Black_Cat's Bumper to Bumper Build Thread - TCCoA Forums

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post #1 of 41 (permalink) Old 09-08-2015, 01:35 AM Thread Starter
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Black_Cat's Bumper to Bumper Build Thread

Well I'm creating this thread to tie together all my future mods and overview past ones I've done in one place so it's easier to follow. Any questions just ask!

Here are some starter pictures.

Current-ish pictures.




Cobra 2 Piston Front Calipers
13" cobra rotors front, 11.65" rotors rear
Full cobra hub swap with relocated rear brake calipers.
03 Cobra 18x9" wheels.

OH and just because it's close to October. Girlfriend and I did this last year.


Don't mess with the car. It doesn't like that.

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
2009 BMW 535i M Sport Package

Last edited by Black_Cat; 09-08-2015 at 01:42 AM.
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post #2 of 41 (permalink) Old 09-08-2015, 01:53 AM Thread Starter
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Did the Grand Marquis headlamp mod with a custom 9005/9006 wiring harness from competition limited, who doesn't seem to be around anymore.

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
2009 BMW 535i M Sport Package
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post #3 of 41 (permalink) Old 09-08-2015, 09:59 AM
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Quote:
Originally Posted by Black_Cat View Post
Well I'm creating this thread to tie together all my future mods and overview past ones I've done in one place so it's easier to follow. Any questions just ask!

Here are some starter pictures.

Current-ish pictures.

...

Cobra 2 Piston Front Calipers
13" cobra rotors front, 11.65" rotors rear
Full cobra hub swap with relocated rear brake calipers.
03 Cobra 18x9" wheels.

OH and just because it's close to October. Girlfriend and I did this last year.


Don't mess with the car. It doesn't like that.
http://i1129.photobucket.com/albums/...gar_Nevada.jpg
Best Pumpkin Ever!

I'd love a sinister black cat. I seemed to cursed to own maroon ones though

Last edited by Trunk Monkey; 10-21-2015 at 08:03 AM. Reason: Remove most quoted images
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post #4 of 41 (permalink) Old 09-08-2015, 09:06 PM
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Those wheels always been my fav!!!!! Looks great !

P.i. intake,70mm tb, cai, Walbro 255 Pump, Intrax 2in lowering springs, KYB front/back, Taylor 8mm Wires, True Dual Exhaust No Cats 2.25in pipe alltheway back Mid mounted dual in / dual out Jones Powerflow muffler then ran out back to 16x3 chrome tips,mark8 Driveshaft, 1.25Rear sway bar, 4:10s, TrackLok, Rear Diff Cover Brace, Sc Wheels 235/60s, Jmodd, Air Bags in Springs,Rear strut Bar,17in Mirror Blk CobraRs, Sc L Brackets, rear torsional load brace, kmember-frame brace, weightloss program, pbr dual pistons drilled/slotted, recaro seats.
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post #5 of 41 (permalink) Old 09-10-2015, 12:42 AM Thread Starter
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Got my differential dropped and torn apart for the upgrades, I'll get pictures as soon as I don't feel lazy. Also got a nice surprise, my rear differential bracket was split all the way up. Glad I caught it when I did.

Start:


What are fire escapes for? Diff teardowns!


Looked great inside:


Gear wear is on point, thanks Rob!


The split!

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
2009 BMW 535i M Sport Package

Last edited by Black_Cat; 09-10-2015 at 08:41 AM.
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post #6 of 41 (permalink) Old 09-10-2015, 07:48 AM
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Originally Posted by Black_Cat View Post
Got my differential dropped and torn apart for the upgrades, I'll get pictures as soon as I don't feel lazy. Also got a nice surprise, my rear differential bracket was split all the way up. Glad I caught it when I did.
All them clutch dump burnouts bouncing against the rev limiter are catching up, bro.

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post #7 of 41 (permalink) Old 09-10-2015, 08:30 AM Thread Starter
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Quote:
Originally Posted by Mgino96tbird46 View Post
All them clutch dump burnouts bouncing against the rev limiter are catching up, bro.
Nope, it doesn't even have to do with the manual. Jmodded autos will do it to, trust me I got the lecture about it from Matt. So might wanna check yours.

