68 F100 SBFS build; CV, T45, DOHC/M122, Cobra IRS

[sargentrs]

Want! Thanks

[Heirloom]

Thanks Randy. I added three inches to the clutch shaft using another shaft. Then made up a spacer. Made a better arm tonight.

[ Image ]

I've bought some bearings to replace the plastic bushings, I'll take a bunch of pics of that too. If some want I could make a write up.

Thanks Pinche

Awesome work S5....I was considering something similar to convert my gas pedal linkage to cable. I never enjoyed the odd feeling of feeling disconnected from the engine (through the pedal) when it torques slightly and changes the throttle position a little. I don't care if the motor is rattling around under the hood, I don't want to feel weirdness in the throttle.

[SATURN5]

Clutch assembly bearing upgrade and conversion to cable.

Will need some 5/8" dia rod, some 1" rod, two 5/8" flat washers, some schedule 40 1 1/2" pipe (1 3/8" id), two 5/8" ID/ 1 3/8" OD bearings with external snap ring. These can be found on ebay cheap. A Fox Mustang aftermarket quadrant. Some flat stock and 1/2" rod.

Drill the pivot hole on the quadrant to 5/8" id, make the shaft extender and spacer per below. I'm not the greatest explainer as most of what I do is on the fly... But everyone gets pictures.

Knock out the original "bearings" from the pedal mount.

Bearings are 5/8" ID/1 3/8" OD with external snap ring. Bearing rings are .310" thick.



Weld rings on center on both sides.



Weld 5/8" flat washers as spacers on the inside.



Blasted the parts, painting..



Modified clutch arm. Extended to catch quadrant, 1/2" dia rod/stud.



Spacer for extended shaft. Shaft extension 3 3/4" drill and tapped to thread on the original shaft, welded with flats matching original shaft. Either make from scratch or from second clutch pedal. Spacer is 2 1/2" long.



Antisieze lube on original plastic brake pedal.



Completed pedal assembly.



I'm using a firewall adjuster, pretty self explanatory...

[SATURN5]

Added a clutch stop and a Mustang neutral safety/cruise switch.




TRANS!!!!! Plus 04 Cobra pedals for the SVO, Hydroboost for the F100, and Cobra front calipers/rotors for my Mark VIII. 04 Cobra IRS, building for a buddy. 4.10 gears, FM rear cover, trac lok rebuild. Custom Delrin bushings replacing all rubber bushings.

[SATURN5]

Took the day off yesterday as it was a bang on nice day and got the T45 installed....







Original trans cross member set the trans up too high, so once setting the driveline angle -3 degrees.... I whipped one out...

[tbone6]

You do some great work! Thanks for the how to on the clutch conversion. Not sure I am up to your quality of work, I sure do like how yours turned out. Interested in making another?

[SATURN5]

Typically, I'm open to doing side work, but since I have not had the chance to "test" this setup on the road, I have to pass at this time, as I don't want to build one for you, then it doesn't work right. The "how to" should have enough information for you to procure the parts, and have someone local weld it up for you. Cheers, Bob

[SATURN5]

Adapted a Mustang hydroboost tonight.... Removed most of the original plate and fabbed up a plate to fit.



Pushrod needed adjusting too..



Raised the opening.



A little trimming later...

[SATURN5]

So I went OCD on the angle of the brake reservoir. It should be ~ parallel to the ground. It was ass end up. The ment cutting my welds, angling the plate and rewelding. This also led to needing more clearance on the cowl and slightly slotting the holes in the firewall to drop the plate some.

[48prerunner]

Nice write up on the hydroboost and the cable clutch. I'm running a t-45 also but mine is going behind a coyote.

[SATURN5]

Thanks, oh... Coyote....

Not much lately, rebuilding the front end, and modding the spindles for Cobra 13" brakes.





Hub OD is stepped, is the same as Mustang where the wheel mounts, steps up some at the rotor so the Cobra rotor won't sit flush. Had a hell of a time getting the hub out of the spindle thanks to corrosion due to dissimilar metals, but using longer bolts and a solid bar was able to press out the hub. Then, cleaned it up, pressed the studs out and chucked it in my lathe, squared it, and a couple passes later no more step. Pressed the studs back in.

Media blasted the spindle, lathed up some plugs for the original cradle holes. Tossed em in the freezer, warmed up the spindle and pressed them in. Milled them flush to the original surface... I need to redrill for the Cobra cradle, and need to space the cradle toward the rotor. How much I haven't determined yet. Bigger brakes, and a ton lighter then the CV stuff.

Cab is currently being stripped and epoxy primed. Hoped to have this done this over the holiday, but weather hasn't cooperated...

[SATURN5]

Took some rework to make the Cobra 13" brakes fit correctly, but not bad.

First is the hub is stepped, with the wheel end the same diameter as Mustang, but at the rotor, was larger for some reason. The Cobra rotor would not sit flush with the hub face. So, press the hub assembly out of the spindle, was a pain due to corrosion, pressed out the studs and chucked it in my lathe. A couple passes later, press the studs back in and on to the next issue. The caliper cradle bolt spacing is different in length and diameter. This required some .566" diameter plugs be made and pressed into the spindle.



Machining the plugs flush with the spindle.



Set the cradle in the correct location and scribed the outline of the spindle on the cradle. Removed the rotor, set the cradle back on the scribe marks and clamped in place. Marked the centers with a center punch dowel, checked my spacing, setup the spindle in the mill and drilled the new holes.



And here we have the cradle bolted to the modified spindle.





Needed to space the cradle toward the rotor to center. A simple washer was perfect. I need to order up the correct bolts and hardened washers to finish, but I've got my big brakes....





Marauder guys, eat your hearts out....

[sargentrs]

That some incredible work! Keep it coming.

[elgemcdlf]

I am not familiar with the Cobra but is it possible to just use the Cobra hubs in the CV spindles? I know I can use Cobra hubs in my IRS to swap over to the larger discs & bolt circle.

[SATURN5]

Cobra rear IRS hubs are a direct swap into a MN12/M8 IRS spindle. That however will only give you the larger 4.5" bolt circle. (I just redrilled the original hubs) To use the larger rear Cobra brakes on the rear, you need relocation brackets for the caliper and rings to center the rotor if you use the MN12/M8 hub. (M8 caliper is best here) (brackets: http://www.sccoa.com/forums/showthread.php?t=120811)

You cannot use the Cobra (really just Mustang) hubs on the CV front spindle. The Mustang hub bolts on with a single nut where the CV is a sealed assembly that uses four bolts to attach to the spindle.