1975 242 DL Mods and Upgrades

  #41  
Old 12-16-2014, 08:14 PM
Former Moderator
Join Date: Oct 2010
Location: 37 North on the left coast
Posts: 9,995
Default

so, one thing bugs me.... this seems like a lot of car for a stock B20 engine with k-jet? or is there something missed back in there?
 
  #42  
Old 12-16-2014, 10:23 PM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

Originally Posted by pierce View Post
so, one thing bugs me.... this seems like a lot of car for a stock B20 engine with k-jet? or is there something missed back in there?
The b20 is in there for the moment. I haven't decided if I'm going to pick up an "e" head for it and side draft it with cam and lifters for this one.

I can also turbo the B20 for cheap.

K-jet is pretty simple and easy to work on.

The B20 is a very nice motor, and this will be my daily driver.

I am still waiting for parts to finish this motor (which will probably end up in this car):

Name:  IMG_0946.jpg
Views: 884
Size:  74.3 KB
 
  #43  
Old 12-16-2014, 11:10 PM
Senior Member
Join Date: Jul 2014
Location: Anderson, SC
Posts: 128
Default

It's been a while since I've read through the thread... are you planning on making those mounts available?
 
  #44  
Old 12-17-2014, 12:24 AM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

The Aluminum engine ones?
I haven't found a reliable place to cut my set yet. I wasn't planning making anymore...
I need to test the steel ones before I would sell them to anyone.
We did send a copy of the V1 aluminum mount file to Ben at Kaphlenke Racing.
If we talk with him, he might be able to offer something for purchase.
 
  #45  
Old 02-03-2015, 05:45 PM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

Update:

Been working on the car at a slower rate than I wanted, but we are in the final stretch for it now.

Name:  _DSC3251.jpg
Views: 866
Size:  60.1 KB



This is where the shifter ends up after moving everything over

Name:  WP_20150131_011.jpg
Views: 840
Size:  37.4 KB



The engine and trans are now in their proper place. Shifted the engine and trans like a .25" to the passenger side.

Name:  _DSC3276.jpg
Views: 846
Size:  61.4 KB



There are the new lower mounts in place. Intake and exhaust still need to come off for new gaskets and wiring.

Name:  _DSC3270.jpg
Views: 848
Size:  59.1 KB



There is the new skid plate I made for the header. Should work well.

Name:  _DSC3280.jpg
Views: 854
Size:  71.4 KB

Name:  _DSC3272.jpg
Views: 905
Size:  65.8 KB



Drive shaft is in.

Name:  _DSC3287.jpg
Views: 843
Size:  52.0 KB



We finally have some decent u-joint angles and working angles now.

Name:  _DSC3290.jpg
Views: 848
Size:  59.6 KB

Name:  _DSC3289.jpg
Views: 846
Size:  55.1 KB




Got the rest of the fuel line parts yesterday, so those should be done this weekend.


That is all for now.
 
  #46  
Old 02-24-2015, 07:46 PM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

Update:


Here is the skid plate. Simple, cheap and works.

Name:  WP_20150105_002.jpg
Views: 840
Size:  50.0 KB

Welds are okay. I was rushing it, but it will work.
Name:  WP_20150105_003.jpg
Views: 838
Size:  55.3 KB


Rear mounted battery. Going to run my yellow top optima.



Name:  _DSC3318.jpg
Views: 829
Size:  60.9 KB


So far, The fuel lines have been taking a little extra time. The fuel line tool works great for pushing the fittings on and making the lines take very little time. It is the running and planning out the paths which takes a while.




New fuel lines, speedo cable, and battery cable.

Name:  _DSC3345.jpg
Views: 836
Size:  65.5 KB

Name:  _DSC3350.jpg
Views: 839
Size:  56.7 KB

Name:  _DSC3353.jpg
Views: 850
Size:  62.2 KB

New Line for return on the tank.

Name:  _DSC3339.jpg
Views: 839
Size:  50.4 KB

The heater control valve cable broke. I just did a temporay fix till the new one comes in. should still work though:

Name:  WP_20150219_004.jpg
Views: 838
Size:  36.6 KB




Last thing done was making a fuel line holder for the intake manifold.

Name:  _DSC3356.jpg
Views: 844
Size:  54.9 KB

Name:  _DSC3357.jpg
Views: 841
Size:  69.3 KB

Name:  _DSC3359.jpg
Views: 831
Size:  67.0 KB

Name:  _DSC3361.jpg
Views: 839
Size:  69.1 KB

It works, but I want to get it CNC cut and use an actual metal brake to form the part next time.


