Projects building a low budget bellybutton 40 ford coupe

Travis, Car is getting real close to being a driver. Maybe we will drop down to see how you are doing. How about the "Caveman '40" ? That one is so darn RAD !

My Modified is getting worked on. Please check my thread.

Dave

 

Thanks guys for all the interest!
Here's a quickee update...

It's really easy,
carry over from the VW days!
Ignition on,
light bulb from the negative to ground.
When placed at TDC or 10 BTDC or whatever,
rotate distributor til light barely goes on.
That's static timing!



I should have done this months ago,
but of course waited til the engine was actually running,
than I wouldn't get ahead of myself and put coolant in before it ran.
Probably the top reason for ruining a perfectly good engine!

Some copper ends were a bit too large.
I knew this but when I got them I was going to do a quick hose and clamp temporary deal.
too hokey!
The 1+5/8" brass freeze plugs fit almost perfect.

I did consider a soldered block off plate,
but if the radiator is ever changed,
at least it can be reused for a flathead.
Some hammering made the gap nice and tight.

The top soldered easily,
but the bottom was a pain in the butt.
A quick unpressured leak test looked dry.

I had already cut and pasted the hoses with the copper reducers,
so it was easy to just find some hose clamps and tighten everything up.
Filled with some drinking water and holey moley no leaks.
Started the engine up and let it idle for a couple minutes,
burning in all that fresh paint and oily hand marks.
So nice...
Still need to add the pressure regulator,
I've been switching the electric switch off and on every little bit to keep the float up.
This is a 90 so doesn't have the manual fuel pump,
otherwise I'd go that route.

Anyway it sounds like a smooth stock engine,
no frills,
but I'd rather pass gas stations than have to stop at every one!
TP

 

John Muir book all over again !

 

Awesome cant wait to see it rolling out of your shop under its own power! Let you get some miles on it before your not so little dudes are old enough to steal it from you!

 

The 40 is in good hands !

 

Awesome build dude! Don't know how I ever missed it.

 

Anything new with my favorite 40?? You're getting close , Man!!!

 

Great 40's I wish I had one.

 

Do you get the feeling that these guys like our support when they are in the build and kind words give them a boost. Then they get close to the end, self boost and leave us hanging while they are out cruzin'? If you need links to other build threads that die on the vine we got 'em.

 

Thanks Bugsy for calling me out!
I'm lagging not on the road yet...

Wish that was the case 6-ball!
I've got 2 of these 40 projects,
the rusty chopped one and this street rod one.
I've been bouncing back and forth,
but lately I've been spending more time on the rusty one,
as it is not costing me any money just time!

So what have I done lately...
Well I hopefully figured out the brakes.
For now the lines finally reach to the front discs,
going through the metering block or valve and a couple 2 lb residual valves.
The rear lines are on hold but are easy.
My excuse is I need to rebuild the rear brakes.

Other than that my starter took a crap.
Took it apart and it was full of oily grease and the brushes were totally worn down.
I'm going cheap and ordered a brush kit should be here in a couple days.

So yeah it's not that exciting but it's not totally on the shelf.
Like I said I've been really pushing on the rusty 40,
and more importantly putting food on the table!

I'll get a good picture post up soon for you guys,
and you know the posts and interest do motivate me that's for sure!

Thanks!

TP

 

Thanks for the update, Bro and glad that you're making some headway! Down to all of the little stuff now, which sometimes seems like the most time consuming and frustrating when you've come so far!! Keep it up and believe me, I totally understand being buried in multiple projects and mainly trying to keep the kiddos fed!! Hope you're having a good summer though and you all are getting in some fun times too!!

 

Thanks for the up date. This is a great thread and it motivates me. I fixed my starter today. I totally understand multiple projects and family obligations. It is fun to watch you solve problems. You have a unique set of skills.

 

Finally caught up the whole thread. My turn to say it Travis, you are an inspiration. Why build only one '40 Ford when you can build two at a time?

You just might be king of the low-budget home-builders, you're like watching an improvizational jazz artist at work . . . see, all that trippy music is paying off for you! A real pleasure to watch.

 

Okay guys here's a really intricate but boring update,
just so y'all know I've been chipping away at the past couple weeks.
Mr Hair this will cement my low-budget prowess!
My go to tunes for now are a couple '73 dead shows,
and then some 74-76 JGB/LOM stuff.
Not the trippiest but some great jams to help focus!

