ADI`s Build Thread - Almost done!

[ADI]

Those look like 94-95 SN95 spindles. Do you have the pin drive front suspension? Wondering as that's what I have ordered.

Yes, SN95 94-04 Spindles...

[ADI]

Done some minor work this weekend, but a nice milestone was achieved! Fuel system is done and ready to go!



Tires came in, still waiting on the wheels.

[ADI]

More work done this past weekend.

Installed the billed fluid reservoir for brakes and clutch:



Decided to run the hoses inside the dash


Ended up nicely and clean.

[ADI]

Next step was prepping the dashboard for cable management. Had to glue the ziptie holders, added a bunch of those (more than needed)


Used a 2 component JB Weld Epoxy glue and ended up a solid bond.

[ADI]

After building a prototype for the dash extension, I ended up modifying a bit my initial design and ended up with some angles instead a square box.

This was the prototype:


Then with the angles:


I added some slots so I can slide up and down and adjust better when the center console padding is installed.

Next was a bold move. I purchased a adhesive backing real carbon fiber veneer:
https://dragonplate.com/Twill-Weave-...Veneer-12-x-24
to match the dash and when it arrived I feared that the sheet would not bend around the corners. After some back and forth it ended up quite nice.


Note that I have some clamps on the 120+ degrees angles on the back, since that side will be clamped against the back wall, should hold nicely.
Final result:

[ADI]

And it is looking like a car!!!!

[ADI]

Now starts the fun part...

Wires, wires and more wires.... Since I`m stubborn and want things made my way, I`ll do the entire harness and electrical system from the scratch.
Installing the FuelTech control forces me to rewire the entire engine.

I`ll keep posting the progress.

[ADI]

And the work continues...
The Coyote Gen 3 has more wires than a house! There are sensors everywhere! (LOL) Manage to find all the essential ones for step 1 of the harness:

Sorting:

Next step was starting to add the connectors, in case I need to remove the engine:

And making the 2, 8 pin connectors (8 Fuel injectors and 8 coils) idiot proof so no one can plug it inverted

Organizing some cables...

[Ted G]

looking good!

[ADI]

And the wiring saga continues...
Below you see the detail for the seat heater wiring:


The rear harness is done:


But still a LOT to do.

[ADI]

I`ve been quiet for a while, running several projects aside of my day work, but wanted to share a bit where I stand.

Quick update:

Front brakes arrived finally and are installed
Installed clutch lines for the Ford MT82 trans
Engine is back and installed (hopefully for the last time)
Removed all direct injection hardware and wiring
Engine wiring is finalized and now it`s time to debug all sensors
E-brake is installed and working
Manual rear balancing brake is installed and working


Very close to start the engine at this point.

Next steps:

Custom driveshaft
Seat cushions and upholstery
Cabin heatshield


Some pics.. kinda out of order, just to update the thread and I promise to keep it update.

Engine stripped out of Direct injection


Weight loss!


Billet cap for the high pressure fuel pump


Best purchase for Coyote owners!


Works like a glove!


Hydraulics to the tranny

[ADI]

Rear Brake balancing

Instead balancing the rear brake at the pedal box, I decided to install a proportional valve from Willwood by the driver seat.

Started locating the position right at the driver seat (but not in the way)


Made a simple bracket to hold the valve:


And fabricated a washer to seal the hole - Done!

[ADI]

Now to the engine..

Final 02 sensors modules installed. decided to place them in the glove box, since there is not much usage once it is up and running.



You can see that the USB cable will also be hosted there, for easy access to plug into a LapTop

New injectors arrived and installed:

[ADI]

Been a very long time since I last posted anything here.

But all this time I was dealing with the Coyote Gen 3 particularities trying to deal with the sensors and stuff. Pioneering the FT550 (Fueltech) to run the Gen3 was not easy. Good thing is that it is FINALY alive !!!!

In order to get this I had to make some sensor and part changes.

for the ones trying to do it here are some of the details:

Crankshaft Sensor.
Coyote Gen 3 uses a Hall sensor but with some electronics that only Ford knows how to decipher it and no way I could get it to read. My option was to use the Gen2 sensor that is inductive. (The clack sensor is from the GEN3)



These sensor are the same size BUT the Gen2 is thinner on the tip and you will need a bushing to keep it from wobbling.

