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Project Coyote Notch interior swap IRS CA smog legal

Discussion in 'Fox Body Mustangs' started by RRRCobraSC281, Sep 23, 2014.

  1. RRRCobraSC281

    RRRCobraSC281 Member Established Member

    Messages:
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    Feb 2, 2011
    Location:
    Fremont, CA
    3 ½ years ago my back was messed up from an accident which made me think that my days of wrenching was over and it was time to hang it up. Well April this year I got my second wind when Casey sent me an e-mail saying that my name was going to be on a feature article in June issues MM&FF. I’ve had a few cars that have made it on MM&FF but this was the first time my name was actually given credit for the work that was done.

    Originally the plan was to do a ’93 Cobra clone with a Termi swap. How cool would that be to have done a Mach 1 rendition in a notchback and to do a ’93 Terminator? Been there, done that, should be a quick swap. Done in 3 months tops. Well looking for available 1993 Mustang GTs or LX proved to be very difficult, at least something worthy of a transplant. After being stranded by my wife in the middle of Stockton with $3500 cash in my pocket, I got to do some real soul searching. Craigslist had a couple 4 banger coupes for sale and thought I’d give it a try again and open up to do another notch. A couple days later I picked up my Notch, paid the back fee and started disassembling the car. I also started searching for a terminator.


    May 2014- Picked up my 1990 4 banger notch
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    June 2014- I thought with the introductory of the GT500 and the 420hp GTs that the price of the terminators would simmer down from what they were 4 years ago. Boy was I wrong. It really didn’t make any sense. 2 months had gone by and countless times being out bid at the last minute. I even sold my Birel Racing shifter kart to free up more money so I could bid with the big dogs. Then a talk with Lee (racerX), steered me in a direction that I was on the fence before about, but he convinced me that the money is in a coyote swap. I think he meant ”my money is going into” a coyote swap. Plus reading up on Jason Hall’s FoxGT500, I felt I have enough information to commit to a Jason Hall type Coyote swap, but mine will be CA smog legal.


    July 2014- My bid for a 2013 Mustang GT won and was delivered. The car initially ran like crap. The car was hit in the rear, so not sure why it was running as rough as it did. After a week of trouble shooting, I finally decided to get a hand held tuner mainly do read codes. While waiting on delivery of the tuner I thought I should start labeling all the wire harnesses. This is were I found a wire connector with no home. Oh looky here, there's a sensor missing. Went to the local Ford dealership and picked up a sensor. Installed it and the harness and vaaaaarrrrrroooommm! Took a trip around the sub-division. Everything checked out fine. Now I'm confident that everything truely is working fine and the engine and driveline works as it should. The next day my tuner came in. It still in the box it came in. Haven't opened it yet.


    August 2014- started removing the interior and engine/tranny/driveline. Wow didn't realize how huge the elecric assist steering rack was. My plan was to incorporate it into the Sn95 K-memeber.
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    September 2014- Trying to make this steering rack fit is much like trying fit a cube into a round hole. Lets just say I test fitted the k-member 4 times before it was perfect.
    This is a picture after my 2nd test fit.
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    In this picture you'll see that I've modified the oil pan for clearance and what you don't see is that I've also bent the oil pick up tube to allow for that clearance.
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    As of now I will put the actual dates of my progress.

    9/23/2014- Started clearing out the engine compartment so I have better access to the firewall and will allow me to see better what I'm up against as far as how much of the firewall need to be transplanted and where to make my cuts to keep things dimesionally correct.
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    Last edited: Sep 24, 2014
  2. Blkkbgt

    Blkkbgt Member Established Member

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    Very cool project. How are you going to make this thing smog legal?
     
  3. 97snakebite

    97snakebite Well-Known Member Established Member

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    Sacramento
    its not that hard.. the vehicle just has to comply with rules.. all emissions attached... probably has to use the tank also...emissions stickers ect.
     
  4. RRRCobraSC281

    RRRCobraSC281 Member Established Member

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    Feb 2, 2011
    Location:
    Fremont, CA
    CA Smog legal

    Got to have all the emissions stuff for year of the motor. Take it to BAR and they will look to make sure everything is connected and functional, then they'll print out a certificate and stick somewhere in the engine compartment stating the year make and model that the car smog has to comply with.

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  5. RRRCobraSC281

    RRRCobraSC281 Member Established Member

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    Feb 2, 2011
    Location:
    Fremont, CA
    My biggest problem is the clearance for the manifold to down pipe flanges. I might have to cut the flanges completely off and weld the down pipe and manifolds together. Long tube headers is the way most people do to solve this problem.
     
  6. SVTORANGE

    SVTORANGE Active Member Established Member

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    Maryland
    Very cool build
     
  7. AMAlexLazarus

    AMAlexLazarus AmericanMuscle.com Authorized Vendor

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    May 30, 2014
    Location:
    Malvern, PA
    Great read and a nice build! Best of luck!

