Thanks for all of the tips and info Matt! For sure this will be a big project but if all goes well, should be a great build! we are headed to SEMA to exhibit and have a few meetings set up with various companies to go over my options and should have a solid plan once I leave there. I have some really good 'industry guys' involved already on this one who approach things from a well engineered approach..
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Originally Posted by Matt@BOS
I kind of figured you were talking about everything involved with getting a Coyote to fit in a Falcon.
I've probably put about 25K combined miles on my '65 Fastback with a 5.0 Aluminator XS engine, and DSE front, Maier Inc. rear suspension. Every hot rod always seems to have a couple little issues of its own, and on my Fastback, its been the alternator and power steering pump, which were about the only non OEM pieces in the drivetrain.
Here are a couple things to keep in mind, the Falcon frame rails are narrower than the Mustang's rails, so most off the shelf aftermarket suspensions that fit a Coyote are going to take a little bit of work to install. That's not a bad thing, but it will cause a few complications, so planning ahead of time is going to be key!
I mentioned before, I'd recommend either Detroit Speed or Cortex mostly because they work really well, but also because out of all the different front end kits, I have some idea of the work involved getting what you want to work!
DSE - You are going to have to do a little more cutting and offset the mounting brackets for the K member off center towards the outside of the rails, notch out the driver's side frame rail, and associated DSE control arm uprights to fit a factory alternator (smaller ones won't output enough to keep fans, ecu, headlights, fuel pump, etc. running at idle). You may also need to notch out the passenger side frame rail to fit a power steering pump.
Cortex Racing - Cortex builds a more race oriented front suspension system. They don't have the same manufacturing capabilities to be able to build OEM quality parts like cast aluminum K members, but their design works well, and in a lot of ways is much simpler, giving you a little more space in the engine bay. You would need to order a "builder" kit that is unwelded to be able to fit the cross member, etc. We are currently installing one of these kits in a Falcon Wagon. You may also need to notch the frame rails for clearance, but won't need to take as much out as you would with DSE, may be able to run a slightly wider front wheel and tire package because you aren't pushing the crossmember out as much to get it to fit as you would be with DSE.
Last things to keep in mind - I chose to keep keep as many factory parts on the front accessory drive as possible because they're durability tested to roughly 8K rpm vs a bunch of aftermarket parts. Unfortunately there is no factory hydraulic power steering pump. Hindsight being 20/20, I might have used an electric over hydraulic power steering pump to free up space and keep from spinning the pump so fast. The last, and possibly most important thing to keep in mind when using the 5.2 Voodoo engine is that you NEED to run the factory motor mounts and transmission mounts because of the flat plane crank and associated vibration, or the car might just rattle itself apart.
You're more than welcome to give me a call if you want anymore specific info. Don't want you to end up with a car that looks great, but is barely driveable.
Matt
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