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 Project Update

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macmurr

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Join date : 2008-11-08
Location : Halifax, Nova Scotia Canada

PostSubject: Project Update   Thu Nov 11, 2010 10:16 pm

Hello all. Red78's birthday cake shot caught my eye a couple of days ago & then I read Revolution909's reference to little board activity and his good-natured dig 'talking to myself'. Thought I'd update you on my boxtop project - one that's been idle for the last few years.

Just pulled a great working six/auto from the '78 and getting ready to have some head machining done (seat grind, new springs, mill carb adapter location & hog out intake to match) + install a T5. Decided to be a little different and play with the 200. Will be installing a Holley-Weber 5200 two barrel, mild cam, double chain, and headers. Some light machining is required on the SROD bell I was lucky to pull from another six and the T5 will connect after enlarging the center and drilling/tapping some new bolt holes. Classic Inlines and the FordSix websites, plus a copy of the Falcon Performance Handbook, have been terrific resources.

Pics show some of the new components on an old block I bought to mock things up. Before the pull I warmed up the car and checked oil pressure and compression. Both were great and fit with my decision to not do anything to the bottom end. Former owner oiled the body frequently and the chassis + engine bay are real dirty. Red78 kindly shared some hints & pics of his clean-up. A tedious task for sure but worth the effort.

The car has good paperwork and confirms the 95,000 km/60,000 miles on the clock. Door bottoms and subframes look great but there are the usual (for the east coast anyway) floor pan holes under the pedals. Will need paint + other cosmetics.

I have a double-hump crossmember for the narrow 2.75" ('78-'80 I think) FOX bracket spacing and will probably need to fabricate an extension for the T5 to sit on. Staying with the 3.08 7.5" rear for now but have a 3.45 & 3.73 R&P set once I see how it behaves. Also plan to mount 10-hole Mustang rims.

Thanks for reading. Work gets in the way of many things so it'll probably be awhile before I get the head off and to the shop. Will post updated pics when I can.

Steve
Halifax, Nova Scotia
Canada











Last edited by macmurr on Sat Nov 13, 2010 1:46 pm; edited 1 time in total
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HandyAndy



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PostSubject: Re: Project Update   Sat Nov 13, 2010 1:32 am

Hey how are you going to hook up the throttle cable that way?

I have a couple of 5200s also and haven't quite got it figured out yet.
When I mock things up they just don't fit.
Throttle cable is too long.
At least going to a manual you won't have to worry about a tranny kickdown.

What cam will you get?
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macmurr

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PostSubject: Re: Project Update   Sat Nov 13, 2010 1:43 pm

Read as much as I could about 200 street cams on the FordSix & Classic Inlines sites. Purchased what CI lists as a Class II aftermarket cam profile 264 duration (.050 lift) and 110 degree lobe separation - lopey idle, adequate vacuum, stock compression, and 1600-5000 RPM range.

http://www.classicinlines.com/select_cam.asp

Throttle linkage will certainly require some fabrication.

Link is to recent postings about this topic...

http://fordsix.com/forum/viewtopic.php?f=1&t=63940

Pictures of different carb linkages...

http://smg.photobucket.com/albums/v296/Powerband/CARBS%20HEADERS%20EXHAUST%20INTAKE/?start=all

Steve

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HandyAndy



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PostSubject: Re: Project Update   Sat Nov 13, 2010 3:44 pm

Yah, I'm JackFish over on that forum.
I'm running a 264/274/112 with a fully modded head.
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Red 78'

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Location : ANAHEIM, CALIFORNIA

PostSubject: Re: Project Update   Sat Nov 13, 2010 4:38 pm

Looks like a terrific project!
Too bad mods like that are not allowed in California, unless you don't want to drive it on the road.
I am wondering if it would be worth it to change it over every 2 years for smog check.
I really like the headers, and the thought of a 2BBl.
Keep us posted on your progress.
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macmurr

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PostSubject: Re: Project Update   Sat Nov 13, 2010 6:53 pm

Nice looking engine & bay Andy! It's the biggest cleanup job ahead for me & I'm not looking forward to it.

What mods did you do to the head? Cam liven things up as expected? Play with exhaust at all?

Think your wagon is the original colour of my boxtop (81) and I'm going to repaint to that code. You the old Winnipeg Bassomatica I pulled an E-brake 'L' for when I lived in Ottawa? Son works for Princess Auto and was out there visiting for 10 days this summer.

And for Red78's thoughts on a two-year carb & exhaust changeover...bet you could do it with a little planning. While the intake log for the 5200 intake adapter I have has to be milled flat and the single hole widen, there are 2V carb adapters that narrow to the original intake hole - making the carb switch easy come the smog check.

