Cam covers, AFCO, KB 2.2, 03 Cobra Installation Pictures - Some assembly req.!

[sonicmach1]

It is getting old! 25K on the odometer now.

 

[sonicmach1]

Major work ahead...

I have gotten the bug again and have been enjoying teaching my son mechanical skills. First up new tires.

I had to get all 4 new tires at the same time this year. The 275 fronts are Toyos new R888R design. Toyo does not make the rear 315 size in the new design yet.

 

[sonicmach1]

Next up... Complete IRS make over!

Parts are on the way so I will be starting the work in a few weeks.

• Full Tilt Boogie Racing (FTBR) Delrin bushing kit, rear deluxe toe links, IRS sway bar end links, and the Ford Racing differential cover.

Which led to:

• New zinc coated hubs, ARP studs, new wheel bearings

Which led to:

• Since the diff is out... new traction lok, high torque pinion bearing, new halfshaft bearings, new (fresh) gears, pinion flange, etc.

Which led to:

• FTBR 13" IRS Rear Brake Conversion Kit

Which led to:

• Powder coating the IRS cradle and the A arms

Which led to:

• Maximum Motorsports full length subframe connectors

 

[TooFast98Cobra]

Nice build!

 

[SJ SNAKE]

Major work ahead...

I have gotten the bug again and have been enjoying teaching my son mechanical skills. First up new tires.

I had to get all 4 new tires at the same time this year. The 275 fronts are Toyos new R888R design. Toyo does not make the rear 315 size in the new design yet.

I remember following your thread years ago when you performed the 2.2 KB install along with the supporting mods and it certainly showed your high level of dedication for perfection! Glad to see you're still wrenching on the Redfire Beast!

As for the tires, did Toyo discontinue the original R888 tread pattern version or are they on the verge to do so?

 

[sonicmach1]

Ha - thanks SJ SNAKE. I said I was done and should just drive it. And yet here I am!

FTBR parts arrived today.

 

[sonicmach1]

More updates and more parts added.

Got the order of OEM Ford parts in from AutoNation Ford.

Just need the stuff on the floor blinked into the Cobra

Unbolting and removing and more unbolting

 

[sonicmach1]

About ready to drop the IRS cradle

And it's out

Not bad looking underneath the body for a 14 year old car!

Trans jacks are great, but they still keep it 4' off the ground. Ha.

 

[sonicmach1]

With the IRS out, it was scrubbed clean with degreaser, soap, and some brake cleaner.

Pressed out the wheel hubs and bearings

Fair bit of wear (forces) from the taper bearing rollers on a 25K mile car. The hub spline O.D. wear make them unusable. I am glad I bought new zinc coated hubs from Full Tilt Boogie Racing. Bruce at FTBR has been a great help in evaluating the part wear as I take them off.

 

[sonicmach1]

Even with all the care the car gets and no track time, both rear wheel bearings had ejected grease on both sides of the bearing seals. Again this is surprising given the duty cycle of the car. However if you run it hot (Dynojet?, drag race repeatedly, road race) the grease expands and gets ejected. Since there is no way to see this while the car is running assembled, I will have to add this to my yearly inspection list to find a way to check for grease signs.

I also started to sand the surface rust off of the halfshafts to prep for painting.

Alot more to come!

 

[sonicmach1]

Sanded the halfshafts some more. I still plan on primer and painting them though.

Using the FTBR bushing removal tools made easy work of the control arm and spindle bushings. Next up is removing the IRS subframe bushings then touch up sanding and welding areas as needed before powdercoating.

 

[Redfire03]

Been following your thread since it started! I will be doing the same project this summer as well on my Redfin's. Was even planning on doing the same things (cleaning, painting, etc.). Keep up the good work!

 

[Stevenbekah]

Great thread! I've got to say though, am I the only one about to inspect their bearings tomorrow? I had no idea they'd need attention like yours did/does after only 25k miles.

 

[sonicmach1]

Been following your thread since it started! I will be doing the same project this summer as well on my Redfin's. Was even planning on doing the same things (cleaning, painting, etc.). Keep up the good work!

We hopefully some of my tips from doing this will help you out.

 

[sonicmach1]

Great thread! I've got to say though, am I the only one about to inspect their bearings tomorrow? I had no idea they'd need attention like yours did/does after only 25k miles.

I was rather surprised too so I am anxious to see how the new setup feels altogether.

I bought two new Timken hub/bearing/ABS ring units for the front spindles too expecting to have to replace them earlier than expected as well.

 

[sonicmach1]

A-arms prepped for powdercoating - after I sand off some of the mold lines.

I am really eyeing this IRS cradle. I think its MIG time (!) to close up some seams, add some blocking in a few areas.

 

[sonicmach1]

It has been a couple weeks, but I got the IRS prep work done and have dropped off all the suspension parts to the powder coater yesterday.

I ended up sanding the IRS cradle to remove weld spatter. I also sanded all the suspension arms and spindles to remove their casting lines.

I added some seam welds to the IRS cradle and added some caps to the top of each main support to give it some more strength in those areas, but also to cap them for any water intrusion.

 

[sonicmach1]

Not ideal sitting on the floor welding.

Now onto the diff work!

Maybe someday I will actually drive it!

 

[Sonic605hp]

Amazing.

 

[sonicmach1]

Got the halfshafts painting started. I used the POR-15 process - degreaser, metal prep etcher with zinc, and the POR-15 base coat paint. Once it dries, I will cover it with topcoat.