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Thread: Making progress on my build...

  1. #41
    Senior Member beeman's Avatar
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    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  2. #42
    LCD Gauges's Avatar
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    Are you going to have room for scissor hinges?
    Custom LCD Gauges , Data Loggers, Control Touch Screens
    www.LCDdash.com \\ 647-522-9953 \\ Voice & Text
    Proud new owner of GTM Gen 1., #105 - 08/27/11
    LQ9 Powered, G96.00 6 speed transaxle

  3. #43
    Senior Member beeman's Avatar
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    Yes, around 99% sure (edit- yes, definitely). I started mocking up a hinge this afternoon, I'll post a quick picture here to give you an idea. Basically had to figure out the axis of the hinge/pivot point. This was based on images from multiple cars with butterfly doors. I then took this as close to the inner fender, as far forward as the hinge would allow. I then created a hinge from 1.5" square from that pivot point to the front edge of the door. Now I just need to attach the pivot point shroud to the chassis below the a pillar. Looks like it should work. Grabbing Chinese food, enough for today.
    This pic was earlier in the process, didn't take any more. Initially I made a 90 degree dogleg in the plane of the pivot bolt, this wasn't right, so I removed some tack welds and fixed it. The hinge basically is angled in 2 planes.
    Last edited by beeman; 01-30-2017 at 12:25 PM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  4. #44
    LCD Gauges's Avatar
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    Right on. If you need any more photos or tips, let me know.

    You should be miles ahead with having the door flush with the hood/fender, as opposed to inset.
    Custom LCD Gauges , Data Loggers, Control Touch Screens
    www.LCDdash.com \\ 647-522-9953 \\ Voice & Text
    Proud new owner of GTM Gen 1., #105 - 08/27/11
    LQ9 Powered, G96.00 6 speed transaxle

  5. #45
    Senior Member beeman's Avatar
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    I've had much worse first attempts! I'd like to tweak the angle a little, slightly more horizontal arc of motion. This came out more like a vertical door than a butterfly door.





    Last edited by beeman; 01-30-2017 at 12:26 PM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  6. #46
    Senior Member beeman's Avatar
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    Version 2.0
    Complete redesign with Toyota door hinge.
    I think it's perfect.







    Yes it clears the fender nicely!



    Not too different from its inspiration...

    Last edited by beeman; 02-02-2017 at 08:41 AM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  7. #47
    Senior Member beeman's Avatar
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    So I've been thinking about the best way to hinge the doors with a rock-solid hinge system, and realized that I'd seen something similar to the Ford GT race car hinges somewhere before...Underneath my Honda Foreman!
    Is there much play in the bushings on these? Maybe too much play? Been thinking about this, maybe the sleeve bushings allow too much play, I'll check into that.

    Not these specifically, but something like it.



    Last edited by beeman; 01-30-2017 at 05:11 PM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  8. #48
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    I think you will find range of motion an issue on those...unless you don't tighten the through bolts down and let the inners rotate on the bolts.
    www.myraceshop.com

    GTM solution kits
    Corvette and Race parts

  9. #49
    Senior Member beeman's Avatar
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    OK, back to the electric power steering. Using an Equinox column. Lower shaft installation appears to be fairly straight forward. Looked at mating the C5 upper tilt column to the EPAS, not a great option. I'm not upset by that, because the C5 tilt system is insanely heavy and has that stupid column lock. Going to use the tilt column from the Equinox..how exotic! Then I ran into an issue finding a 6-bolt (Momo) hub adapter that works with the Equinox. Most GM steering hubs are 3/4" 36 spline. This one is 5/8" 36 spline. I could not find ANY hub adapter from Momo, NRG, etc. anywhere for a 5/8" 36 spline. That changed this morning. Found a place out of Arizona that makes all sorts of hub adapters, billet aluminum. Looks like a quality piece. They build a 5/8" 36 spline for AUSTIN HEALEY SPRITE MK1/2 1958-64 ; MG MIDGET MK1(SLIDING WINDOW CAR) 1961-64. Sweet! And about half the price of a Momo/NRG hub adapter, $48 with free priority shipping.
    Should have it in a few days. EPAS unit fits well in the footbox.
    http://www.flashpowerparts.com/en/au...let-black.html
    Last edited by beeman; 02-01-2017 at 09:33 AM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  10. #50
    Senior Member dallas_'s Avatar
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    Good progress, keep posting!
    FFR 7123 tilt front, Levy 5link/wilwoods/LCA's, webers.
    SL-C, LS3 525, Mendeola SDR5,

  11. #51
    Senior Member beeman's Avatar
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    Waiting for packages to arrive, got bored. Saw the Sawzall laying there.