Exhaust flip would require more time (original manifold needed for the EGR valve and pulsed exhaust air injection port + pipe to cat). With a header Y to a single pipe, you might be able to fashion an easier connect just after the cat for an in/out swap. Don't know the rules in CA but doubt it follows the spirit of the regs lol Wink

Steve
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HandyAndy



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PostSubject: Re: Project Update   Sun Nov 14, 2010 1:24 pm

Yah that's me. The head was milled .050, 1.75 and 1.5 SI valves with backcut on the intakes.
Dual valve springs, pocket ported, exhaust gasket match. Block is .030 with cast pistons and moly-rings.

Stock exhaust and induction, but I did put a larger jet in the carb, and drilled a hole in the butterfly. But I'd like to go to a 2bbl when I get it figured out.

It runs out of air at about 4200+rpm WOT. But has lots of power up there and is crying out for more.
The stock engine pooped out at about 3500+rpm.
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macmurr

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PostSubject: Re: Project Update   Mon Nov 15, 2010 12:48 pm

Looks like you've set things up well with your cam, dual springs, porting, pistons & rings. No short block work for me other than a cam. I plan to do as much valve pocket smoothing as I can before it goes to the shop for a three-angle cut, head mill, carb adapter install, and the 3 & 4 exhaust port divider. I've got a flat top log on the head I'll be using (above pic shows it on a hex log) so the adapter will be a little easier cut & fit. The shop said they had replacement soft plugs for the log ends so I plan to pull those and do a little smoothing there too.

I ordered 302 exhaust valve springs as suggested by Classic Inlines. The stock retainers work OK for your spring replacement?
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HandyAndy



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PostSubject: Re: Project Update   Tue Nov 16, 2010 12:28 am

No they did not. Classic Inlines supplied the retainers.
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Aug

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PostSubject: Re: Project Update   Sat Nov 27, 2010 3:10 am

On cleanup....

My '80 boxtop had been oiled yearly before I got it, then the doofus painted over dirt!

By far, the quickest and most effective method of cleaning the entire engine compartment/underside of the car is the use of a hot-water pressure washer, or "Steam Jenny". You wouldn't believe how clean everything got, and how fast it got clean. It uses 160º water and pressure (and some soap sometimes). I will own one of these someday, but it's worth the rental.

Hope this helps,
Mike.
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Revolution909

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PostSubject: Re: Project Update   Mon Nov 29, 2010 11:26 am

Thats a beautiful box-top. From the looks of your engine, it should run just as good as it looks.


Handy Andy that is a gorgeous 200, good work.
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macmurr

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PostSubject: Engine Bay Cleaning   Sun Dec 12, 2010 11:08 am

Thanks for the post about getting it steamed cleaned Mike...and the note about 'painted over dirt'. Nothing like taking a scraper to the muck and having the top coat coming along with it. Car's in the garage on a hard floor with no drain & the driveway's steep - so it's a real pain to get it out to a commercial steamer. Used to be several mobile units around here but disposal of the runoff closed a lot of guys down. Wonder if I could still do the steam with floor tarps covering a makeshift sump to pool the water/debris? Big volume of water/gunk left when you did your car? Had a '57 Ford frame done with steam years ago and it's the way to go.

If not steam, then it's a long slog with a brush/degreaser/tarp/newspapers. What degreasers and methods have you guys used that might work well over a garage floor? Thanks for any hints .

Steve

Aug wrote:
On cleanup....

My '80 boxtop had been oiled yearly before I got it, then the doofus painted over dirt!

By far, the quickest and most effective method of cleaning the entire engine compartment/underside of the car is the use of a hot-water pressure washer, or "Steam Jenny". You wouldn't believe how clean everything got, and how fast it got clean. It uses 160º water and pressure (and some soap sometimes). I will own one of these someday, but it's worth the rental.

Hope this helps,
Mike.
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macmurr

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PostSubject: Re: Project Update   Sun Dec 12, 2010 11:45 am

Thanks for the comments on the sedan/engine Rev909. Liked the shots of your 'drop curtain paint booth' when you sprayed the wagon. Did the same thing when I helped a friend paint a track car. Making sure the light plastic didn't get blown onto the new paint was always a worry.

How is the F/Z parts situation in southern Ontario? It's non-existent here on the east coast where there's more salt than asphalt on winter roads. They all died early. Was lucky to have worked in Ottawa 2002-08 and found a yard that hadn't crushed everything. I think I was the only one that cared about them so they looked pretty ugly after I finished my rounds - no trim or interiors left untouched Very Happy

Also bought a few pieces from a nice chap in Whitby who had a bunch of F/Z's and a boxtop with a different trim package. Believe he bought it at an auction in Penn and hauled it north. Original V8 car that had been hit on the side. Almost 'too many' trim accents for my liking. Final paint was dark green and the car looked real good. These pics are from about 2004.











Thanks for taking & posting lots of pics of your work on the wagon. Will try and do the same as my own project proceeds.

Steve


Revolution909 wrote:
Thats a beautiful box-top. From the looks of your engine, it should run just as good as it looks.


Handy Andy that is a gorgeous 200, good work.
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