My 67 Cougar Build
 

I started this build a couple years ago. It is a slow build. And I mean really slow. I have posted some pics of the things I did in other threads but figure I'll include them here.

I started with this:

https://i.imgur.com/6f7gZKJ.jpg

https://i.imgur.com/WTbJli9.jpg

https://i.imgur.com/nbNCjBo.jpg

https://i.imgur.com/xEL0v2j.jpg

As I mentioned before I did some small things here and there. Here are a few pics of the front brakes I will be installing.

https://i.imgur.com/ED8xODt.jpg

https://i.imgur.com/VEcDMio.jpg

https://i.imgur.com/CClOYH1.jpg

I did some prelimnary mock up with the coyote engine.

https://i.imgur.com/OnorvDb.jpg

https://i.imgur.com/T29xu1B.jpg

Along the way I built an engine lift fixture because I didn't feel comfortable with the lift brackets supplied with the coyote engine. I can see them bend as I lifted the engine. Getting the CG right also proved to be cumbersome with the supplied lift brackets.

https://i.imgur.com/NIiTvS5.jpg

https://i.imgur.com/cOuV4CN.jpg

https://i.imgur.com/0QyAyzo.jpg

To date, I have mostly installed the front suspension. Still need to weld upper control arm mount gussets, top coil over mount, and and the down tubes. I'll tie the gussets, coil over mounts, and down tubes together.

https://i.imgur.com/bGDSXht.jpg

https://i.imgur.com/jJ6ANvK.jpg

https://i.imgur.com/hxsYnbc.jpg

Coyote in a cougar, I don't see anything wrong with that. And it looks like you've got a good thing going with your front suspension.

What are your plans for the rear? Full floater 9" with a decoupled 3-link? Built 8.8" with an offset 3-link? Cobra IRS?

I have a 9" already, but I plan to convert it to a semi-floater similar to what speed tech offers with theirs that use the c6 SKF hubs. I will be using a SRT8 setup instead because the wheel bolt pattern is similar to a Ford. I'll redrill the hubs for 5x4.5 since the SRT8 bolt pattern is 5x4.527. That way when I need to replace rotors I can go to the parts store. The holes are oversized in the rotors that I can use the 5x4.5 bolt cirlce.

That frame...
 

is beefcake! Kudos for the Coyote swap

Great project. This is going to be one fun ride! Nice job on the lift fixture.

Small update. Fabbed up and tacked motor mounts in. Hope to finalize engine placement, then install both engine ans transmission so I can fabricate the transmission cross member.

https://i.imgur.com/SW6MXfu.jpg

What car did the 6 piston brembo setup come from?

The brakes are from a 2013 Shelby GT500. With my build, I'm trying to use stock parts where possible so I can go to the parts store/dealer in an emergency.

Very nice!

Very nice - I agree with sticking to factory parts where you can.

I disliked the Brembo/OEM pads with my CTS-V brakes - so I went with Hawk HPS pads.

Another update. Mocked up my hydroboost to see if I can get it to clear the coyote engine. Results look promising. Used a reproduction Boss 429 Mustang brake booster wedge to tilt the hydroboost up. Still need to figure out what to do about the billet hood hinge interference and determine what the brake pedal ratio needs to be. If anyone has a later model mustang with hydroboost perferably the SN-95 (96-2004, prefer 2003-2004) variety would you mind telling me what the pedal ratio is.

https://i.imgur.com/TR9Z03r.jpg

https://i.imgur.com/4VUZwRM.jpg

I guess a cougar is an okay choice for a build.

Have an 03 cobra pedal assembly here, measured out to a 5:1 brake pedal ratio.

Like your build!! I have a 69 Cougar I'm doing a slow build on also.

Thanks RidiCat69 for the info. Would you mind sending me the measurements you took. I want to eliminate any possible rounding errors when I calculate where my pivot point will need to be. I'm a little surprised, I was thinking it would have been closer to 4 than 5. Also, did you take your measurement from the center of the pivot to the center of the pedal pad or the bottom of the pedal pad? I've seen illustrations showing both. Thanks again.

Robert

No problem, Robert.

I retook measurements for both ways and you can decide which to use.

Center of pivot to center of pushrod lug is 2.75"
center of pivot to absolute bottom of pedal pad is 14.25".
this is what I got 5.1:1 ratio with.

Center of pivot to center of pedal pad is 12.75", giving a ratio of 4.63:1

Ryan

What pedal setup are you looking to use?

Very interesting build. :thumbsup:

Thanks Ryan. I am using the power brake pedal for the 67 cougar. Right now the pin is lower than the hydroboost rod. I will move the pin and also likely the pivot so that the arc of the pedal matches the direction the hydroboost rod travels (currently it travels up at an angle because of the wedge). I believe the stock 67 ratio for power is around 3:1.