    Anyone adamantly opposed to me incorporating this fascia? Speak now or forever hold your peace...

    Last edited by beeman; 02-03-2017 at 04:40 PM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  12. #52
    Senior Member beeman's Avatar
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    OK, figured I should have a real crash structure up front. Going with 1.5" DOM. Tube bender was feeling neglected. Funny, 'Dead Man's Curve" by Jan and Dean playing now on Pandora. When I was building my roadster, I enjoyed listening to the stuff Carroll listened to when he was out in his shop. That has carried over to my GTM build. Takes me back to a time when guys were building no-nonsense muscle cars, and the next champion could come out of anyone's garage.

    Getting started :




    Edit: notching is a necessary evil. Really messy with the cutting oil... In this pic, the wheel is in full lock to verify clearance.

    Last edited by beeman; 02-04-2017 at 07:52 AM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  13. #53
    Senior Member beeman's Avatar
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    Here's a basic photoshop of this fascia on a GTM without modifying any of the intakes...couple colors...



    Last edited by beeman; 02-04-2017 at 10:20 AM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  14. #54
    Senior Member dallas_'s Avatar
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    Interesting. Might help to see what you plan for headlights.
    What is that fascia from?
    FFR 7123 tilt front, Levy 5link/wilwoods/LCA's, webers.
    SL-C, LS3 525, Mendeola SDR5,

  15. #55
    Senior Member beeman's Avatar
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    The fascia is from an mr2 spyder, what do you think of it?
    I actually have 5 different OEM headlights in the shop that I have gathered over the past year, each has its pros/cons. I'm leaning towards an HID projector setup from a superbike

    Since you asked politely, Dallas, here is a sneak peek:

    Last edited by beeman; 02-04-2017 at 11:46 AM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  16. #56
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    Bee-

    I like the new fascia. I also like your colors; no chance of not seeing you coming! One thing that I think makes a big difference with how these cars look, is complementary, or even contrasting colors. Things like painting the screens or intakes black, or a contrasting stripe make a big difference.

    I like the headlights in the above pic. I also think the new trend of the line of LED lights looks awesome on the GTM.

    Mad skills by the way! This is a very cool build, and I respect the work you are doing!

    Regards,

    Steve

  17. #57
    Senior Member beeman's Avatar
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    Thanks Steve! Yeah I agree about the contrasting colors, the photoshops above are not predictive of my planned paint, just wanted to throw the fascia on the GTM shape.
    Slowly but surely, the complex intersections are a nightmare to get notched correctly...



    Update, got the upper crash structure tacked in collinear with GTM chassis to 1/16" and 0.1 degrees. Will fit the radiator before building lower structure. Upper edge of center of structure 19.25" off the ground.







    Last edited by beeman; 02-04-2017 at 06:16 PM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  18. #58
    Senior Member dallas_'s Avatar
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    I think whichever front clip you go with, you'll make it look great.
    There are things about both that I like, such as the vertical slits at the front wheels on the original clip.

    By the way, the roadster looks fantastic!
    FFR 7123 tilt front, Levy 5link/wilwoods/LCA's, webers.
    SL-C, LS3 525, Mendeola SDR5,

  19. #59
    Senior Member beeman's Avatar
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    Getting the radiator mocked up. I can angle it from vertical to horizontal... I'm thinking angle it as close as possible to the path of airflow exit? Still trying to decide whether to exit at hood or vented wheel wells. All airflow before and after the radiator with be completely sealed (I think this is critical for high speed aerodynamic efficiency, not to mention cooling efficiency). Any thoughts on which is better (hood vent vs send to wheel wells)?
    This is a Champion radiator for a Cherokee. My calculations suggest it will be more than adequate. I have plenty of room for a size upgrade if needed down the road.

