5.0L General DiscussionThis section is for non-tech specific information pertaining to 5.0L Mustangs.
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Following this post I'll add pictures to my profile of the progress from last week.
The dash frame has been hung in the vehicle. I built a bracket for each end of the dash frame, and had them welded onto the frame. I then built inner wall brackets, and had those welded onto the vehicle to meet the brackets on the dash frame. The dash frame then bolts into the inner wall brackets. During planning and design phase I wasn't sure of the angle that I wanted to hang the dash, and unsure if I was going to need to pull the dash out further from the wall. Thus I built the dash frame brackets in a manner that would allow the dash to be manipulated. A lower bracket will secure the dash preventing movement. An additional "set bolt" on both sides of the dash into the inner wall will also provide additional insurance that the dash won't shift during vehicle use.
After trimming the dash top and sides, the dash married up to the frame easily. Now I'm working on the lower bracket and prepping the steering column for installation. The steering column, and steering wheel is also from a 2005.
I'm still in the planning phase of the instrument cluster. I've been researching and designing a custom instrument cluster. Thanks for some of your comments they really helped. However after a conversation with a friend, I'm wondering if I can use the 2005 instrument panel by splicing the connector onto the 1990 harness for the fuel, water temp, tach, and other incidental gauges and alerts. Items that aren't available on the 1990 like ABS, I won't connect into. For the speedometer I was looking at an electronic speed sensor from the manual transmission to the 2005 instrumental connector (bypassing the 1990 ECC). Open to any thoughts or suggestions on this one.
Interesting note, I thought my pillars were free of rust till I pulled the weather stripping away when I was prepping for the welding of the brackets on the inner wall. Thankfully I caught it in time and only one layer of the pressed frame was shot. Now I have another weld project to reinforce the pillar.
Hopefully by this weekend I will have the lower bracket completed and installed.
Happy Holidays to all.
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Nope it's still has four seats. I had the seats in the other day to ensure I still had leg room. I was a little worried about leg room but there is plenty of space.
I finished the bottom dash bracket and am currently working on placing the 2005 steering column in now. I did my first cuts to the 1990 pedal assembly bracket. I ended up cutting approx 4 inches off the driver side of the bracket. This will allow the steering column to attach to the dash frame.
Since the 2005 rack&pinion connector for the steering control arm is different I initially was going to have the 1990 connector machined onto the 05 steering column. However a friend told me tonight that the 94-95 connector will match up to the 1990 Rack&Pinion but also has the same type of upper arm connector that the 05 has. That would be ideal to only bolt on vice having it machined. Less worry about the machined part failing while I am driving.
More pics coming this weekend once I get the steering column bolted on.
I planned to offset the shifter back with an shift extender that I built. As for the center console I developed a design that brings the HVAC, "radio", and shifter inwards to meet the change in position of the dash. Some other big changes in the center console are: movement of the parking brake closer to the driver vice next to the passenger, cup holders. The arm rest / console compartment is also redesigned. I'm using the old console as a baseline to work from since it has the contour of the bottom and building from there. I'll scan the design and post it later on.
Does anyone know where I can get a 1994 Mustang GT lower power steering shaft & steering knuckle? I need it to modify the 2005 steering column that I'm placing in the vehicle. Preferably used since most of the prices I see for aftermarket are extremely high; $250+. I already tried all the salvage/junk yards on Oahu and no luck. Unfortunately they discontinued the part at the dealerships.
I'll say it again - I can't wait to see the results of this! Thats what makes a site like this so cool - people like me who have no time or facilities to undertake such a project can live vicariously through other's projects
I have to tell you that I am flat out impressed. This is by far one of the most ambitious projects that I have seen. But that is what make a car "your" car. Way to go it looks great and can't wait to see the out come.
I've had to put it on hold for awhile. I'm preparing to make a transition out of the Marine Corps this summer. Finding a new career has been top priority, but it's tough to decide on what I want to be when I grow up, ha ha.
I have been working on the project but not early as earnest as I was able to do over the holidays.
Dash and frame were wider than the fox body. Cuts had to be made. That part of the project is primarily form fitting. Top of the dash had to be trimmed as well. The 05 dash sit deeper than the fox. To lock down the dash like the fox dash was, I've cut out the end cap from the top of the fox dash that screwed into the firewall. That piece will be fiberglassed to the under belly of the top of the dash.
Shifter is angled back. If your interested I'll post the measurements once I get to that part of the project. Center console is redesigned to be more functional. I'll have to post the prelim drawings.
Currently hung up on building the firewall mounting bracket. Primarily trying to find the time to work on it. Steering shaft is nearly completed. Can't build the last segment of the steering shaft until I have the firewall mounting bracket built.
Air ducting 90% complete. Built fiberglass air box connectors onto existing fox and 05 air ducting to match them up.
