thread, now a 4V snob - TCCoA Forums

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post #1 of 652 (permalink) Old 04-29-2011, 03:46 PM Thread Starter
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XR7-4.6's disjointed Build Thread, now a 4V snob

Decided to change up my annual spring Cobra wheel install a bit by FINALLY reinstalling my Cobra brakes as well as check the passenger side for any rust development...




The good:


Oh yeah

The front portion of the rocker had some surface rust and pitting but like the driver side it turned out to be rock solid after going at it with a wire wheel and my trusty hammer. So that's a load off my mind.



The bad:

This area was a bit of a concern since I've owned the car, I initially put some rust converter (not POR15) over it and hoped for the best. Just recently I was looking around and noticed a audible crunch sound when I push up on the fender liner...



That hole used to be a 1/4" punched by the factory lol The good part is all the bad rust was concentrated to the bottom area, the upper rail is solid other than some surface rust the foam touched.

Strangely the driver side fender support has no rust in this area it seems, normally the driver side gets the brunt of the problems

The hole was actually smaller than that initially, but I enlarged it to get every last bit of this out...



Did I mention I hate this foam? Further opening it up also allowed me to scrape off and seal the surface rust inside and better yet get to clean metal.

I'll be posting more pics as I go...

-Matt

Last edited by XR7-4.6; 04-29-2011 at 03:53 PM.
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post #2 of 652 (permalink) Old 04-29-2011, 04:27 PM
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the foam.....you should smell it when its burning...lol.

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post #3 of 652 (permalink) Old 04-29-2011, 07:36 PM
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Good work! Gotta keep that clean car lookin clean!

Winter mods included:
- Developing Rocker Rust
- Saggy Suspension - fixed!
- Chipped paint
- I'm sure more to come... TOTALED
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post #4 of 652 (permalink) Old 04-29-2011, 07:38 PM Thread Starter
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Good thing I didn't try torching it out before

Anyway, I'm done:







Well actually I still have to put the rear wheels back on and eventually flush the fluid(I just bled the calipers for now). My eyes almost popped out doing a brake slam at a nearby parking lot

Oh and a good way to help prevent crap building up under the fenders is to swap the steel plate spacers for round washers or spacers.

Reasoning behind this is there's a drain channel stamped into the bottom of the fender. With the large factory spacers there's nowhere for anything to drain.




I used scraps from my dads golf club graphite extensions, nice and lightweight

-Matt

Last edited by XR7-4.6; 04-29-2011 at 07:46 PM.
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post #5 of 652 (permalink) Old 04-29-2011, 08:00 PM Thread Starter
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Quote:
Originally Posted by 94mncougar View Post
Good work! Gotta keep that clean car lookin clean!
Thanks! I've considered finding a southern shell but this one's just too solid for me to give up on(not to mention sentimental, I'm beginning to like it's battle scars lol). Plus I'm more and more convinced that being in the salt belt has less effect than a rainy or humid climate does on these.

-Matt
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post #6 of 652 (permalink) Old 04-29-2011, 08:41 PM
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That car isn't bad at all. My MarkVIII was a Florida car when I got it, and after 2 NJ winters, I have a little surface rust on the underside and my driver's side rail has that same rot that your passenger's side does. That's a nice trick with the spacers on the bottom of the fender. I'll have to do that on mine.

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post #7 of 652 (permalink) Old 04-29-2011, 09:42 PM
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I love how you can see those red springs!! Looks great with the cobra brakes! Good job Matt!

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post #8 of 652 (permalink) Old 04-29-2011, 09:53 PM
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Finally you put your rims back on! Looking good!

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post #9 of 652 (permalink) Old 04-29-2011, 10:03 PM
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Looks damn good! I FINALLY have a free and open weekend to get some things done to both my cars. Hopefully now I can get the LCA, and strut rod bushings in mine tomorrow or sunday.

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post #10 of 652 (permalink) Old 04-29-2011, 10:17 PM
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I agree about the salt thing, it all depends on how well the owner maintains it I guess. My dad got my car in the fall of 05 from Cincinnati and drove it strictly in the cold months as a winter car. The relatively minute amount of rust and corrosion after three winters and three years of DD duty truly surprised me.

Anyway, looking good, as always.

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post #11 of 652 (permalink) Old 04-30-2011, 08:43 AM
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Looks good, love those Cobra brakes and wheels.

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post #12 of 652 (permalink) Old 04-30-2011, 02:16 PM Thread Starter
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Quote:
Originally Posted by cobra R Thunderbird View Post
I love how you can see those red springs!! Looks great with the cobra brakes! Good job Matt!
I won't lie, a deciding factor in using red calipers was for those to match


Thanks everyone!

-Matt
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post #13 of 652 (permalink) Old 04-30-2011, 05:14 PM
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Very nice work. I'm very picky about how people modify these cars and I think yours sets a benchmark.

I've been fighting rust in the rear rockers since last summer. I have it bested so far...


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post #14 of 652 (permalink) Old 04-30-2011, 11:15 PM Thread Starter
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Quote:
Originally Posted by cougarcragar View Post
Very nice work. I'm very picky about how people modify these cars and I think yours sets a benchmark.

I've been fighting rust in the rear rockers since last summer. I have it bested so far...
Thanks man, your car was a big influence in mine, hell I copied my smoked headlights and "dechromed" tails from your 96

I've got rocker rust on the rear drivers side corner, It's still solid enough to not punch through but I know I'll have to open a window eventually.


Today I painted the rear calipers, put on the rear wheels and cleaned up the IRS cradle a bit...