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
2009 BMW 535i M Sport Package
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post #8 of 41 (permalink) Old 09-10-2015, 08:37 AM
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Last I checked, it was still good.

Michael M. ASE P2 Automobile Parts Specialist.

1996 Thunderbird LX. Gone, but not forgotten Oct 1995-March 24 2016

1985 Mustang GT. modified stock Holley 4180C, Weiand Street Warrior intake manifold, equal length headers, true dual exhaust, 5 speed, 3.55:1 8.8'' rear end, Ford Racing 10.5" clutch.

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post #9 of 41 (permalink) Old 09-10-2015, 08:40 AM Thread Starter
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Quote:
Originally Posted by Mgino96tbird46 View Post
Last I checked, it was still good.
Make sure you check the right side of it, just behind the two bolts that cross through the diff cover where it starts to bend to go into the rubber isolators. That's where mine split.

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
2009 BMW 535i M Sport Package
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post #10 of 41 (permalink) Old 09-10-2015, 11:40 AM
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How does your case have more rust than my original one?

-Matt
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post #11 of 41 (permalink) Old 09-10-2015, 11:29 PM Thread Starter
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Quote:
Originally Posted by XR7-4.6 View Post
How does your case have more rust than my original one?
If you mean the entire thing, I have no clue lol. If you mean the part where the cover bolts to, that's actually copper RTV.

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
2009 BMW 535i M Sport Package
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post #12 of 41 (permalink) Old 09-11-2015, 06:56 AM
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Fire escape? I was thinking it was great that it looked like you were rebuilding it in the living room

I picked up a used aluminium FRP diff with 3.73's for mine. While it won't go in till spring I'm thinking that a LPW diff cover and poly diff mounts to minimize movement are probably must does.

Love the car. The color, the wheels and the brakes. I suspect that the cobra brake swaps probably the best thing you can do for the brakes on these. Just not sure I want to buy new rims and rubber. So the PBR swap is probably on my short list instead.
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post #13 of 41 (permalink) Old 09-11-2015, 07:11 PM Thread Starter
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Fire escape? I was thinking it was great that it looked like you were rebuilding it in the living room

I picked up a used aluminium FRP diff with 3.73's for mine. While it won't go in till spring I'm thinking that a LPW diff cover and poly diff mounts to minimize movement are probably must does.

Love the car. The color, the wheels and the brakes. I suspect that the cobra brake swaps probably the best thing you can do for the brakes on these. Just not sure I want to buy new rims and rubber. So the PBR swap is probably on my short list instead.
I took it apart on the fire escape to avoid the wretched friction modifier smell. I am continuing construction on the coffee table in the living room lol. Thanks for the compliments on the car, and yeah pbrs arent bad either.

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
2009 BMW 535i M Sport Package
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post #14 of 41 (permalink) Old 09-15-2015, 10:40 PM
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You know you wanna use that brand spanking new crush sleeve. lol

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1985 Mustang GT. modified stock Holley 4180C, Weiand Street Warrior intake manifold, equal length headers, true dual exhaust, 5 speed, 3.55:1 8.8'' rear end, Ford Racing 10.5" clutch.

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post #15 of 41 (permalink) Old 09-16-2015, 06:38 AM Thread Starter
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Quote:
Originally Posted by Mgino96tbird46 View Post
You know you wanna use that brand spanking new crush sleeve. lol
I'd rather sell it and recoup the money. Jegs is sending me a fresh one.

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
2009 BMW 535i M Sport Package
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post #16 of 41 (permalink) Old 10-08-2015, 10:48 PM Thread Starter
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New progress. My differential is permanently done for the life of the car, needs no more mods and will only be dropped for maintenance if necessary, but now I actually have drain plugs yay!