We will finish the fuel system this weekend, and finish the battery cable.


I am working on some rear deck enclosures for some 6.5" component speakers. Right now, I am trying to get a large enough volume so the mid woofers have some decent bottom end. Lucky the amp has some filters options to give a slight boost at the low end. Right now, these enclosures are only 2.3 cubic Liters.

Name:  image%202.jpg
Views: 855
Size:  32.8 KB

Name:  Image%201.jpg
Views: 836
Size:  30.9 KB

Just doing some testing of the stock shape here. I'm going to have to expand the lower sections under the deck more to get me to my goal of at least a 3 cubic liter enclosure. The final shape will be really annoying to make out of wood, so I'm thinking I will have to make some fiberglass versions if I cant get them 3D printed. Have to avoid the battery, the subwoofer and amps.


Oh. The rims are finally getting repaired. Should have them hopefully in a couple of weeks.


That's all for now, more this weekend...
 
  #47  
Old 02-26-2015, 04:08 AM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

Small Update:

Did some measurements of the rear deck and trunk space. Made a simple model showing the boundaries to check my clearances and see how large of an enclosure I can get for the mid woofers.


Name:  8.jpg
Views: 838
Size:  28.0 KB

Name:  9.jpg
Views: 837
Size:  20.3 KB

Name:  10.jpg
Views: 849
Size:  20.0 KB

Top View (looking down)
Name:  6.jpg
Views: 830
Size:  32.6 KB

Front view (looking from the passenger compartment into the trunk)
Name:  5.jpg
Views: 839
Size:  25.7 KB

Side View (from the driver side)
Name:  7.jpg
Views: 819
Size:  37.6 KB


Name:  1.jpg
Views: 832
Size:  26.4 KB
The amp will mount to the side of the sub
Name:  2.jpg
Views: 838
Size:  25.0 KB

Name:  4.jpg
Views: 843
Size:  22.4 KB

The mid woofer enclosures are roughly 4 cubic liters, which is not too bad. that should only need some very slight boosting in the amp. The Sub enclosure is 26.4 cubic liters. As mentioned above, looking at 6.5" components in the rear deck, and a 10" sub powered by a small digital amp that puts out 400watts. 100watts to the 6.5" component each and 200watts to the 10". Should be a nice balanced setup when it is all said and done.

So...everything looks good for clearance, just need to finish the enclosure models and make them. I am looking into printing some test parts, and templates, then a fiberglass final part. I have not decided if I will sand and paint them or just carpet them. The Sub will be carpet so I might just keep it all the same.
 

Last edited by TIPSP; 02-26-2015 at 12:29 PM.
  #48  
Old 02-26-2015, 12:19 PM
Former Moderator
Join Date: Oct 2010
Location: 37 North on the left coast
Posts: 9,995
Default

we all have our favorite brands, but I've been very happy with the upper midrange JL Audio component and/or coaxial 6.5" speakers, with the separate crossovers. Very clean sounding, handle plenty of power.
 
  #49  
Old 02-26-2015, 06:28 PM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

Originally Posted by pierce View Post
we all have our favorite brands, but I've been very happy with the upper midrange JL Audio component and/or coaxial 6.5" speakers, with the separate crossovers. Very clean sounding, handle plenty of power.

I have some I was going to stick in the other 240 before the accident. I have been doing all the measurements for the enclosures with the speakers I have.

Got this in the mail today:

Name:  _DSC3366.jpg
Views: 891
Size:  58.2 KB

Those are rear "R" caliper adapters. They will not go on the car yet as I'm going to drive with just the fronts and modified rears for now. Going to see how that works first, then I will step up the rears and upgrade to a mustang master cylinder.
 
  #50  
Old 04-12-2015, 11:18 PM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

Update:

Lots of things happening, but progress has been made.

Making an adapter for the filler neck for the older cars.

