Narly1's Speedstar build

[33fromSD]

So the completion kit came today. It's all been inventoried with only 1 POL item, that being the fuel tank vent gasket.

There does seem to be a mix up though in terms of what was sent for engine/transmission mounts & driveshaft vs what I need for my 302/AOD combination.

I'm sure we'll get that sorted out in short order.

Earl

Long time coming Earl, congrats!! I look forward to watching your build.

Jim

[TxMike64]

There does seem to be a mix up though in terms of what was sent for engine/transmission mounts & driveshaft vs what I need for my 302/AOD combination.

I'm having an issue getting my 302/AOD mounts, brackets, hardware as well. Also J-pipes... I've also been told that the shorty headers are on backorder.

[FF33rod]

For the 302 block, these are the BBK headers you want
https://www.summitracing.com/parts/bbk-15150

Steve

[TxMike64]

For the 302 block, these are the BBK headers you want
https://www.summitracing.com/parts/bbk-15150

Steve

Yeah, I've got those on my Summit Wishlist, but I paid for a complete install kit.....

[narly1]

Prepping suspension parts for powdercoating this morning. Polishing the sharp edges and weld spatter out of the unpainted pieces with the exception of the front lower arms which after disassembly are sitting in solvent to wash out the grease in them first.

I feel bad about undoing somebody's work, but it has to be done. All of the rear pieces came powdercoated black with their bushings, sleeves and zerk fittings installed. They will be getting the paint strip & polish treatment as well.

Earl

[narly1]

I separated the body from the frame and made this raised table on wheels for it to sit on. That way I can store it over top of the frame and wheel it out of the way when I need to work.

20230512_115735[1].jpg

[narly1]

I ordered my fame bare as I wanted something different than black.

So I've taken it upon myself to clean up any sharp edges and weld spatter as the first step before powdercoating.

One positive outcome of this is that I'm getting a good understanding of the frame layout and a real appreciation for the workmanship that goes into them.

Beautiful.

20230512_115431[1].jpg

Apologies for the surface rust, an unavoidable consequence of the long, wet drive home and monsoon season here in southern Ontario.

Note that I've been using what are known as "surface conditioning" discs for the clean-up. If you never used them, they're like scotchbrite pads on steroids.

Earl

[narly1]

I should also give you an update on my POL situation.

Parts have been dribbling in every so often over the past month. I have almost everything now except for the correct driveshaft and motor mount parts (got the wrong ones in error).

My takeaway from this is that FFR's new inventory management system is making a difference. These parts delays are nothing compared to what I went through when I was building my engine.

Earl

[TxMike64]

20230512_115735[1].jpg

I think that's the first time I've seen the Speedstar body in the raw. I didn't know the entire cowl was different! I though just the cowl where it meets the windshield frame. Which means the back edge of the hood and side covers is different too. this body will probably not look good without side covers.

Guess I need to go look at the Speedstar gallery again...

[narly1]

Sometimes not working on the car is working on the car if you know what I mean.

This past weekend's activity was a garage clean-out and yard sale. As a result I now have the extra space needed to move all of the parts boxes from inside the house into the 2nd garage bay, plus some stuff cramping my workspace in the 1st bay where the frame is.

My car wanted its garage back, LOL!

Earl

[narly1]

This past weekend's activity....

I'll openly admit that I should have had this done long before the kit ever showed up, but building the new garden shed (that was also part of the garage clear-out/clean-up task) consumed all of my free time last summer/fall.

At least I can say that I'm getting it done, there is light at the end of the tunnel.

Earl

[narly1]

Center section and C-hubs got a wash and coating of Nyalic.

My first time using this stuff and I really like the results.

Earl

20230623_131243[1].jpg

[TxMike64]

Center section and C-hubs got a wash and coating of Nyalic.

My first time using this stuff and I really like the results.

Earl
20230623_131243[1].jpg

Looks very similar to Sharkhide, similar price too. I heard about Sharkhide through a youtube channel I watch and was going to use it similar to you.

[narly1]

Looks very similar to Sharkhide, similar price too. I heard about Sharkhide through a youtube channel I watch and was going to use it similar to you.

Sharkhide seems to be a bit harder to come by up here in Canada. I found this stuff in a discussion somewhere about Sharkhide alternatives and it was given high praise so between that and the fact that a fairly local farm implement dealer carried it, I pulled the trigger.

It's a bit on the runny side, like thinned out polyurethane, so you have to watch for drips on the underside of parts. Nyalic also sells a cleaner for their coating, not sure how critical it is that you use it, but I did after giving everything a good wipe-down with lacquer thinners as a degreaser.

I really like the way it coats ferrous parts that would otherwise start rusting if not protected.

Earl

[Dgc333]

I think that's the first time I've seen the Speedstar body in the raw. I didn't know the entire cowl was different! I though just the cowl where it meets the windshield frame. Which means the back edge of the hood and side covers is different too. this body will probably not look good without side covers.

Guess I need to go look at the Speedstar gallery again...

Here is my Speedstar.

IMG_20230112_112410158.jpg

[narly1]

"Date with the Devil": prepping the frame for powdercoating

I say this because:

1. The devil is in the details.

2. Some of those welds (and there are a ton of them) are the devil to get at.

3. I somehow managed to mess up my back and it hurts like the devil.

Nonetheless I'm pressing on, I added a few vacation days onto the long holiday weekend and have made some great progress cleaning up weld spatter (surprisingly little), sharp/rough edges & welds, and the little laser cutter lead-in/lead out pips left behind on the plate steel parts.