When I installed it I ran with the original GEN3 trigger wheel which is 60-2 and would loose sync when the engine started, probably because the Induction sensor would not count properly the small teeth.
This made me have to take out the transmission (such an easy job...LOL), clutch a.o. to install the trigger wheel from the Gen2, this one is 36-1 and the sensor reads it perfectly.

You can see the differences here:


AS FYI This is how it looks like when Cyl#1 is at TDC:



The thick sharpie mark is the missing tooth.

After that I had to change the TPS as well. It is also an electronic design that could not be read used the F150 one that has 6 wires instead of 5 (double reading) and is P&P.

Couple of changes in the programming and it fire right up!!!

[F500guy]

I have a question, I was not following this forum last year but I just saw the Carbon fiber veneer you used. Impressive! I was looking for something to do with the transmission cover to incorporate carbon fiber without having to make one. Do you think that would work and be durable for that purpose?

Question for others-has any one used this on any panels in their build, thinking engine bay, trunk? asking for a friend...

[Glen Davis]

Glad you were able to make Fueltech work!

[ADI]

I have a question, I was not following this forum last year but I just saw the Carbon fiber veneer you used. Impressive! I was looking for something to do with the transmission cover to incorporate carbon fiber without having to make one. Do you think that would work and be durable for that purpose?

Question for others-has any one used this on any panels in their build, thinking engine bay, trunk? asking for a friend...

If you look back some posts, you will see that the under dash module I build I used aluminum plus a Carbon fiber self adhesive. (not vinyl veneer) it worked well but because I do not have any sharp bends. I`m pretty sure you will not be able to bend it hard. That thing is tough!

But I guess It would work well on the flat panels.

[ADI]

Got some (good) news.

FINALLY got the Coyote to work properly. was a ride but we have figured it out...

Took it last week down to GA into FuelTech dyno and Cameron (tuning wizard) tuned it up in 3 maps (Racing, Street and Rookie)

Ended up @ 466.5HP at the wheel. not bad...

[ADI]

AND.. why not a much waited neighborhood GoKart ride!

[Railroad]

RPM seems high? My Aluminator red lines at 8K. I would think a crate Gen 3 would be closer to 7K.
Really high HP numbers at the wheels.
Nicely Done!
Can you post the dyno sheet?

[ADI]

RPM seems high? My Aluminator red lines at 8K. I would think a crate Gen 3 would be closer to 7K.
Really high HP numbers at the wheels.
Nicely Done!
Can you post the dyno sheet?

That RPM is from the Dyno, I believe he was in 4th gear, should be around 6700 rpm. I forgot the dyno sheet, but asked the guys to send me and I`ll post soon

[Railroad]

You definitely handled tuning the Coyote, outside the box. Great job.

[Jonathan D]

Just stumbled into your build thread for the first time and I'm really enjoying the build...well done!

[ADI]

I`m back!!! Finally found some time to restart my build! Will be posting some news soon!

[ADI]

As promised, some quick updates

Carpet is in the cockpit and dash is installed for the (hopefully) last time!

Feels like a car now!



Still some cosmetics to finish, but happy to get to this stage!

[ADI]

Interior is COMPLETE!!!! (Finally!)

[ADI]

Body is on, it was easier than I anticipated! Now it is up to align doors and hood/trunk, install headlights and mirrors and get it licensed!






My goal is to drive around on the gel for a couple of weeks to fix any issues before start preparing the body for paint

[Blitzboy54]

This is honestly one of the best interiors I have seen. Just really great work.

Question, how did you setup your turn signal switch and where did you source your wheels?

[ADI]

This is honestly one of the best interiors I have seen. Just really great work.

Question, how did you setup your turn signal switch and where did you source your wheels?

Thanks for the compliment!!!
Many are asking me about the turn signal.
I used a VW turn signal witch kind looks more modern to match the interior. And I designed a 3D print housing for it. And yes, it does include the automatic cancelling with a sleeve that is attached to the shaft.
I`m actually redesigning the housing to better match the dash angle now. but it works pretty well and the ergonomics is also ok.



The wheels are from Konig Racing (Dekagram model), bought it through Summit Racing - KNG-DK08514185 and KNG-DK98514355 are the part numbers.

[ADI]

Good news!

I decided to drive it around on Gelcoat only until the winter comes, so the build is in its final stages! Can`t wait to put it on the road!