Name:  _DSC3410.jpg
Views: 831
Size:  346.0 KB

Name:  _DSC3397.jpg
Views: 849
Size:  250.1 KB

Name:  WP_20150330_005.jpg
Views: 842
Size:  257.4 KB

Name:  WP_20150330_006.jpg
Views: 838
Size:  282.8 KB

Name:  _DSC3502.jpg
Views: 841
Size:  310.0 KB

Here it is:

Name:  _DSC3496.jpg
Views: 831
Size:  237.2 KB

Name:  _DSC3493.jpg
Views: 832
Size:  231.1 KB

Name:  _DSC3504.jpg
Views: 858
Size:  328.2 KB


Finished the battery cable and fuel lines:

Name:  _DSC3414.jpg
Views: 828
Size:  348.4 KB

Name:  _DSC3515.jpg
Views: 829
Size:  308.5 KB


Name:  _DSC3526.jpg
Views: 837
Size:  337.2 KB

Name:  _DSC3528.jpg
Views: 833
Size:  357.9 KB



Lines are not in the clamps yet, as we are waiting to prime the system and check for leaks.

Name:  _DSC3547.jpg
Views: 838
Size:  376.2 KB

Made a heat shield for the cables and lines:

Name:  _DSC3420.jpg
Views: 898
Size:  364.5 KB

Final Shape:

Name:  _DSC3539.jpg
Views: 842
Size:  357.4 KB
 
  #51  
Old 04-12-2015, 11:18 PM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

We decide the wiring harness was a mess and are currently looking at it/ removing some things.

Decide to go with the Denso 100amp alternator internally regulated (much simpler to install this than mess around with the stock 55amp and external regulator/ terrible wiring and connectors:

Name:  _DSC3460.jpg
Views: 836
Size:  328.4 KB

Name:  _DSC3463.jpg
Views: 821
Size:  346.6 KB

Name:  _DSC3457.jpg
Views: 840
Size:  347.7 KB

Name:  _DSC3486.jpg
Views: 841
Size:  373.1 KB

3d printed a temp bracket to test belt lengths:

Name:  WP_20150404_002.jpg
Views: 835
Size:  170.0 KB

Stock belt length works but a little too short: got a longer one from napa:



Still making the bracket for the alternator, but here it is partly done (not using that bolt...don't worry):

Name:  _DSC3511.jpg
Views: 826
Size:  327.9 KB


There has been more done to it, but I will not post any of that yet.

More to come next weekend.
 

Last edited by TIPSP; 04-12-2015 at 11:21 PM.
  #52  
Old 04-19-2015, 02:16 AM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

Finished the Alternator bracket and mounted it. Just have to wire it up now.

Name:  WP_20150417_014.jpg
Views: 806
Size:  242.7 KB

Name:  _DSC3563.jpg
Views: 835
Size:  343.0 KB

Name:  _DSC3565.jpg
Views: 837
Size:  394.7 KB

Name:  _DSC3566.jpg
Views: 946
Size:  354.2 KB

Name:  _DSC3567.jpg
Views: 822
Size:  351.8 KB

Also Started to address some noisy panels in the car. No buzzing or resonating any more.

Name:  _DSC3577.jpg
Views: 837
Size:  389.1 KB


Rubber foam pads are installed on the panels themselves.

More tomorrow
 
  #53  
Old 04-19-2015, 10:54 PM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

Finished the interior sound paneling.

Name:  _DSC3589.jpg
Views: 823
Size:  390.9 KB

Wiring the fuel pumps up:

Name:  _DSC3591.jpg
Views: 840
Size:  334.7 KB

Name:  _DSC3593.jpg
Views: 839
Size:  370.2 KB

Carpet on the trunk panel, looks sooo much better than black paint board they had

Name:  _DSC3594.jpg
Views: 840
Size:  336.4 KB

Started the trunk sound paneling:

Name:  _DSC3596.jpg
Views: 841
Size:  353.6 KB

Name:  _DSC3598.jpg
Views: 824
Size:  324.0 KB

Just have to make the rear shelf assembly for the speakers and brake light holder ( adding a 3rd brake light to the car)

That Dynamat stuff is pretty nice. Works really well, and doesn't weigh that much. It really makes the car sound solid. A nice dead thud sound. Good for low frequencies and no more rattling panels.

More wiring crap next weekend.
 
  #54  
Old 04-26-2015, 09:01 PM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

Update:

More wiring stuff. It takes a while to lay everything out and make custom panels to hold everything.

Tire clearance is still good with the carriage bolts.

Name:  _DSC3600.jpg
Views: 830
Size:  339.5 KB



Factory rear trunk carpet for the wheel bumps. Pretty rare I believe. Lucky to have got these with the black carpet I bought for the car.

Name:  _DSC3604.jpg
Views: 835
Size:  335.7 KB



Circuit breaker panel made and carpeted.

