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Thread: Stix's Gen 3 Coupe Build - Striped Steel

  1. #81
    Senior Member q4stix's Avatar
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    Kicking off the weekend with a bit of tire, wheel, and widebody eye candy
    I'm still kind of blown away by the size and these are only 295/40R18.


    No spacers here! Just 2015 Mustang GT axles and future custom A-arms


    Gen 3 Type 65 Coupe builder

  2. #82
    TheBabyBadger's Avatar
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    GONNA BE A MONSTER!!! Love it! I'm running the same size wheels and tires... Now I'm SUPER excited for them to show up! Keep at it!
    Gen3 Coupe: BOSS 302/Coyote & T56 Build Thread - https://thefactoryfiveforum.com/show...733#post312733

    Arrival: 6/21/18 1st Go Kart: TBA Registered: TBA Painted: TBA Complete:TBA

  3. #83
    Senior Member SkiRideDrive's Avatar
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    This is amazing. I just found this thread and I feel like I am waiting for the next season to pop up on Netflix. Keep at it!
    ----------------------------------------------------------
    Youtube Channel: http://www.youtube.com/user/idothingsquickly/videos

  4. #84
    Senior Member q4stix's Avatar
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    Quote Originally Posted by SkiRideDrive View Post
    This is amazing. I just found this thread and I feel like I am waiting for the next season to pop up on Netflix. Keep at it!
    And like Netflix, I'll keep you waiting for months for the next update :P Just kidding, I hope to be able to spend more time getting things underway again in the near future.
    Gen 3 Type 65 Coupe builder

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  6. #85
    Senior Member q4stix's Avatar
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    Back with an update. Work and everything else have been busy so I'm happy to report there is still progress being made on the car. Right now it just happens to be off of the car.

    I'm getting close to wrapping up the transmission to transfer case adapter modifications needed. To sum it up, I'm using a different transfer case (Borg Warner 4412) than what the original adapter was designed for (BW4404) and in a different position which is further complicated by the fact that the 4412 has a different input shaft length and depth.

    First step was to jump in with both feet and cut the adapter in half. Second was to modify it, and third will be to get it back in one piece.

    I did some dumpster diving to get some scrap pieces of thick steel plate. The plates had 1/2" holes in it all over but I was able to work around that and create a fixture to hold the input and output flanges concentric to each other. Essentially making two tight tolerance round plates welded to a tube to hold the top and bottom relative to each other. You can see the two halfs and the tool fixture in this picture:


    On the back side of the output flange I used the lathe to cut a groove for the transfer case alignment ring but only 0.1" deep so not to weaken the flange too much. The groove isn't square and the bottom is more of a \__/ shape so stress concentrations shouldn't be too high (I hope). This way I can also use the BW4404 as a fall-back option since both can be held concentric to the transmission output shaft. You can also see the places I used a dry-erase marker as an indicator to wear off where the groove hit before seating the transfer case and needed machined more. Low cost tech for the win!


    Here's the fixture in the output flange for reference:


    Here's the input flange half added with the fixture aligning everything and at the right height. I also ground off the paint in a few areas for an electrical ground path while welding depending on where it's clamped:


    Finally a side view with the shortened parts. The butt joint on the center tube should minimize flange distortion and I can still skim the input flange face to make sure everything is parallel. I added a chamfer to each part on the suggestion of a coworker to help with welding penetration since this will be reacting the output torque:


    Next is to weld it up and then test fit the adapter. After that is to try to get the whole mockup (engine block to transfer case) in the car to check that fit!
    Last edited by q4stix; 12-18-2018 at 02:49 AM.
    Gen 3 Type 65 Coupe builder

  7. #86
    Senior Member cgundermann's Avatar
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    Really, really enjoy your posts and engineering details. Way, way cool!

    Chris
    MK4 Basic Kit #7404, 347 EFI - Pro M Racing ECM, 30# injectors, 70 mm throttle body, 80 mm MAF, Edelbrock Performer aluminum heads & RPM II intake, all new G-Force T5, 3:55 gears, Pro 5.0 shifter, 3-link, carbon fiber dash/custom Speedhut gauges and paint by Da Bat.

  8. #87
    Senior Member q4stix's Avatar
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    Quote Originally Posted by cgundermann View Post
    Really, really enjoy your posts and engineering details. Way, way cool!

    Chris
    Thanks! Glad to hear that because sometimes I feel like I go overboard describing things not related to a 'normal' build. Lots more to go to make this all work
    Gen 3 Type 65 Coupe builder

  9. #88
    Senior Member q4stix's Avatar
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    We're shortened, welded, and test fit!

    Seems like we got good penetration on the weld area and pretty good color distribution showing the heated regions. We skipped around similar to tightening lug nuts to minimize any distortion too.


    Here's it back together at the proper length and ready to test fit next. This should happen sometime over the Christmas to New Year's break and then I can figure out how much to raise the rear differential and see how to run the forward driveshaft


    I'm also still working on my mill cleaning and restoration. Amazing how much grease, oil, etc. keeps coming out of the castings but I'm getting close to wrapped up smelling Zep Purple in the garage and house for a while
    Gen 3 Type 65 Coupe builder

  10. #89
    East Coast Speed Machines Erik W. Treves's Avatar
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    Geez! That is a quite a piece there... I think you have quite a vision...a tip of the hat to you for setting off in a direction and making it work! I am excited to see the front D/S go in and the front end assy....this should be a pretty nice machine and a one of a kind when complete... keep at it please!!! 4WD Gen 3 coupe.... that's cool.
    FFR 1879, Blown DSS 306,REDLINE management, VeryCoolParts Tuned 460RWHP