I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
2009 BMW 535i M Sport Package
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post #17 of 41 (permalink) Old 10-21-2015, 02:04 AM Thread Starter
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The new-old sub frame I pulled from a V6 tbird.


71,000 lb flux core ship welds for you CWI's to inspect. Done by a former ship welder/welding instructor. He said these welds will out-live us both. Ron any thoughts? He added 10 lbs of weight to it in wire alone during the welding process.







Ron and this guy could literally have talked for days about weld roots, puddles, tensile strength, tearing, donkeydicks (welding term), and who knows what else. This guy knew his stuff, and he even offered to teach me how to weld if I buy a welder, GM why don't you send your welder my way so I can show you how to use it when I learn

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
2009 BMW 535i M Sport Package

Last edited by Trunk Monkey; 10-21-2015 at 08:10 AM. Reason: Fix wait to weight typo.
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post #18 of 41 (permalink) Old 10-21-2015, 08:25 AM
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Welds look good for the most part.

There's a goober (welding term) at the tie-in in the first weld picture that should be ground out and blended.

There's weld splatter (spatter) in the next to last photo. This is really a non-issue.

There's cold roll (lack of fusion) at the lower right side of the weld in the last picture.

It doesn't look like he did any surface prep work. The accessible welding locations should have been ground clean down to bare metal with a wire wheel prior to welding.

After welding they should be wire wheel or wire brush cleaned again for inspection.

First photo - Grade B - Poor tie-in
Second photo - Grade C
Third photo - Grade C - Again - poor tie-in at the corner
Fourth photo - Grade A - Good weld in a tight location
Fifth photo - Grade C - Cold roll

Overall Grade C

Trunk Monkey - AWS CWI

If we have any welding done here I'll show you what our welders are capable of. They never cease to amaze me how good our welders are.

Mods? Yea, I got mods ...
Air silencer delete, warp drive, dilithium crystals, flux capacitor, Slingshot Rubber band power adder, Moonshine & Gas, Leaf Blower Supercharger, Hamster Wheel & Hamster, Energizer Bunny generating 1.21 gigawatts, Mr. Fusion® Home Energy Reactor, hover conversion and a sextant celestial navigation system (The original GPS)
Best 1/4: 1,320 nanoseconds @ 670,616,629.2 miles per hour

"There isn't that much difference anymore between spacecraft, aircraft and modern automobiles..." - Keith Henry, NASA's Langley Research Center
See a list of my real mods and pictures of my car HERE. The true performance of my car was made possible by the Carolinas Crew Chief, RobertP at Rob's Tire & Auto.

Last edited by Trunk Monkey; 10-21-2015 at 08:34 AM.
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post #19 of 41 (permalink) Old 10-21-2015, 06:00 PM
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Learning how to weld isnt necessarily about being taught, but teaching yourself and gaining muscle memory. Good luck getting GM's welder.

I thought Donkeydick was an electrician term - you know when they lube up the donkey dick and you have 10 electricians tugging on the dick. They enjoy that type of thing as long as their safety vest doesnt get dirty.

Pretty sure any power plant / refinery quality welds Ron shows will be made by people in my trade - SteamFitters and PipeFitters.
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post #20 of 41 (permalink) Old 10-21-2015, 07:51 PM
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Donkey dick - as it relates to welding - is excess penetration (drop through) of the weld bead on a joint weld. Usually on a pipe root pass but some times on a fillet - depending on direction of the weld joint.

Pipe welders are - generally speaking - head and shoulders above structural steel welders.

Mods? Yea, I got mods ...
Air silencer delete, warp drive, dilithium crystals, flux capacitor, Slingshot Rubber band power adder, Moonshine & Gas, Leaf Blower Supercharger, Hamster Wheel & Hamster, Energizer Bunny generating 1.21 gigawatts, Mr. Fusion® Home Energy Reactor, hover conversion and a sextant celestial navigation system (The original GPS)
Best 1/4: 1,320 nanoseconds @ 670,616,629.2 miles per hour

"There isn't that much difference anymore between spacecraft, aircraft and modern automobiles..." - Keith Henry, NASA's Langley Research Center
See a list of my real mods and pictures of my car HERE. The true performance of my car was made possible by the Carolinas Crew Chief, RobertP at Rob's Tire & Auto.

