Mustang5l5's Progress Thread - Archived Progress thread '08-'20.

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Grinding wheels shows up (from McMaster). So I cleaned up the welds.

I did some small stitch welds on the backside that I didn’t grind. Figure that side can stay ugly. I am gonna fill those holes. I just want to get the rail done first. I’ll use a little filler later to smooth it out

Time to clamp my frame rail piece in place and make sure I like it.

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Are you doing your welding with 110 volts ?
If so I would imagine the amp draw has to be in the 15 amp range, any breaker tripping issues or are you on dedicated circuit ?

I’m running it on a 15a circuit. No breaker tripping yet. I do have a 20a circuit I can use if needed a short distance away but hasn’t been necessary yet.

Not using max power. To weld the thickness I am, I’m using the machine at about 50% on the volt dial. The spot welds take a bit note power but no issues. It says max draw is 14.8amps. I’m probably in the 7-9amp range although if I can manage it I’ll try to measure.

I did wire the garage with 20a circuits and 220 power but my feeder run to my subpanel is just a huge PITA that I don’t want to deal with right now.
 
I did some work in the garage last night til 1AM. It’s rreally the only time I can get in there. Got the frame rail all patched in. I thought I took pics but guess not.

Wasn’t bad to stitch it in. The metal is thicker so I could use more power and not burn through. Initial pass was good, but then I made the rookie mistake of welding on top, so the bead is high. Nothing a grinder won’t fix.

I’m only going to grind the inner side in the engine bay for looks. On the outer rail I did fill some holes. I was tempted to start filling engine bay holes but I want to save my gas for the other side first.

I did spray the Eastwood frame coating. Very interesting, thick, stuff.

Just need to spot weld the top plate in, and fold the little tab back over and stitch weld it to the inner rail.

Almost done with first side.
 
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A little more work today.

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Ground the welds down on this face. I left the rear weld mostly intact. Nobody will see it and I feel more comfortable leaving most of it high. The folded over tab covers most of it anyway

On the underside, I ground the front weld where the k member needs to sit. I left the rear weld intact. It looks high and cold because I made the mistake of welding over it and all it did was build up higher.

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I didn’t plug weld the top plate yet. I need to drill my holes and adjust the tabs to sit nice and tight. Once I get that all set I can weld this in and spray some frame paint inside and call it a day.

I did fill the holes on this side. I wanted to practice filling plus with the coil overs I needed to move the brake and fuel line clip to a new spot. . I left the bottom seam weld intact with no grinding.

Yes, this side is uglier. I did a couple stitches on the tower from the backside

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Looking ahead..the other side. I still have some rusty metal to cut out. I’m not confident the Scott Rod patch is going to cover enough.

I’m going to do something else for this side. I need to get that booster out first.

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Sweet! What Master is on that thing? Will it work right with the Brembo fronts and 43mm or 38mm rears?

1 1/8” bore. I know guys are using it with hydroboost and the ATS/43 and claiming pedal feel is close to stock. The max motorsports kit includes a new pedal to corrrct the ratio so not sure how that will affect things.

Reason for changing it is because it’s easy with the engine out to plumb it up and install it, and I want some unique touches.
 
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1 1/8” bore. I know guys are using it with hydroboost and the ATS/43 and claiming pedal feel is close to stock. The max motorsports kit includes a new pedal to corrrct the ratio so not sure how that will affect things.

Reason for changing it is because it’s easy with the engine out to plumb it up and install it, and I want some unique touches.



AAAANNNNNDDDDDD it lays the foundation for a Coyote swap later... #amiright?
 
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From the outside, all you saw was a little bubble. I prob could have just done a small plate, but I wanted to cut all the rust out and get fresh metal in there.

Other side will be a little bit bigger hole...
 
Added the Max motorsports sway bar reinforcement plate. Prob not necessary for my driving style...but they were cheap, and I’m here. Might as well.

Didn’t do other side yet til I finish that rail

I’m also wirewheeling and cleaning the metal as I go and spraying some primer. I’ll do a bulk sanding later on before I paint the bay.


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