    Alex
     
  8. RRRCobraSC281

    RRRCobraSC281 Member Established Member

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    Feb 2, 2011
    Location:
    Fremont, CA
    9/24/2014- Well today I've exposed more of the firewall, and started to cut some of the spot welds on the frame rails, but find myself having to be careful around the fuel and brake lines. Been hesitant to remove these, because it almost mean that the rear end will need to be dropped and space is at a premium. I guess I just gotta do, what I gotta do.
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  9. RRRCobraSC281

    RRRCobraSC281 Member Established Member

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    Staying focus.

    Seems like forever since I last worked on the project. For the past month and a half I've been doing some crazy hours at work. We're talking 11-14 hour day 6-7 days a week, plus trying to work on this project. Yes, I'm still married. Well last Monday it started to wear on me and by Wednesday I caught the flu bug that damn near put me out. Past few days I've been sleeping in. Man that felt good. Caught my second wind and worked on the project again.
    Started to cut out important paneling that I'm planning to transfer to the FOX, and removed the roof since it and the floor were the only straight pieces on the car. Then I get a call from a buddy and need the rockers to use as a jig to manufacture some side pipes. So then I decided to start chopping in manageable sizes and loaded it up in my mobile storage.

    I'm halfway done removing the passenger side frame rail. This is were I'm at for now. Once the frame rails are removed then it cutting the firewall and then the floors all to come out as one piece.
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  10. me32

    me32 BEASTLY SHELBY GT500 TVS Established Member

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    man awesome job so far. ill keep my eye out on this thread
     
  11. RRRCobraSC281

    RRRCobraSC281 Member Established Member

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    Thanks. I'll try to update once I get to a milestone. But honestly I do more staring and thinking than actually doing. My goal is to drive it to the next Knott's Ford Car show.
     
  12. Hotrodx13x

    Hotrodx13x New Member Established Member

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    Location:
    Denver Colorado
    Dig the build. I went with an 8.8 rear with 4-10s and a 6 speed T65 because the car is throwing down some power....this is my coyote notch


    92 notch back roush coyote mustang: http://youtu.be/axuSN0aQaDs
     
  13. P49Y-CY

    P49Y-CY selfie deaths ftw Established Member

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    south oc, cali
    very cool! you've got skills :beer:
     
  14. RRRCobraSC281

    RRRCobraSC281 Member Established Member

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    NOTE***This was the method used on one of the magazine article. I soon found out that it's not the best and fool proof way of doing this. The best way is the cut and peel back the section of the floor pan. Install the flanged nuts on the inside of the subframe and tighten the brackets in position. Then weld the nuts to the inner subrame and then close the floor pan and weld the floor pan shut.

    Some people like to do word puzzles. I'm just not one of them.

    Started mounting the IRS brackets. Made up some pieces to help with the install.
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    Last edited: Nov 20, 2014
  15. RRRCobraSC281

    RRRCobraSC281 Member Established Member

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    Started removing the floor in manageable pieces. It's a rough cut for now.
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  16. mavericks-03svt

    mavericks-03svt Active Member Established Member

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    subbed. this one is gonna be good. Looks like fine work from here. Keep it up, can't wait to see the final results!
     
  17. RRRCobraSC281

    RRRCobraSC281 Member Established Member

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    Location:
    Fremont, CA
    Well I got the IRS in as much as I could. Realized that I was missing the lower shock bolts and they are long. Found some bolts at the local Pick-n-Pull only to find out they are about 10mm too short.

    This weekend got the engine in the Fox Body for the first time. It sure looks like it belongs in there. Getting more and more of the garage back. Trimmed the S197 floor and it is also in sort of. I will have to cut the flange off the passenger side exhaust manifold and weld the catted down pipe. The flange is hitting the firewall. The driver side looks fine. Right now I've cut off a big chunk of the cowl panel. I know I will be needing some of that space. It's just easier to remove the big piece first and then once everything is in then see how much of it will be welded back in.

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  18. RRRCobraSC281

    RRRCobraSC281 Member Established Member

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    NOTE** Just in case people are using my build thread as a guide, don't cut the S197 firewall where the forward wheel wells are. It's easier to just cut the Fox wheel well to allow the S197 firewal fit more naturally and when pulling up the carpet the floor looks more natural than pieced together. I over thought this when looking at Jason Hall's build and wanted a more natural look from the wheel well side, but trying to fit the brake booster and the hydraulic clutch lines, patch work is unavoidable.

    more progress pics
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    Here's a sneak peek of the lower radiator support I fabricated.
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    Using Sn95 upper radiator mounts and the S197 lower radiator mounts.
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    Last edited: Nov 20, 2014
  19. Mnstr50

    Mnstr50 Member Established Member

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    Arizona
    this project is INSANE. Very cool!
     
  20. 2L8IWON

    2L8IWON "I'm on the Mutha Fugger" Established Member

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    This is an inspiration! Great work and best of luck to you bud!!!!
     

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