Robert

Oh wow! Didnt know they were that low! The had an 04 Cobra as a daily for a few years, loved the hydroboost. Had good pedal feel without being over assisted. Did a 70 Mach build recently and used the stock pedal setup. Got a needle bearing setup for the stock clutch pivot rod. Don't know what you're doing in that area, but it's much smoother than the bushings if you haven't already done so.

Finally getting settled into my new digs, and trying to get back to mine. Only other cougar on here right now from a brief search. Keep the updates comin!

Ryan

Yeah, I was a little shocked too when I took the measurements. My brother had an 04 Mach I and I loved the brakes on it too. I was fortunate to find a used 04 cobra hydroboost for cheap and decided I would adapt it to my car. As for the clutch setup, I did install the roller bearing conversion. I used a Scott Drake kit. I hope to get the new wedge soon so I can modify my pedal accordingly.

Robert

More updates. Brake pedal mod for adapting an 03 cobra hydroboost to the cougar pedal support. I replicated the pedal ratio from the cobra.

https://i.imgur.com/fPdiqAR.jpg

https://i.imgur.com/jYwmTZY.jpg

Pedal support setup with hydroboost, S197 mustang hydraulic master, and roller bearing conversion

https://i.imgur.com/fPaM5Iz.jpg

Used parts from the S197 mustang and adapted them to the cougar clutch pedal.

https://i.imgur.com/I4aVXFD.jpg

Hydroboost mounted using a reproduction Boss '9 mustang brake booster wedge to clear the coyote engine.

https://i.imgur.com/9Bx9t75.jpg

Sweet deal man! The wedge seems like it will add quite a bit of clearance. Keep the updates comin!

Thanks Ryan. Your measurements on the cobra brake pedal helped immensely. I do have a lot of clearance between the engine and the hydroboost. You can see in the picture below. This is with the engine set at 3 degrees down and not having to shift the brake assembly towards the driver's side like I've seen in other builds. I can get to 2.5 and still have plenty of clearance. Only issue I have now is clearing the billet hood hinge shock which I never really liked because it limits the height the hood can be opened. I have an idea that will solve those 2 problems.

https://i.imgur.com/pcDqfp6.jpg

https://i.imgur.com/qmTLou0.jpg

This is going to be amazing.

Much win.


Sent from my iPhone using Tapatalk

Nice work! Glad to see you making progress on the car.

Updates? Hell has frozen over since I worked on my coug the past 2 weekends straight....hasn't happened in months... :poke: eh?

Lol. No updates on my end either Ryan. Been helping my brother with his 66 mustang. His car is much closer to completion than mine. I have some pictures of it if as proof I did some work. :lol:

https://i.imgur.com/9zJOQLk.jpg

https://i.imgur.com/PGC9eqA.jpg

https://i.imgur.com/GqUUz5l.jpg

I'm hoping the color evened out or the phone pic just gave it a greenish hue because it was suppose to be matte black.

A few updates. Was able to roll the car out of the garage this weekend on it's own suspension. Finished welding in the upper control arm gussets, upper shock mounts, and frame boxing plates. Still need to weld in the down tubes and shock tower delete plates, but I will first fab up the transmission cross member so I can return the coyote motor to my buddy.

https://i.imgur.com/7kPq9Sb.jpg

https://i.imgur.com/TkZwpeT.jpg

https://i.imgur.com/jlCbqTv.jpg

Hope the car is not sitting too low once the real wheels and tires are on.

https://i.imgur.com/lgQvbpb.jpg

Man that motor is huge. It looks good in there though. Congrats on getting the car back onto its wheels.

Thanks Trey. The motor sure is big. I believe it is even wider than the boss '9 motor.

Fabbed and installed my transmission cross member

https://i.imgur.com/U8wQFuC.jpg

https://i.imgur.com/FpfAs02.jpg

https://i.imgur.com/Vcm5utA.jpg

Nice job on the crossmember! Where did you get those rubber bushings, I would like to use that ice on my 68 Torino.

Thanks, Joe

Right!

Joe/Curtis, I bought them through Off Road Warehouse. From what I remember they are just bulk bush kits. Another alternative would be to buy bushings from energy suspension like these and use the appropriate tube diameter.

http://energysuspension.com/universa...isolators.html

Christmas came early.

https://i.imgur.com/jNMxClx.jpg

https://i.imgur.com/ctT5Zdk.jpg

https://i.imgur.com/sVQ5FgI.jpg

That's a nice package!

Merry Christmas!