Last edited by Trunk Monkey; 10-21-2015 at 08:01 PM.
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post #21 of 41 (permalink) Old 10-22-2015, 08:21 AM
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The welds look alright IMO..You know, the whole point of welding up the subframe is to provide substantial strength to the stamped frame..

I'm just curious why you didn't box any of it in with tubing?



This TCCoA article is great at pointing out what needs welded-->> IRS Build-up How-To

You should consider picking up some of the Delrin control arm/knuckle bushings from Jay aka 98mark8lsc..If you're really interested in getting rid of any potential wheel-hop that is..

That and also either aluminum or Delrin rear subframe bushings..

Keep us posted on your progress..This has the potential to be a very good thread..






Rayo..

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post #22 of 41 (permalink) Old 10-22-2015, 06:01 PM
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The welds look alright IMO..You know, the whole point of welding up the subframe is to provide substantial strength to the stamped frame..

I'm just curious why you didn't box any of it in with tubing?

Im wondering why anybody thinks the subframe NEEDS additional welding. Any engineers care to chime in ???
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post #23 of 41 (permalink) Old 10-23-2015, 01:49 AM Thread Starter
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Spoke to my welder prior to letting him loose. He said the boxing of the control arm boxes is extremely overkill. He said there is more than enough structural strength, especially after he welded the areas he did to reinforce it. I plan on getting UHMW mounts from Jay with Delrin bushings and the custom DSS $1700 axles. My rear half of the car will be bullet proof.

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
2009 BMW 535i M Sport Package
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post #24 of 41 (permalink) Old 10-23-2015, 12:23 PM
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FYI, you can buy the chromoly outer joints for about $500. 99% of the time, that is what breaks, so you could likely save yourself $1000 and still have a pretty bulletproof rear. Not sure what your ultimate plans are, but considering how much power stock axles have held up to after the delrin bushing upgrade, I think that should be sufficient, and it is what I am going with behind by 427" Windsor.

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post #25 of 41 (permalink) Old 02-22-2016, 10:34 PM Thread Starter
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Order for Pro-level axles from DSS has been placed through RobertP, now to wait.

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
2009 BMW 535i M Sport Package
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post #26 of 41 (permalink) Old 05-21-2016, 02:48 PM Thread Starter
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A large update. Axles came in, and Delrin bushings arrived. The beast is back on the road, it needs some minor adjustments, but the car is super stiff and tracks straight as an arrow.

1,500 HP axles (DSS Pro-levels)



MN-12 Arms with Delrin Bushings



Pro Level Custom Hubs with ARP wheel studs and Cobra Caliper brackets.



Shiny new progress.



Fresh 3M undercoating and putting the puzzle together (New Driveshaft was in that long box)



Trimmed the wheel studs to fit my cobra wheels. (Thanks Mike!)



Money shot! (No, seriously...so much $$$ in the ass of this car.)



On the last step, adding fluid.



After a quick test drive, all was well, threw the exhaust back on.


I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
2009 BMW 535i M Sport Package
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post #27 of 41 (permalink) Old 05-21-2016, 08:16 PM
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Car looks great. I wish I had room, money and time for a Cougar and a Mark 8. Nice work!

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I'll forever bleed Ford Blue

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post #28 of 41 (permalink) Old 05-21-2016, 08:47 PM
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Good job looks great I wish I had time to finish mine
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post #29 of 41 (permalink) Old 05-21-2016, 08:54 PM
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Shame it's all obscured by the crappy exhaust Yes I'm jelly lol

-Matt
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post #30 of 41 (permalink) Old 05-22-2016, 01:44 PM Thread Starter
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Quote:
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Shame it's all obscured by the crappy exhaust Yes I'm jelly lol
Indeed, but hey gotta build the car before you build the powerplant.

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
2009 BMW 535i M Sport Package
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