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  #1  
Old 01-01-2023, 07:29 PM
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Date:around 12-6-22

While waiting for a few small parts to arrive we decided to mock up a few intake arrangement options. My original idea was to have a side entry lid facing the passenger side. This arrangement will make it a challenge to snake the charge pipe from the compressor outlet to the throttle body, but I think it can be done.



This is an alternative side entry. Obviously the charge pipe will be longer, but the path should be easier to lay out.



This is the front entry options. Again snaking the charge pipe will be a challenge, plus, I am pretty sure the peak of the lid will hit the hood.



Front view of the front entry option.



You'll have to use your imagination and add another 3" to the front of the intakes for the throttle body.

Andrew
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Old 01-01-2023, 07:30 PM
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Date: around 12-7-22

Made some baby steps today...

We chose to do this intake orientation, just to make the plumbing path not so arduous. There will be a simple silicone coupler at the throttle body. The rest will be fitted and welded together, with the V-band at the compressor discharge. Still unsure about the hood clearance, but that is a problem for future me.

You can also see the pump for the A2W intercooler mounted to the fan. The Volt actually had a little water pump mounted in that location.



I also got and installed the 90 degree fittings from Vintage Air. These will allow us to go straight down with the AC hoses and keep it neat and tidy. We also got the upper radiator hose sorted out with a Dayco D71576.



One of the Earl's 90 degree swivel heater hose adapters showed up. These will route the hater hoses away from the up-pipe to the turbo. I will probably add high heat sleeving over both of the heater hoses, just in case.



Lastly, Vic and I finalized the design of the turbo support bracket and it was uploaded to Send Cut Send to be cut out. It will be made from .190" 4130 steel.

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  #3  
Old 01-01-2023, 07:31 PM
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Date: around 12-15-22

Had another, fairly productive day with Vic today. We started putting the rest of the Holley mid-mount system on the front of the engine, so that we didn't have any surprises down the road. Everything went together pretty well, but this power steering return might become a problem. That's a problem for Future Me...



I am not sure where Vic got it, but he has the whole Dayco radiator hose catalog as a PDF. I sat down and looked up hoses that were 1.5" I.D. which matches the lower radiator and the thermostat housing hose size. I found this gem. It has 3 usable, tight 90 degree bends and plenty of straight section, and all of it is 1.5" I.D..



I had also ordered some 1.5" stainless, tight bend J-pipes, one with a 90 degree bend and the other with a 120 degree bend. Both were from Vibrant performance.



This is the configuration that we chose to do, in conjunction with a swivel thermostat housing.



In each picture it looks like it is tight in certain areas, but in reality, there is a solid 3/4" of clearance between all critical areas.



Vic had this nifty, home-made bead rolling tool.



It took a little effort, but we got a nice bead at each end of the tube.



This is the final shape of the lower radiator hose. Murray clamps will be used everywhere on the engine.



Like this one that I got for the intake pipe.



It is finally starting to look like something...



The turbo bracket that was made by Send Cut Send should be here on Wednesday. My friend Tom is also coming for a visit from Alabama and our mission is to get the new Ford 9" from Quick Performance installed. I will also get my new rear tires on Wednesday. Should be interesting!

Andrew
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  #4  
Old 01-01-2023, 07:32 PM
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Date: around 12-17-22

My friend Blake is a Solid Works wizard and we designed this bracket to support the turbo. I uploaded the file to Send Cut Send and less and a week later I have the part. The holes were left a little undersized on purpose.



Today the tires showed up. Hopefully they fit (they should according to my calculations).



I took the bracket to Vic and today he sent me these pictures.











Pretty excited to finally see the turbo installed without an engine hoist holding it up!

Andrew
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  #5  
Old 01-01-2023, 07:33 PM
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Date: about 12-17-22

I consulted with Todd, who works for Holley and is a great engineer, and he suggested that the poly mount may no do well being so close to the exhaust manifold. So I got these billet aluminum mounts from ICT.




I got a pair, but I only used one on the passenger side, and it fit perfectly, after we milled .050" off each end to give them enough wiggle room between the ear of the frame stands.




Good to go now! More updates coming really soon.

Andrew
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  #6  
Old 01-01-2023, 07:34 PM
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Date: around 12-18-22

My friend Tom visited me from Alabama and our goal for his visit was to mock up and ultimately install the Quick Performance 9" rear end. I knew that things were not going to just bolt together because the brackets on the QP rear are not exactly the same as an original 12 bolt, plus I ordered mine with multiple holes on the lower control arm bracket.

You can see in this picture how the Ridetech coilover bracket is designed to bolt to the original shock mount and then a tab comes around and gets bolted with the lower control arm bolt.



The bracket was trimmed to allow the use of all the holes on the lower control arm bracket.



The bracket was also trimmed on the side to remove a little excess material where it rests against the shock mount on the QP housing.



Then Vic went to work doing his thing...



Here is the final result, with the Ridetech coilover bracket fully welded to the QP housing.



We also pressed the Ridetech R-joints out of the old 12 bolt and into the QP upper control arm ears. Ridetech included a tool to make this process very straightforward.



When I ordered the QP housing I checked all the boxes for the extra internal gussets...



..and the back brace. I also chose the fill and the drain option.



After the Ridetech coilover brackets were welded, I went over the whole housing and softened up all of the hard edges on the brackets and Tom shot a coat of Rustoleum primer.



..followed by a couple of coats of Rustoleum semi gloss black.



More to come...

Andrew
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  #7  
Old 01-01-2023, 07:35 PM
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Date: around 12-20-22

The most expensive tires I have ever purchased showed up as well. If I can get two seasons out of these I'll be happy.



Had them mounted and balanced at my local Discount Tire. They have taken good care of me with the tires for the Cougar.

The fit in the wheel wells is pretty good. This rear end was ordered to be 1/2" narrower on each side, but it almost feels like they narrowed it 1" per side. I have not compared the width to my 12 bolt yet. Using a 1/2" spacer will put the tire dead center in the wheel wells.



This is with the 1/2" spacer, so the new tires are good to go.



The same can't be said for the hood.



Doh!!!



Andrew
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