Mustang5l5's Progress Thread - Drivers side frame rail using donor piece

Mustang5L5

i'm familiar with penetration
Mod Dude
Feb 18, 2001
32,867
9,029
224
Massachusetts
A little more work today.

9F6C28B7-89CE-4C40-8B80-989163952618.jpeg


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.

0DEA8C83-1621-49F5-8C3E-21CD63016C2C.jpeg


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

AB79279B-FAF1-4F6F-8548-7EFF3B86EB8A.jpeg
 
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Mustang5L5

i'm familiar with penetration
Mod Dude
Feb 18, 2001
32,867
9,029
224
Massachusetts
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.

3865DDE8-3F43-4B3F-8545-63771996281D.jpeg
 

Rdub6

Mustang Master
Dec 29, 2017
1,342
990
123
Long Island, NY
So that booster is coming out, and going in the parts bin!!!
Towers looking good. Making quick work of it now that your getting going!!
 

Mustang5L5

i'm familiar with penetration
Mod Dude
Feb 18, 2001
32,867
9,029
224
Massachusetts
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.
 
Last edited:

bird_dog0347

still married haven't seen testicles in years
5 Year Member
Jun 7, 2012
1,093
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Little Elm, TX
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?
 

2Blue2

will be trying this sex one when I can find it
Mar 5, 2019
1,727
967
123
52
Oahu
liking the progressive shots

dang you cut a big ole hole in that car...
 

Mustang5L5

i'm familiar with penetration
Mod Dude
Feb 18, 2001
32,867
9,029
224
Massachusetts
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...
 

Mustang5L5

i'm familiar with penetration
Mod Dude
Feb 18, 2001
32,867
9,029
224
Massachusetts
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.


3E38824D-3966-4750-ABCC-591BBE7EC87C.jpeg
 

Mustang5L5

i'm familiar with penetration
Mod Dude
Feb 18, 2001
32,867
9,029
224
Massachusetts
In my quest to track down supplies that don't take 4 weeks to show up, I needed some flap disks.


If you use the coupon code "FREEMIX" at checkout, the disks are free and you just pay $10 for shipping. I thought that was pretty good for basically $1 a flapdisk.

No idea how many weeks it will take though.
 

Mustang5L5

i'm familiar with penetration
Mod Dude
Feb 18, 2001
32,867
9,029
224
Massachusetts
Pass side done.

Time to start drivers side. I think I’ll be taking a different approach here. I bought @Gravydog driver new edge rail.

Quick cleanup.

1CD7268B-79DB-42A1-94DC-47E9423819A5.jpeg

CA4B5ECA-A4D9-4985-B588-07D98DB241FA.jpeg


Next step is pull my booster. I need access to inspect the rail. I think the main rail metal is too thin to weld to. Just not sure I want to take the chance but I want to drill ou the inner rear apron and inspect first. I have two plans.
 

Mustang5L5

i'm familiar with penetration
Mod Dude
Feb 18, 2001
32,867
9,029
224
Massachusetts
WOrked a bit on stripping the donor rail down. Pulled off the front and rear aprons (what was left of them) the top cap and the rear firewall support. I may weld up some of the holes while I am here.

427594DF-85DB-42D9-BE80-24196165CEE0.jpeg


There is a small brace inside the firewall support that holds the rail. Interestingly enough, it has a part number on it
AA6DFB84-BF8F-41A2-9DE8-DF811D529CFD.jpeg


Need to get the booster out now. I need to remove the rear apron/top cap to see the extent of thin metal back there. Then I’ll know my plan

8FBE1B4C-C8F9-406E-A2F6-D0B261F8E440.jpeg
 

88LX5.Oh

5 Year Member
Dec 30, 2011
1,445
207
84
Arkansas
I haven't logged on to this forum in probably 7 years. It's wild to see some of the same usernames still around on here. Anyways I'm just glad I'm not the only one here with an unfinished car after all these years lmao
 

CarMichael Angelo

clearly, I’ve got something going on in that hole
SN Certified Technician
Nov 29, 1999
12,499
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m.imdb.com
I cant see how as.........What's the right word......"thorough"? As you are, that you are not dealing with the 50 bagillion holes in the strut towers that are in front of you.

Right under your nose.
 
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