Hey Six you know I kinda stall out on the mechanical stuff sometimes.
It's not the difficulty level it's the time and money issue,
exactly like Bugsy stated.
When cutting metal I can see it and then get it done.
Mechanical stuff takes so much more time to do what seems like small projects,
then a setback to me will totally derail my momentum.
That is what happened this past couple weeks,
and I went to the rusty project just to get some immediate satisfaction!

Thanks guys for checking up it definitely stokes the fire!



So I had found this fuel pressure regulator.
It was huge and too much time was spent looking for a spot.
The fuel line was lined too precise to throw it in anywhere.
You wouldn't believe how much time was spent on the crawler.



One day I realized hey,
maybe one of those cheapy inline regulators would be better.
Dang those are over $30 now!
They used to be $15.
But I've got one on our RPU!
And lookie there the big holley regulator fits perfect...

The old setup was rushed for the GNRS deadline years ago,
and this was the perfect time to clean it up.
A bit unplanned but worth it in the long run.

The old inline regulator was hard-lined in the perfect spot.
Now it was time to test it out.

What the heck.
The battery was dead.
Chugga chugga click click.
chit.
This battery's been with the car for 7 years and I got it used.
What could I expect!

No problem there's another trusty test battery that's 8 years old!
Same thing.
Chugga chugga click click.
Dang.

Okay let's pull out 5 year old blue from the reserves.
to be on the safe side I charged this one overnight,
and rewired it as close to the solenoid as possible.
Chugga chugga click click.
Okay somethings not right.
What are the chances of all my 5-8 year old batteries failing?

TP

 

Time to troubleshoot.

The only thing left was the starter.
This worked fine in the Lincoln for years.

popping the top and lo and behold.

This thing did sound a bit wheezy!
How did it even turn?!

A new brush kit was sourced online at half price of the local shop. ($16 vs $35).
Way better to gamble $20 then buy a new one or spend time at the junkyard.
Hey this is a low budget build!
I've missed any important deadline so of course I went the cheapest route,
even though it took 4 days to get here.

There was a definite learning curve putting this all back together.
If you're interested in the hijinx read here...
http://perichbrothers.blogspot.com/2013/07/how-to-rebuild-ford-starter-in-week.html
There's definitely a trick to replacing that.

So did it work?
You bet.
Started up just like new.
And guess what,
all the batteries work fine!
I'm over the hump and ready to get back on it!

TP

 

Looking good! Thanks for the update....I know it takes time to stop and take progress pics but the masses dig it........

 

Oh yea, we dig it.

 

I realized the green 40 was really close to being a driver.
Not a pretty driver but at least a driver.
A STD(shit to do) list was made,
and it looks like if I thrash it could be driven to the Ventura Nationals.
If not then at least it will be closer.

This project was before the list was made!

The first carburetor had some issues.
A friend (dynodanny) donated a good running one,
and it was easier to modify the linkage for the TV cable,
then to troubleshoot the old one.
Another washer was welded to the end there.

I liked the linkages better anyway,
as they were cleaner and closer to the center.
The pic is a comparison to the old carburetor,
it stuck out 5/8" or so.

Unfortunately it meant modifying the TV cable holder.

After a month of thinking it only took 2 evening to finish.
Now the TV cable isn't so close to the valve cover,
and more importantly the engine will run with the fuel pump on!

Next up was switching around the two 40's.
It was time to put the rusty 40 in hibernation.

The kids helped swap them around,
no easy feat with an uphill alley!
Cool to see the differences in the chopped and unchopped bodies.
Now that the green one is outside,
I can clean up the front sheetmetal,
and put the bumper back on.
The garage door wouldn't close!

You would think it's nicer to work inside,
but there was a space issue with this next project.
It's also nice to idle the engine out in the open,
not in a stuffy garage!

This was a junk craigslist special 8" rearend,
and the pumpkin was a little sticky.

Finally I had enough space to remove the axles.
The housing was cleaned inside and the seals replaced.
I'll need to replace one axle bearing pretty soon.
The brakes need going through anyway so it'll be added to the list.

The old center section was in good shape,
I think the yoke was jammed on without a washer or something,
as there was a little rub.
Whatever the case it was easier to swap out to another one I had found.
This had the same 2.80 gears.
Hey remember this is gonna be a freeway flyer!
I'm hoping there's enough slush with the AOD transmission.
The Lincoln donor had I think 2.7x gears in it,
and hopefully it drives similar.
If anyone has a 3.2X posi center section send it my way!

The next hurdle was the firewall.
This was needed mainly as an attachment point for the accelerator pedal,
so it was time to get it done.

