The Ford Lightning required several coolers, including the radiator, steering cooler, transmission cooler, and a supercharger heat exchanger. Adam fabricated a series of mounts and close out panels to stack all the coolers in the nose of the ‘69. He used a Mittler Brothers bead roller, box pan brake, and punch and flare set to add contours to the panels as well flared holes for strength.

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Here, he uses an HTP Versa Spot welder to weld the pieces together.

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The panels form a housing and are designed to duct cool air through the cores.

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We used a larger aftermarket aluminum radiator (designed for the Lightning) as well as an upsized heat exchanger. Also required is the Vintage Air A/C condenser coil.

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The next task was to build the exhaust system. The crew started by removing the factory exhaust manifolds and replacing them with a set of BBK Shorty headers designed for the Lightning.

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The BBKs fit tight to the block, and the driver side was a challenge to install.

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It took a set of hands topside and below the truck to snake the driver side header into position. Kelle, Adam, and Trevor traded inappropriate words throughout the process.

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The customer wanted a stainless steel mandrel bent exhaust system with a set of electric cutouts. Straight pipes were run from the headers to the middle of the truck to the cutout location.

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The cut outs were placed in an area where they could cleanly dump the hot exhaust.

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Magnaflow 2 1/2 inch mandrel bent stainless tubing was used with the stock muffler and the exhaust was extended to the rear of the truck. It is TIG welded for a clean look.

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The system exits behind the rear wheels, and a pair of slash cut stainless tips provide a finishing touch.

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Nice update Kevin. :thumbsup:

That thing should make some inappropriate noises.

:D

Nice progress exhaust looks great

wow....this is really impressive!

You guys are doing a great job with this. Keep it up. Should be a really nice truck when it's done.

Love the work on the radiator mount. You have some talented guys.

Next up was the air intake tubing and filter. We wanted to isolate the filter and opening to breathe cool air, and reduce the underhood noise. A tubular intake was built.

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A baseplate / filter mount was made. This also holds the Mass Airflow sensor.

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The filter would point downward and breathe air from the inner fender area.

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