Name:  _DSC3606.jpg
Views: 834
Size:  330.9 KB



Ford Starting Solenoid being used to bypass the breaker for starting.

Name:  _DSC3610.jpg
Views: 837
Size:  302.4 KB



Driver side Carpet

Name:  _DSC3611.jpg
Views: 842
Size:  312.8 KB



Made the a new cover plate out of aluminum for the sender unit access panel.

Name:  _DSC3614.jpg
Views: 832
Size:  312.5 KB



It's the little things that make a difference and take time. The trunk will look 100x better with them.

More Next weekend.
 
  #55  
Old 07-22-2015, 12:09 AM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

Another long time since updated... Busy with things, but this project is close to being down.

Couple things, the wiring is back in the car and fixed. The stock harness was in bad shape. That is now repaired. As that was being worked on, the stereo was also being worked on.

Here is the custom door lock switch I made.

Name:  _DSC3814.jpg
Views: 883
Size:  343.2 KB

Power locks are nice to have.



Anyways, the stereo project:

Rear shelf being made



Name:  _DSC3844.jpg
Views: 820
Size:  280.4 KB

Name:  _DSC3858.jpg
Views: 825
Size:  325.8 KB

Name:  _DSC3854.jpg
Views: 818
Size:  363.8 KB

Name:  _DSC3856.jpg
Views: 825
Size:  278.2 KB



Name:  _DSC3863.jpg
Views: 822
Size:  302.2 KB

Still have to make the rear cover for that to hide them and the 3rd brake light.

Name:  _DSC3865.jpg
Views: 815
Size:  283.7 KB

Made a new gasket for the air box and fuel dist.

Name:  _DSC3869.jpg
Views: 821
Size:  345.9 KB

Making the sub box

Name:  _DSC3870.jpg
Views: 833
Size:  299.0 KB

Cutting the lower mounting surface

Name:  _DSC3879.jpg
Views: 809
Size:  301.1 KB

Name:  _DSC3882.jpg
Views: 824
Size:  290.4 KB

Name:  _DSC3900.jpg
Views: 808
Size:  218.4 KB

Name:  _DSC3901.jpg
Views: 807
Size:  248.5 KB


Carpeting

Name:  _DSC3902.jpg
Views: 806
Size:  290.0 KB


It has .83 cubic foot box volumn. and is made of 18mm Baltic birch plywood.



Name:  _DSC3910.jpg
Views: 815
Size:  259.2 KB

It is a 10" woofer

Name:  _DSC3912.jpg
Views: 814
Size:  258.2 KB

This AMP is now where the sub amp goes. The 4 channel amp is on the lower piece below the sub amp (not pictured).

Name:  _DSC3915.jpg
Views: 812
Size:  266.1 KB
 
  #56  
Old 07-22-2015, 12:16 AM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

Fitting the unit

Name:  _DSC3927.jpg
Views: 810
Size:  298.9 KB

Name:  _DSC3946.jpg
Views: 800
Size:  301.5 KB

The rear power center

Name:  _DSC3949.jpg
Views: 787
Size:  282.0 KB

Making the rear Shelf covers

Name:  _DSC3954.jpg
Views: 799
Size:  366.5 KB

Name:  _DSC3956.jpg
Views: 794
Size:  329.0 KB

Name:  _DSC3967.jpg
Views: 790
Size:  300.9 KB

These have been painted, carpet'd and fiberglass'd. Now I am making my mounting bracket for them.

Finished the wiring and stuff in here...

Name:  IMG_0031.jpg
Views: 793
Size:  371.6 KB

Name:  IMG_0032.jpg
Views: 792
Size:  401.9 KB



And look what finally showed up today.

Name:  1513202_1024043777607026_8312769780197497065_n.jpg
Views: 785
Size:  90.3 KB

It took a couple years, but finally here. Now I can start the new motor for the car.
 
  #57  
Old 07-27-2015, 05:45 AM
dnarby's Avatar
Senior Member
Join Date: Jun 2010
Location: New Haamp-sha
Posts: 195
Default

Ooo, shiny!!!

Forged pistons and connecting rods?
 
  #58  
Old 07-27-2015, 03:45 PM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

Originally Posted by dnarby View Post
Ooo, shiny!!!

Forged pistons and connecting rods?

Yep. From RSI. They are for the 16v turbo motor shown in this thread somewhere. Going to stick that motor in this car eventually.


