Progress Thread 2001 Bullitt #265 - Build Thread (LOTS OF PICS)

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weendoggy

Active Member
Jan 14, 2019
130
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Aptos, CA
Just been enjoying driving her around this summer... until this happened. Stranded! Was out filming some back country driving with the Bullitt and my new GoPro. Pulled over to swap out camera angles and wouldn't start. Starter is done for. Here is where I was stranded for a little bit.

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Got her started with a push start and made it all the way home. Went on vacation and now back, with some parts on order. Coming soon:
  • New starter
  • New clutch
  • New flywheel
  • New shifter
Bummer! I'd put in a ACT flywheel and good clutch. I also like the MGW shifter (multiple adjustments). jmo
 
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MineralMan

Active Member
May 17, 2005
128
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San Diego, CA
When I was younger, reading forums and build threads and sometimes they would go dormant for several months before updates. I now know why that is the case, especially with project cars. Life just gets in the way sometimes, which is did for me. After a long 4+ months, the Bullitt is back on the ground and took her out on the maiden drive Sunday.

How she looked for the past 4 months

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All the new parts:
  • Exedy Mach 400 Stage 1 clutch
  • Exedy Lightweight flywheel
  • SVE High Torque starter
  • Steeda Tri-Ax Shifter
  • pilot bearing
  • throwout bearing
  • rear main seal
  • lower shifter boot
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After the first drive, everything feels good with a couple of exceptions. The bite on the clutch is still pretty close to the floor. It feels like the clutch cable is pretty stretched. I already have in hand a new adjustable clutch cable, clutch cable firewall adjuster, and an SVE billet aluminum clutch quadrant to install this coming weekend. The shifter is also a little too notchy and difficult to get into first gear. I think I need to do some tiny adjustments on the shifter.

But very happy to have the Bullitt back on the ground and on the road.

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The first drive since before Halloween!!!

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** and I need to trim the shifter. The Bullitt shifter will not twist fully to the correct orientation of the numbers.
 
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MineralMan

Active Member
May 17, 2005
128
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38
San Diego, CA
About to embark on the next big project, and that will be replacing the suspension. Over the last few months I've amassed all the parts that I will need for this project. According to my dad and brother, the only thing that has been replaced on the suspension is the right front shock. Nothing else has ever been replaced. So i've been riding around on a factory suspension with 188K miles on it!!! No wonder she floats and bobs and weaves like a 1972 Grand Marquis.

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Parts List:
  • Ford Racing "C" springs
    • I went with these because the Bullitt is low enough for me. Even know I have to be careful entering my own driveway to avoid scraping the exhaust as I come in.
  • Bilstein B6 shocks front, rear and quad.
  • Eibach sway bars, 35mm front and 25mm rear
  • Urethane sway bar end links
  • Maximum Motorsports HD Adjustable lower rear control arms
  • Replacement upper rear control arms
  • Moog inner and outer tie rod ends
  • Front lower ball joints
  • Urethane bushings for front lower control arm, rear lower control arm, front sway bar, steering rack, and spring isolators

Just before pulling into the garage to start the project, had to take the Bullitt to get the bi-annual California Smog Check. She passed! Which also means that she's been CA road legal for two years now.

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MineralMan

Active Member
May 17, 2005
128
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38
San Diego, CA
Rear Suspension

Over the past couple of weekends I've made some progress on the suspension. The rear is all complete. Ford Racing "C" Springs, Bilstein B6 shocks, Bilstein quad shocks, MM adjustable lower control arms with poly bushings, factory replacement upper control arms with new bushings, and an Eibach rear sway bar.

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MineralMan

Active Member
May 17, 2005
128
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38
San Diego, CA
Front Suspension

All ready for surgery.

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I've also made some good progress on the front suspension. All new inner and outer tie rod ends installed. Steering Rack bushings were replaced with Polyurethane bushings. I've installed the front Bilstein shocks. The front control arms removed, and dropped off to have the new ball joints replaced and new polyurethane bushings installed. Once I get those back, then it will be time to bolt everything back up together.

Check out these ball joints. They could have given way at any moment.