    Last edited by beeman; 02-06-2017 at 02:05 PM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  20. #60
    LCD Gauges's Avatar
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    I think wheel wells might offer an easier escape as the cowl seal is imperitive for keeping rain water out of the front end.

    I'm thinking GTM however and your front end is no longer equal.
    Custom LCD Gauges , Data Loggers, Control Touch Screens
    www.LCDdash.com \\ 647-522-9953 \\ Voice & Text
    Proud new owner of GTM Gen 1., #105 - 08/27/11
    LQ9 Powered, G96.00 6 speed transaxle

  21. #61
    Senior Member beeman's Avatar
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    Do you mean keeping water out from the front fascia or from the wheel wells? Where does the GTM typically draw air for cabin HVAC? Typically OEM setups have vents at the base of the windshield to take advantage of the high pressure area there. I plan a smooth transition from hood to windshield. Climate control air will come in through one of the front fascia openings (probably) vs a hood NACA duct.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  22. #62
    Senior Member beeman's Avatar
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    Getting column mocked up for installation.
    Will retain tilt function... If there's enough room! I mean I might want it as high as it can be all the time.



    Last edited by beeman; 02-10-2017 at 12:34 PM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  23. #63
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    The two pieces of tubing you have going from the frame to your front facia look dangerous. They're aimed right at the two occupants and it seems to me, IMHO, that with an impact they might enter the cabin. There's no real crush zone with heavy tubing the way you have it. You might want to redesign or maybe use a thin wall tubing and drill some holes through them like the front end tubing on the 818. Just a heads up.

  24. #64
    Senior Member beeman's Avatar
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    Thanks for the feedback, always open to comments!
    I do plan on additional DOM tubing tied into the backbone, do you think that is enough?

    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  25. #65
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    double post

  26. #66
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    818 frame 2.jpgIt's that the two tubes are too stout for the job, and there's no real "crush zone". That design transfers too much energy straight into the frame. You need to use something strong enough to hold up the front end but weak enough to crumble in an impact. It would probably be easiest to use thin wall square stock to build the front sub-frame.IMG_3480.jpg
    Last edited by carbon fiber; 02-10-2017 at 06:40 PM.

  27. #67
    Senior Member beeman's Avatar
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    I understand what you are saying. I wasn't going to triangulate the front structure, so it would buckle in a collision. Maybe I should redo it.
    To me, the front tubing that FFR uses on the GTM seemed too wimpy to protect the cabin in a high speed collision. Does anyone agree, or is it more than adequate? I think it's 3/4"?
    I also felt like the supplied front structure would ramp a colliding vehicle up towards the cabin... So I tried to create a higher structure that was more robust. I live in the land of pickup trucks and whitetails!
    What does everyone think?
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  28. #68
    Senior Member beeman's Avatar
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    I just looked this situation over. The DOM tube we are referring to measures 25". If a collision drove that tubing in completely, it would end up at the level of the gauge cluster. More likely, an intrusion would occur to the level of the frame between the suspensions, an intrusion of 17". This would potentially drive the DOM tube to the mid-dash level. With the additional triangulation, I guess I would be surprised if the DOM was drive in like that rather than be end up deformed.
    It wouldn't be much work to redo it in small square stock, but I don't want to go wimpy...
    Thoughts?

    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  29. #69
    Senior Member beeman's Avatar
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    Big gains on the EPAS this morning. The donor lower shaft (when disassembled) is a steel rod, about 0.80". I called up a machine shop this morning (Saturday!), about an hour and $20 later, had this machined to 3/4" double-d.



    If you look at the FFR lower shaft, the splines are simply attached to a double-d stub by a couple set screws.



    Now I have a nice (collapsible for safety!) lower shaft. Donor splined coupler/male double-d >female double-d shaft >male double-d /FFR splines >rack.



    Really happy with this. Thought I was going to go nuts finding couplers, also thought I was going to lose collapsiblility.
    Last edited by beeman; 02-11-2017 at 12:01 PM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  30. #70
    Senior Member beeman's Avatar
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    Got a little sidetracked earlier, bought a cafe bike project. Don't plan to do much with it until the GTM is done!