    FFR 818S, The Flash, Chassis #5, 2.0L, LSD, Electromotive TEC-S, VCP Tuned, 278RWHP 265 RWTQ

    FFR 6651, Green Lantern, 408W Crate, Hellion 66mm Turbo, JGS Waste gate / Blowoff valve, Tec-GT management, VCP Tuned, 575 RWHP, 690 RWTQ

    FFR 8335, Black Mamba, 289 FIA CSX 2001 tribute car, 347, 48 IDA webers, VCP Tuned, 311 RWHP 386 RWTQ, 3-link, Trigo's

    FFR 0004, Gen 3 , Hawk Coupe, Coyote twin turbo, 683 RWHP 559 RWTQ, IRS, VCP Tuned. "not too shabby"

    US ARMY Maintenance Test Pilot (CW4 Retired)

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  12. #90
    Senior Member q4stix's Avatar
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    Quote Originally Posted by Erik W. Treves View Post
    Geez! That is a quite a piece there... I think you have quite a vision...a tip of the hat to you for setting off in a direction and making it work! I am excited to see the front D/S go in and the front end assy....this should be a pretty nice machine and a one of a kind when complete... keep at it please!!! 4WD Gen 3 coupe.... that's cool.
    Thanks! Means a lot coming from you after your great builds!

    Maybe I'll have this all figured out for when the Gen 3 based supercar is released and then I can twin turbo the setup in that car like you did
    Gen 3 Type 65 Coupe builder

  13. #91
    Senior Member q4stix's Avatar
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    Mockup Install Update!

    A friend of mine was able to come over and help me get the bare engine block, transmission, and adapter into the chassis so I could start getting a better idea of the actual space and the number of additional modifications required to make this crazy idea actually work.


    While this looks straightforward, the output shaft sticking out so far meant we had to pull things back forward to slide the transfer case on. You might be able to see that I cut to additional tubes on the tunnel near where the shifter location is because of interference (mid and rear shift are not options on the AWD transmission because of the rear adapter)


    Then, like all good things I try, there were more interferences. I handed my friend the recip saw and said go at it but he was a bit hesitant. After I showed him I already chopped that particular tube and it just had to be even shorter he had a go. This was the X member on the floor that also had the driver's seat belt tab on the tunnel side. That'll be sure to be added back.


    More cutting and grinding occurred on the transfer case and frame:


    Tada! I'm in a seat and in the car next to the giant drivetrain!


    One pic from the front:


    One from the side:


    It's not ideal yet, but I'll work on that some.
    Gen 3 Type 65 Coupe builder

  14. #92
    Senior Member q4stix's Avatar
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    Also, I got my first real TIG welding lesson. I've done stick, used a torch to weld, braze, and cut, and done MIG but not really TIG. I'm keeping it too cold and using too little filler, but apparently my general technique is pretty good for a self described beginner:

    This will all come in handy when I fix the frame, make new motor, transmission, and differential mounts, and then eventually the new suspension arms and exhaust headers.

    Fun times!
    Gen 3 Type 65 Coupe builder

  15. #93
    Senior Member cgundermann's Avatar
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    Freaking cool! Incredible work...

    Chris
    MK4 Basic Kit #7404, 347 EFI - Pro M Racing ECM, 30# injectors, 70 mm throttle body, 80 mm MAF, Edelbrock Performer aluminum heads & RPM II intake, all new G-Force T5, 3:55 gears, Pro 5.0 shifter, 3-link, carbon fiber dash/custom Speedhut gauges and paint by Da Bat.

  16. #94
    East Coast Speed Machines Erik W. Treves's Avatar
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    Well cool! Just some bracing to add back in there... looks like the shifter is a little father forward than stock but manageable for sure. More filler on the welds for sure.
    FFR 1879, Blown DSS 306,REDLINE management, VeryCoolParts Tuned 460RWHP

    FFR 818S, The Flash, Chassis #5, 2.0L, LSD, Electromotive TEC-S, VCP Tuned, 278RWHP 265 RWTQ

    FFR 6651, Green Lantern, 408W Crate, Hellion 66mm Turbo, JGS Waste gate / Blowoff valve, Tec-GT management, VCP Tuned, 575 RWHP, 690 RWTQ

    FFR 8335, Black Mamba, 289 FIA CSX 2001 tribute car, 347, 48 IDA webers, VCP Tuned, 311 RWHP 386 RWTQ, 3-link, Trigo's

    FFR 0004, Gen 3 , Hawk Coupe, Coyote twin turbo, 683 RWHP 559 RWTQ, IRS, VCP Tuned. "not too shabby"

    US ARMY Maintenance Test Pilot (CW4 Retired)

  17. #95
    Senior Member SkiRideDrive's Avatar
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    Itching for more updates!
    ----------------------------------------------------------
    Youtube Channel: http://www.youtube.com/user/idothingsquickly/videos

  18. #96
    Senior Member q4stix's Avatar
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    Hey SkiRideDrive! I've been spending a lot of time working and not at much time doing actual physical work on the car. I'm still trying to design things here and there and hope to be back to things soon. On the bright side, I've learned enough Mastercam and G code to run our CNC machine here at work (a 30x16" travel, 3 axis) to make a few things for work that are fully contoured, use 8 different mill bits, and 12-15 hours of machine time each (yes, it's not a high speed machine, but still works haha).

    I'd like to be putting in more hours before too long.

    I'm trying to search out a 3d scanner so I can better design and fit the front and rear suspensions, so if anyone has a 3d scanner they're willing to loan out, I'm all ears!
    Gen 3 Type 65 Coupe builder

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