Unbox the Aluma-frame. Chassis number 108.

http://i616.photobucket.com/albums/t...psqoygdiov.jpg

Placed the DSE shock tower delete panels in place to see how everything looks.

http://i616.photobucket.com/albums/t...psgqlnzfcc.jpg

I need to get hole saws to drill the frames for the crush tubes. :G-Dub: More reason to buy tools I guess.

Update
 

As I mentioned before, the car is 99% rust free, but here's one spot that has some rust-the battery apron. I decided to replace that before proceeding any further with the DSE install, since the DSE adapter plate will be in the way of replacing the apron.

http://i616.photobucket.com/albums/t...psmo57c1ux.jpg

Cut out the offending part.
http://i616.photobucket.com/albums/t...pslfxpbhvg.jpg

Replacement apron from CJ Pony welded in place.
http://i616.photobucket.com/albums/t...psufdbydad.jpg

Mock the Aluma-frame in place and centered it between the rails. It appears that the frame rails were not centered with the rockers. One side is off by 1/8". We chalked it up as factory tolerance.

Holes for the crush tubes drilled and sprayed with weld thru primer.
http://i616.photobucket.com/albums/t...psi9xv4blf.jpg

http://i616.photobucket.com/albums/t...ps0qragqim.jpg

http://i616.photobucket.com/albums/t...psurji2it4.jpg

Crush tubes installed.
http://i616.photobucket.com/albums/t...pswnfbnymp.jpg

Adapter plates mocked up.
http://i616.photobucket.com/albums/t...psdppdwnzy.jpg

I was following DSE installation video, and it showed the stock sway bar brackets being removed and DSE brackets welded in. So I did, and in restrospect, I think it was not necessary since the DSE brackets are identical to the stock ones. I would have saved about 2 hrs of work had I leave the stock ones on.

Hit the plates with weld thru primer.
http://i616.photobucket.com/albums/t...pswpdoiggl.jpg

Crush tubes/adapter plates/sway bar brackets welded in. The welds on the crush tubes are not the prettiest, as I was laying on my back welding. I hate welding up side down.

http://i616.photobucket.com/albums/t...pskhbqwsea.jpg

http://i616.photobucket.com/albums/t...psyc6w3hqi.jpg

http://i616.photobucket.com/albums/t...psplnyudyq.jpg

Welded in the jounce bumper brackets
http://i616.photobucket.com/albums/t...psbql0zm19.jpg

http://i616.photobucket.com/albums/t...psomhhuxnm.jpg

Aluma-frame bolted in place.
http://i616.photobucket.com/albums/t...psvgq38yd8.jpg

That's it for the DSE install for now. Next up I will work on installing the front torque boxes. Then I will go back to installing the remaining DSE suspension pieces.

I left the stock sway bar brackets but had to slot the holes some. Apparently there were several installs where the brackets didn't even come close so DSE decided to fab up new brackets and include them.

Looking good!

I had to slot the holes on the DSE brackets also. DSE "paper" instruction does not mention removing the brackets, but the video does. Oh well, it's done.

Serious stuff
 

That is one beefy casting!

Some updates
 

The car did not come with front torque boxes, so we decided to install them to add additional rigidity to the chassis.

I striped down the interior to prepare for torque box and sub frame connectors installation.

Floor boards are quite clean, with some surface rust here and there.
http://i616.photobucket.com/albums/t...pszxptkgk2.jpg

Passenger side. Someone put on a ton of undercoating from the firewall forward, and those things stuck on pretty good.
http://i616.photobucket.com/albums/t...pstw186fuh.jpg

An hour later with a scraper/wire wheel, we have bare metal.
http://i616.photobucket.com/albums/t...psch5cp4es.jpg
http://i616.photobucket.com/albums/t...psoy1lhpbc.jpg

Painted on some weld thru primer.
http://i616.photobucket.com/albums/t...psav7osrit.jpg

Pass side welded on. The car was off about 1/8" on the pass side, so I had to slice and dice the torque box to make it fit.
http://i616.photobucket.com/albums/t...pssue1pqya.jpg

Repeat the same process on the driver side.
http://i616.photobucket.com/albums/t...pskwjs5aqu.jpg
http://i616.photobucket.com/albums/t...psdf0sw1xp.jpg

With the torque boxes installed, I took a break from fabricating and decided to bolt on the remaining DSE front suspensions.

Steering rack out of the box.
http://i616.photobucket.com/albums/t...psixhltqoa.jpg

Bolted in the frame.
http://i616.photobucket.com/albums/t...ps8bgfxmkm.jpg

Lower control arms bolted.
http://i616.photobucket.com/albums/t...psaemtlgql.jpg

Roll bar out of the box and slid into place.
http://i616.photobucket.com/albums/t...ps7ynect4k.jpg
http://i616.photobucket.com/albums/t...psbuxaq036.jpg

Coil overs out of the box and assembled.
http://i616.photobucket.com/albums/t...psgg11uurq.jpg
http://i616.photobucket.com/albums/t...ps0dso3jmo.jpg

Driver side assembled with the spindle
http://i616.photobucket.com/albums/t...psjmtpalec.jpg

Pass side.
http://i616.photobucket.com/albums/t...psbbdcyxsr.jpg

Shot of the engine compartment with the DSE front suspension.
http://i616.photobucket.com/albums/t...ps8bgfxmkm.jpg

As usual, the DSE parts are very high quality and fit like a glove. Everything slid into its place. The only gripe I've had so far is their instructions suck. I had to redo several steps, because the instructions were lacking; or spending additional time on extra unesssary steps. But, it was a pleasure to install.

Well it's been 6 months since the last post. I got caught up in life and having moved to a much smaller space, the cars sat idle while I dealt with life and the move. Finally got the garage set up, and I got going on the Mustang again.

Since I did not have the new wheels at the time of the move, and the old 14" wheels did not fit over the DSE front suspension, I had to come up with some wooden wheels to move the car to the new place.

http://i616.photobucket.com/albums/t...psb5kwa6wa.jpg

I got the DSE mini tubs/torque boxes/sub frame connectors installed, but did not take any pictures of the tub installations.

Torque box installed (driver side).

http://i616.photobucket.com/albums/t...psfkoutcbz.jpg

http://i616.photobucket.com/albums/t...psx2qyz7dt.jpg

DSE subframe connectors

http://i616.photobucket.com/albums/t...ps6gupp9kw.jpg

http://i616.photobucket.com/albums/t...ps6qkfkbko.jpg

http://i616.photobucket.com/albums/t...psr7q2r7ce.jpg

Wilwood 6-pistons for the front suspension

http://i616.photobucket.com/albums/t...psrrcxpkrn.jpg