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MineralMan

Active Member
May 17, 2005
128
46
38
San Diego, CA
Front Suspension - Completed

This weekend I finished up the front suspension and the Bullitt is back on all 4 tires. All new tie rods (inner and outer), polyurethane steering rack bushings, polyurethane control arm bushings, new ball joints, Bilstein shocks, Ford Racing "C" Springs with polyurethane spring isolators, and an Eibach sway bar.

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Back on the ground and ready for the first test drive. The battery died so I had to charge it overnight. Will be taking the first drive later today after work. Looks like she is sitting a tad higher than she used to, probably due to the new springs that need to settle and the old springs that had settled way too much.

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Here's the pile of old parts that came off the car.

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MineralMan

Active Member
May 17, 2005
128
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38
San Diego, CA
It's been a while since I've updated. Since the suspension work has been done, I've just been enjoying driving her around without worrying that a ball joint might fail, etc. Now that fall has descended and summer travel is over, I'm starting to get back into a few projects. This weekend I tackled this small project.

Fuel Door Refinishing

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The fuel door on my Bullitt has some corrosion bubbling up from underneath the finish on the main door, as well as around the lower left mounting hole. The hardware, as you can see, has a lot of corrosion on it as well.

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I could have sprung for a NOS one on eBay, but I wanted to try something a bit different. I snagged some brushed aluminum vinyl for about $5 that I would apply to it after removing the corrosion. Here you can see the difference in color between the door and the vinyl. The vinyl is a bit brighter than the door itself. I didn't mind as right now I'm not going for a concours restoration.

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I pulled the door off and disassembled it. If you've never disassembled one, the spring and black cap in the middle of the photo are all that hold the door to the outer frame.

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I sanded through the finish and removed all of the corrosion. Then a small coat of filler to smooth things out.

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I then used my vinyl cutter to cut out BULLITT # 0265 from some left over vinyl that I had to apply to the door. The font I chose is BROADWAY, which is a very close match to the BULLITT badge font.

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I laid over the brushed aluminum vinyl to get this very subtle look to the gas door. I also applied the same vinyl to the outer door ring as well.

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And here it is installed with some refreshed hardware. It is hard to see in the direct overhead light. It's subtle and unique.
 
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MineralMan

Active Member
May 17, 2005
128
46
38
San Diego, CA
The Shaker GT Returns Home

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I am going to be starting the bodywork soon, and there are some pieces that I need for the Bullitt. It's missing one of the Bullitt side scoop delete panels, and I want to do a smoothed 03/04 Cobra rear bumper and a 03/04 Cobra front bumper. I knew of a source for a smoothed OEM Cobra rear bumper as well as OEM Bullitt side panels, my former 2001 GT convertible. I called up my friend who still owned it, and she was ready to sell. We went to New Mexico over the Christmas break and towed it back to San Diego. Now both of the 2001 Mustangs that we owned in the mid-2000s are back together, at least for a little while.

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When I first bought the Mineral Gray 2001 GT 5-speed (and why my username on this board is MineralMan), it was bone stock. I loved the look of the Mach 1, but they didn't make a Mach 1 convertible. But that was my visual goal. Mods that I did to the car:
  • OEM Mach 1 hood
  • OEM Mach 1 Shaker scoop adapted to the SOHC engine
  • OEM Mach 1 chin spoiler
  • 18" Mach 1 replica wheels
  • Mach 1 style side stripes
  • smoothed OEM 03/04 Cobra rear bumper
  • OEM Bullitt scoop deletes
  • OEM Bullitt instrument cluster
  • Borla Stinger exhaust
  • H&R SS lowering springs
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The Bullitt scoop deletes and rear bumper are destined for the Bullitt. I will also be removing the Bullitt instrument cluster, replacing the convertible top (has a gash from when someone broke into the car) and refinishing the wheels. I will probably remove the Shaker hood & scoop and keep those around, not sure if I will sell those separately or add them to the Bullitt as well. Eventually the 'vert will be sold again after returning it mostly to stock.

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Here's a picture of them together about 18 years ago, the day I bought the 2001 GT convertible.
 
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