After all my thinking of some trick removeable sheetmetal piece,
I ended up welding in the original pieces.
Now the engine and tranny will have to be separated upon removal,
but what the heck it looks cleaner,
and most importantly it only took a couple hours (so far)
So if anyone is wondering this is all you need to notch out for a SBF.

If I had known this was all that was going to be done,
it could have been finished months ago,
instead of a late night alley thrash with a single 34 watt bulb!
Nice to not see that gaping hole behind the engine anymore.
TP

 

Your work amazes me.. After reading your posts on both cars, I should close the garage door, take up stamp collecting, and spend all my spare time and money in strip bars.
Very cool stuff. Thanks for posting..

 

Weird reading updates with out kayak trips in between posts haha. Lookin good man! Still looking for an old stool like yours for my own stool time posts haha.

Keep it up


Posted using My Dick Tracey watch and the full custom HAMB app

 

Like Gus said in Lonesome Dove, "I'm having a hard time remembering which is which."

Oh yea, this is the nice one! (Love 'em both)

 

Hey Williebill - this next update may change your mind!

Here's a quick update.
Progress has been slow but steady.

OK Tim you may have seen this but here's some stool time for ya!


Next up was modifying the gas pedal.
After thinking how to disassemble the whole thing,
I found it easier to just cut the pull rod,
extend it,
and reweld it on the other side.


This was affectionally dubbed the "gyna-spoon" years ago!



A linkage was scrounged up,
and extended to reach the pedal end.



The first time sitting in the drivers seat,
pushing the start button and controlling the gas is always surreal.



The firewall is ugly.
The neighbors just had a kid,
and I'm trying to be as considerate as possible,
which means restricted grinding time.
The engine side is just plain tough to reach with a grinder.
I'm hoping it will stay rough as I don't want to pull the engine!

Now back to the STD (shit to do) list.
The next easiest thing was modifying the brake push rod.


The rebuilt master came with a mustang pushrod,
and the original 40 push rod was too short.


Yes it passed my hammer test!
Fortunately my rough measurements fit.


TP

 

Coolest, original idea I've seen in a while. It's so cool that I'm going to have to steal it.

 

No problem Mr King!
While you're making it,
you're going to wonder wow this is tedious!

+++++++++++



Ok now it was time to cut some corners.
Remember this is low budget and I'm feeling the pinch with 2 projects!
The biggest cash outlay I can jump over is the exhaust.

The magic behind the Lincoln setup is this flared flange.
There is no gasket needed and virtually leak proof.
The main reason I chose to use the cheesy lincoln headers.

The original flathead exhaust used 1-3/4" tubing,
and it slid perfectly into the 2" lincoln remnant.
I studied over and over and found most Mustang guys like 2.25-2.5" tubing,
but I had to at least test out the junk I've got.


The forward pieces were cut and pasted,
and then hose clamped to the muffler extension.
A quick idle and man this wasn't nearly as bad as I thought.
I wasn't looking forward to a low rumbly pipe,
we've had it on our old '64 nova and its just too much for a daily driver.
This thing sounded just like a normal car!

Now it was time for some creative welding.
One of the more annoying things is unfinished top welds,
they make those little whistles.
The fix was using a mirror,
actually a stainless IPOD holder.
One of the toughest things I've done even if the welds were only 3/4" long.
The welding is reversed,
and in addition I'm working in the side yard with the wheels set up on our brick lift!

You gotta know those mufflers were patched up too!

Anyway yeah it's a hack job,
but the exhaust is complete and leak free,
and sounds just like our neighbors buick!



With the money saved the driveshaft was dropped off the local shop,
and hopefully will done in a couple days.

TP

 

The memory of having a newborn (my youngest is 18 months) is fresh enough in my mind to say thank you for the consideration on behalf of your neighbors. I wish the bottle-rocket enthusiasts who lived next to me back then had been similarly inclined.

Also, thanks for the update. I love reading about this car and seeing the work you do.

 

Hey Big we've had a couple kids too,
so I totally understand how it is.
Funny thing though,
I had the hot rod parked maybe 6 feet over his imaginary property line on the street,
and the guy actually came over and complained,
saying he had to parallel park in the spot in front of his house.
Even though it is a public street not a gated community!
Now I've realized maybe I was a little too considerate,
so I'm not as quiet anymore!

TP

 

Some people's kids.

 

Exhaust looks good.

Mirror welding is tough, I knew one ex-navy guy who was great at it, for the rest of us its a bear.

 

Great job.

 

I get it. Cool. You're blowing my mind here, Travis (the two-at-once thing).