Here are a few more from the testing and fitting.


Name:  IMG_0048.jpg
Views: 798
Size:  389.0 KB


Name:  _DSC3982.jpg
Views: 775
Size:  274.1 KB


Name:  _DSC3983.jpg
Views: 786
Size:  302.9 KB


Name:  _DSC3985.jpg
Views: 797
Size:  310.0 KB


Name:  _DSC3986.jpg
Views: 790
Size:  307.1 KB
 
  #59  
Old 09-15-2015, 01:14 AM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

Update:

The rear speaker stuff is basically done. I just have to do the ground wires for the amps and head unit, and then make a board to close it off... maybe.


Ground wires are just put there. not staying like that.


Name:  _DSC4006.jpg
Views: 798
Size:  548.3 KB

Wheels are on now. Just have to order new studs and spacers to align the back

Name:  _DSC4022.jpg
Views: 791
Size:  519.3 KB

Plenty of room. too large of a spacer. going to use a smaller one.

Name:  _DSC4024.jpg
Views: 789
Size:  466.2 KB

Name:  _DSC4029.jpg
Views: 788
Size:  510.5 KB

Name:  _DSC4033.jpg
Views: 796
Size:  619.0 KB

Name:  _DSC4037.jpg
Views: 791
Size:  445.2 KB

Fronts are out a little too much. going to pull it in.

Name:  _DSC4038.jpg
Views: 804
Size:  517.4 KB

Name:  _DSC4039.jpg
Views: 777
Size:  485.1 KB

Name:  _DSC4042.jpg
Views: 783
Size:  505.9 KB

Before rolling and spacing out the back

Name:  _DSC4040.jpg
Views: 779
Size:  470.0 KB
 
  #60  
Old 09-15-2015, 01:22 AM
TIPSP's Avatar
Got Boost?
Thread Starter
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,551
Default

After Rolling and testing:

Name:  _DSC4043.jpg
Views: 787
Size:  482.2 KB

Name:  _DSC4045.jpg
Views: 789
Size:  494.4 KB

Name:  _DSC4048.jpg
Views: 789
Size:  523.9 KB

Name:  _DSC4054.jpg
Views: 775
Size:  567.8 KB

Name:  _DSC4057.jpg
Views: 780
Size:  432.2 KB

Name:  _DSC4061.jpg
Views: 782
Size:  537.8 KB

Name:  _DSC4063.jpg
Views: 783
Size:  501.5 KB

No rolling on the fronts.

Name:  _DSC4065.jpg
Views: 788
Size:  488.9 KB

Name:  _DSC4066.jpg
Views: 772
Size:  534.3 KB

Yes it rubs this far out in the rear. It will not stay here. It will move in slightly. Stiff suspension and solid mounts, the axle has no sloppy movements.

Name:  _DSC4067.jpg
Views: 784
Size:  437.8 KB

Name:  _DSC4069.jpg
Views: 785
Size:  457.4 KB

Name:  _DSC4070.jpg
Views: 779
Size:  466.4 KB

Name:  513b9739-d634-463e-8a99-6ca1b7a3dd79.jpg
Views: 769
Size:  325.4 KB

The passenger side fender was a mess. So much rust. It rolled but some was cut out and now I have to fill it and under coat it again.

But, It is basically done for now till I get the new studs and spacers for the back.


The suspension alignment has not been done yet either, so it will have even more clearance in the front once the camber and toe is adjusted.

The brakes are bleed, rotors are cleaned. Ready to drive it almost.

Oh, and after a month of problems with wiring, bad parts, messed up distributor and fuel distributor, and messing with dirty injectors: This happened.







It runs super rich. The Injectors are at a friends shop being cleaned right now. There is some nasty rattle. I have to check that out. There are some possible causes, but I haven't run the car long enough to find out the part rattling. Have to check the cam for wear. The idle is way to high. Car will hopefully be running better We rebuilt the fuel distributor, and it works pretty well now. Have Excellent pressure and everything is back in spec. Going to tune it next weekend.

This engine is interesting. Stubborn little guy. But I plan to keep it for a while. I'm going to add a supercharger to it. should be a fun, reliable power plant till I finish my 16 turbo motor.
 

Last edited by TIPSP; 09-15-2015 at 01:57 AM.

Thread Tools
Search this Thread
Quick Reply: 1975 242 DL Mods and Upgrades


Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service

© 2019 MH Sub I, LLC dba Internet Brands

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.