Door panels redesigned to carry on the traditional 65 panels. Big change to the door handle location because of personal tastes. Hope to have those built in three weeks.
My biggest challenge of all is going to be the instrument panel. Still don't have a solution that matches what I am looking to achieve. More to follow on that topic in a couple of weeks.
I have a ton of pics and need to post them up. Lots of little things for anyone that ever decides to take on this type of project.
Steering shafts and firewall mounting bracket are built and connected. Working the fine tuning. Air Ducting is complete. Began working the shaping for the door panels and center console design measurements are in progress. Noticed a little movement in the dash frame while testing the steering; will be adding a top support thats a hybrid between the 90 and 05 top support once I splice the two together and weld them. Also will add the security bolts to the lower sides that I had pre-planned early in the planning process.
Have decided to paint while the vehicle is apart and have begun body work. Cut out a piece of top layer metal that was on the pillar under the door weather stripping and welded in a new piece, grinded down the welds, and painted with POR. Pulling weather stripping and trim like its cool looking for more hidden rust. This Hawaiian salt air is tough on the cars here.
I owe pictures, just need to find the time between working the car and looking for a new career to step into after the Marine Corps. Best of luck to all.
Its been awhile since I have been back on. Project is nearly completed. I ended up stopping on the body work mid way through after having a realization that if I needed to do any excessive work on the vehicle I didn't want to accidentally damage the new paint. Had to spend a couple days re-working brake lines after finding the salt air here in Hawaii played havoc on them.
Dash is installed and air ducting competed to include the windshield venting. Going to do another add on project to the windshield vent at a later time by doubling up the 1990 windshield vent moulding but that will be after I get her back to Texas in July/August time frame.
Built an instrument panel using the 2005 instrument cluster plastic housing. Cut and placed specific gauges from the 1990 instrument cluster into the housing, and installed an aftermarket 4 inch tach and electric speedo.
In the process of finishing up the door panels that I customized. I took the original 1990 door panels and stripped them down to the metal top piece. The cardboard backing was so deformed and molded it was beyond repair. I used a plastic board that I bought from a supplier for auto upholstery products here on the island. Cut out the arm rest holes and other needed areas to be able to hang the panel on the door. Decided to move the door handle from the top forward position to under the arm rest (personal preference). Cut out the door handles from the door and welded them to the area I wanted. I wanted to keep a design that was matching close to the look of the classic Stangs door panel. I wanted a smooth metal look but wanted an insert. I'll place a pic of where I am at with the door panel, not really sure I can explain this one too well. I'm painting them gloss black to match the upholstery of the seats. The insert will have an outer black vinyl ring with white pony vertical stripes on the inside. The arm rest will be painted black with a vinyl pad. Needless to say I'll be taking this down to my upholstery guy this week to make my inserts.
Decided to go with the 2005 center console and parking brake. Took out the 1990 parking brake, and built a bracket to install the handle on. Routed the parking brake cable through the use of a 3/8 diameter brake line tube. Used an old brake cable line (stranded metal cable) to attach to the 1990 parking brake hanger to connect to the two separate parking brake cables. The parking brake was designed to be adjustable by placing an eye loop bolt through the parking brake hanger. I'll have to take a pic of this one, because i think I just confused myself.
Just built the front and rear bracket for the center console. I decide to use the 1988 GT A/C controls that I had in my donor car. Fiberglassed that onto the bottom of the 2005 dash cut away that I had when I trimmed the dash skin earlier in the project. I cut out shift extenders from 1/4 steel and will clean those up and drill out holes to attach to the shifter on tuesday.
I've collected up most of the connectors from the 2005 mustang and have been researching wiring diagrams for the 05 and 90 to determine how to connect the 05 switches to the 90 components. Wiring is next, and if I keep on schedule i should have it all wired in within the next week and half. I'll be doing the Fog light fix in the process so as to not have any problems with too much amperage melting the switch.
Finishing the wiring up this week. Hoping to fire her up this weekend or next Tuesday.
Door panels are with my upholstery guy getting an insert built. Hope to pick those up at the end of the week. Shift extender works, but will incorporate a heims joint into the design at a later date to reduce movement.
Probably the least fun of the whole project has been the wiring. It's definitely been a kick in the gentlemen area.
Wiring Complete, started her up last week, fine tuned some wiring, and drove her around for a test drive today. Now have a fully functioning 2005 Dash, tilt-steering column, and center console in a 1990 Mustang Convertible. Still have some minor items to complete (A/C Controls integrated into Dash, and IPad 2 installation), but those will wait till after I move back to the mainland in July.
I'll post some new pics tomorrow. I driving her with the top down felt awesome. Now in the process of prepping the vehicle to paint. Already have body work complete on half the car. Hoping to shoot primer on Tuesday if all goes well.
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