-Matt
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post #15 of 652 (permalink) Old 05-02-2011, 02:57 AM
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wow men the last picture looks great
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post #16 of 652 (permalink) Old 05-02-2011, 03:01 AM
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What's up with the different angle on the exhaust pipes?

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post #17 of 652 (permalink) Old 05-02-2011, 01:01 PM Thread Starter
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Sloppy workmanship I guess, I got this exhaust third hand. I'll possibly be redoing the whole exhaust in stainless in the summer depending on fundage.


My current idea will make the visible pipes like those much prettier, similar to the IRS Cobra setups...


-Matt

Last edited by XR7-4.6; 05-02-2011 at 03:55 PM. Reason: added example
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post #18 of 652 (permalink) Old 05-02-2011, 02:54 PM
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What did you use to paint the calipers? I've been trying to build up the motivation to do this, and decided I just need to do it.

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post #19 of 652 (permalink) Old 05-02-2011, 03:39 PM Thread Starter
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Duplicolor spray stuff...



I originally used it to paint my spring ends after I cut them. So far it's held up pretty good.

Though masking and shielding them on the car is kind of a PITA, I'd probably do the brush on stuff they have instead. You won't really notice any runs once it dries on the cast surface anyway.

-Matt
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post #20 of 652 (permalink) Old 05-08-2011, 03:27 PM Thread Starter
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Havin' some more fun today... Warning Large pics!!

...Actually yesterday.

I decided to finish the wiring project I put on hold since fall, it basically It consists of replacing the dash harness I swapped in back in 07. While it was functionally fine initially, adding a few things to it since made it a little hacked, plus my wiring/loom skills weren't quite as refined when I originally wired it for the 97 cluster(which I no longer will be or be able to use) so I decided to redo the next harness with every conceivable factory feature I wanted by the book(or EVTM).

Thanks again to Rob (rmfk13) for supplying the stock harness!

So to start I added the following:

-Circuits for illuminated cruise buttons as well as the pigtail for the mark VIII clockspring
-Starter interrupt relay, ignition tamper sensor and misc circuits for factory alarm
-Clutch position switch (3 circuits; starter interrupt, cruise interrupt, and PCM reference). These will be jumped as long as an auto is in the car.
-96/7 electronic cruise control
-SC Handbrake light
-Factory foglights
-cornering lights
-SC auto ride control

-Epoxy painted dash frame, I just had to lol




Heres the harness bare


The circuits that are out are for cruise, I basically used the individual curcuits going to the stock servo and tied them into the individual inputs and junctions. This way I can just plug and play a jumper harness for the 96/7 servo/amplifier under the fender.

I also had to add a 96/7 electronic brake pedal travel switch as well as the pedal bracket...



Painted black of course


This is C217, it goes to the ABS sensor/EVO module on LX/XR7s, on SCs it goes to the ARC module, handbrake sensor and foglight switch. As you can see, there aren't any unused terminals anymore.


Almost fully bundled up...



I pretty much reversed the factory tape sequence, it's hard to explain but you start in, work out, and work back in until you reach the end of the harness portion you are wrapping. Keeps things nice and tight as well as organized. All the clips are held on with friction tape, another thing used OEM.

-Matt
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post #21 of 652 (permalink) Old 05-08-2011, 03:41 PM Thread Starter
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Continued




old




new


Pedals






Dash in





All for this


-Matt
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post #22 of 652 (permalink) Old 05-08-2011, 05:50 PM
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Thats an amazing job there matt! I'm glad that harness got put to good use! BTW I finally put those COP's in my trunk so remind me next time you see me to give them to you haha

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post #23 of 652 (permalink) Old 05-08-2011, 08:22 PM Thread Starter
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Thanks Rob! I was sick for a few days during the week and it all kicked back in halfway through the project making it pretty miserable, the dash and seats felt like they were 50 lbs heavier than usual Plus I ran into the stupidest little problems upon reassembly I had to solve.

I'll be starting the next phase as soon as I get my head gasket kit and timing cover gaskets, so I'll make sure to see you before hand, I'm thinking of redoing the whole engine harness while the miscellaneous RTV spots dry

-Matt
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post #24 of 652 (permalink) Old 05-08-2011, 08:24 PM
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I see the yellow paint did the trick! Almost makes me want to do the work to achieve that.

-Brandon
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post #25 of 652 (permalink) Old 05-08-2011, 08:29 PM Thread Starter
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Yep, thanks again for the trick! I updated the article to include it as well.

My only complaint (which is also apparent with the blue) is the unevenness of the lighting, I'm going to see if I can solder in some bright LED's and use some white vinyl paint on the black rubber in the right pod (it's white on the left and it lights up much more uniform)

-Matt
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post #26 of 652 (permalink) Old 05-09-2011, 02:15 PM
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Get lots of pics of the PI headswap. Of course, I know firsthand that you know that swap pretty well.

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post #27 of 652 (permalink) Old 05-09-2011, 03:48 PM Thread Starter
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I'll make sure to pick another set of batteries for the camera in addition to the parts, I'm hoping to get a bunch of stuff done while I'm there to take pictures of.

-Matt
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post #28 of 652 (permalink) Old 05-09-2011, 04:12 PM
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Ha that looks awesome. Looks like a lot of patience was required to get it all back together

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post #29 of 652 (permalink) Old 05-09-2011, 06:11 PM
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Wow, Matt. That some ambition there! Looks great so far.

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post #30 of 652 (permalink) Old 05-09-2011, 06:49 PM
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Why use tape on the harness? Personally I would have used spiral wrap. Looks good though.

If all else fails get a bigger hammer!

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