    Going for something like this



    Got the EPAS about 80% installed, everything in, just have to finish welding. Removed the tilt function, going with a fixed mount.
    Last edited by beeman; 02-11-2017 at 11:06 PM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  31. #71
    Senior Member beeman's Avatar
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    Tacked in more frame. Had to wait until steering installed before this beam could be placed.

    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  32. #72
    Senior Member beeman's Avatar
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    The EPAS is mounted in 2 locations, at the motor housing and at the stationary housing over the upper steering shaft. Neither of these locations worked easily for my build. I fashioned a bracket from square stock to mount it at the motor housing location. The upper mount was not as easy for me to figure out. The chassis tube is not perpendicular to the steering shaft, off by 10-15 degrees. I also needed to make sure that the mounts would not trap the EPAS in the frame should it need to be serviced. I rummaged through the junk hardware and found a solution. Welded it up, works perfectly.





    Ordered 4 of these, they are 4.75" long weld-on barrel hinges. I'll cut them down in similar fashion to the Ford GT door hinges.

    Last edited by beeman; 02-14-2017 at 07:52 PM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  33. #73
    Senior Member beeman's Avatar
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    Per concerns discussed above, moved the front collision structure down to the mid aspect of the front chassis. Maintained same height at front bar ~19.25" (which I think is an excellent bumper height for a car this low!)



    Last edited by beeman; 02-15-2017 at 12:57 PM.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  34. #74
    LCD Gauges's Avatar
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    The amount of talent on this site is outstanding. This is by far the most radical build I've come across and likely ever will...unless someone decides to redesign the rollcage and body from ground up!
    Imagine a 'dream team' of FFR members building a car one day.

    Anything you can do for safety is a step in the right direction. I often wonder if I'd ever walk away from a head-on or side collision at regular speeds inside of this car. Staring at the lug nuts of a big rig
    passing by at eye-level is motivation for taking extra time to make it right!
    Custom LCD Gauges , Data Loggers, Control Touch Screens
    www.LCDdash.com \\ 647-522-9953 \\ Voice & Text
    Proud new owner of GTM Gen 1., #105 - 08/27/11
    LQ9 Powered, G96.00 6 speed transaxle

  35. #75
    Senior Member dallas_'s Avatar
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    Looking good beeman! Rock on bro.
    FFR 7123 tilt front, Levy 5link/wilwoods/LCA's, webers.
    SL-C, LS3 525, Mendeola SDR5,

  36. #76
    Senior Member beeman's Avatar
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    Wondering how my bumper height compares to what I may be running into out there...
    Bumper height laws are state specific. No minimum height, but lots of maximum allowed front bumper heights, ranging from 20-24 inches or so. Interesting.

    http://drivinglaws.aaa.com/tag/bumper-height/

    But it sounds like Federal laws mandate a minimal height of 16". This probably does not apply to a built vehicle.
    To meet federal rules, car bumpers must be 16 to 20 inches off the ground and limit the amount of damage that can be sustained in a low-speed crash. The idea is to ensure that the bumpers on colliding cars engage, absorbing most of the energy of the impact
    http://www.iihs.org/iihs/news/deskto...and-cars-alike
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  37. #77
    Senior Member dallas_'s Avatar
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    I've never heard of bumper height being an issue getting a custom car registered and titled.
    Not to say that some states might make that part of their process.
    FFR 7123 tilt front, Levy 5link/wilwoods/LCA's, webers.
    SL-C, LS3 525, Mendeola SDR5,

  38. #78
    Senior Member beeman's Avatar
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    Yeah I don't think that they would even check that at inspection, I was just wondering where my bumper would meet the average oncoming car.
    I measured where 19.25" met my F150, was surprised to see that it was right in the meat of the bumper, at the lower 1/3.
    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  39. #79
    Senior Member beeman's Avatar
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    Getting ready to create a hood. Then will merge the FFR and aftermarket front end.

    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

  40. #80
    Senior Member beeman's Avatar
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    MK3.1 2004 Mach 1 donor. ABS, PS, TC.
    GTM #304 LPE 525hp LS3
    2000 C5 Lingenfelter LS1@489hp
    1999 Corvette FRC/Z06 track car

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