I'm hoping to be at the point where I can flip the frame upside down on the weekend to catch the last little bit.....then it's off to the powder painter's shop.

Earl

[narly1]

Still working on the daily grind. This back pain thing is really slowing my progress. I'm at the point where I do what I can when I can. Getting close to being able to flip the frame over though.

In other news I managed to score a used air rivet gun in almost new condition for $40.

Earl

[progmgr1]

I can sympathize with your back pain issue. I had 3 surgeries during my (still ongoing) build and am now fully fused from L2 to S1. I hope yours doesn't come to that.

Keith HR #894

[narly1]

I can sympathize with your back pain issue. I had 3 surgeries during my (still ongoing) build and am now fully fused from L2 to S1. I hope yours doesn't come to that.

Keith HR #894

I've been doing physio and getting great immediate (after visit) and encouraging between visit results. Part of the issue I'm having goes back to when I broke my femur. Scar tissue. Everything relates to everything, the human body is a finely balanced machine.

Earl

[progmgr1]

Yup. Everything is connected and there are always unintended consequences. Now that my back is fully fused, I'm having trouble with my sacroiliac and hip joints. I just succeeded in moving the problem to another area. That's why I suggest continuing with PT and exercise as long as you can.

Keith HR #894

[33fromSD]

Yup, my back doctor tells me some time in the next 5-10 years I'm going to need surgery for L3-L4 pinched nerve issues (lose complete feeling in my right leg down to the knee which is kind of scary). We've figured out if I can get an epidural injection every 4-6 months in that L3-L4 area and then continue on with daily exercises me and my PT worked on I can prolong the "S" word for a few years, maybe longer. Been almost a year now (just got another injection the other day) but eventually they tell me injections/PT just won't do it any more.

Keith & Earl, I feel your pain (excuse the pun), we do what we can do, when we can do it, sometimes our bodies just don't cooperate anymore.

Jim

[narly1]

Disappointed and a bit embarrassed that I've made almost zero progress since my last update due to the back pain thing. Almost 2 whole months lost! No joke. The good news is that I'm starting to feel more like my old self again. The frame is flipped upside down at the moment so I can get at the last of the welds and clean them up. While it's in this attitude I'm going to drill the outer floor panels. I've decided to delay powder coating the frame until much later in the build process.

20230827_203835.jpg

Earl

[progmgr1]

I also went with the bare chassis, since I planned to do a lot of customization that would require welding and structural modifications. However, I recently recognized that I went too far down assembly road before tearing everything off for powder coat. Stuff gets much more complicated when you make it to be removeable and easily reassembled. Also, I found that it could be difficult to get all the rivet holes to line up if I had to mount panels several times, so I recommend that you not pre-drill the rivet holes.

I suggest that you make a detailed plan of the chassis mods you want to make and make those a priority - then get the chassis powder coated as soon as you can fit it in the budget. Life will be easier and you won't have as much to do twice.

Have fun with your build!

Keith HR #894

[narly1]

I also went with the bare chassis, since I planned to do a lot of customization that would require welding and structural modifications. However, I recently recognized that I went too far down assembly road before tearing everything off for powder coat. Stuff gets much more complicated when you make it to be removeable and easily reassembled. Also, I found that it could be difficult to get all the rivet holes to line up if I had to mount panels several times, so I recommend that you not pre-drill the rivet holes.

I suggest that you make a detailed plan of the chassis mods you want to make and make those a priority - then get the chassis powder coated as soon as you can fit it in the budget. Life will be easier and you won't have as much to do twice.

Have fun with your build!

Keith HR #894

Thanks for the great perspective. Not looking to do anything crazy, I just want to make sure that the sheet metal drilling, brake/fuel lines and a few other misc brackets are sorted out before painting.

Earl

[TxMike64]

Disappointed and a bit embarrassed that I've made almost zero progress since my last update due to the back pain thing. Almost 2 whole months lost! No joke. The good news is that I'm starting to feel more like my old self again. The frame is flipped upside down at the moment so I can get at the last of the welds and clean them up. While it's in this attitude I'm going to drill the outer floor panels. I've decided to delay powder coating the frame until much later in the build process.

Earl

I know how you feel - I'm just now getting back to work on mine after about 3 or 4 months... But I don't have any health excuses. It's been hotter than hell this year and I couldn't manage. Work and kids/family are my main excuse. But I'm happier to be back working on it.

Glad to hear you're back at it as well!

[narly1]

I haven't posted in awhile as there wasn't much to add. Ended up busy over the winter finishing up a rec room reno that I started back before I hurt myself. Glad that's done LOL. Then over the past few months I've been finishing up the frame prep for powdercoat.

I just got the frame back last week, here's the result. It looks blue-ish as it's partly in the shade:

20240716_153047[1].jpg

[progmgr1]

I'm hoping to soon be at the powder coating step. Did you also have the various suspension bits done? What about your aluminum sheet metal panels? I'm still weighing all the options while I finish up some other tasks...

Keith HR #894

[narly1]

Yes I had the suspension parts done as well. Pictures coming soon.

For the sheet aluminum I am taking a couple of different approaches. For the surfaces facing the road a coat or two of self etching aluminum primer followed by Rhino. Engine bay side of firewall will be powdercoated. Inner surfaces of exterior facing panels will get a coat or two of homemade Lizard Skin (the same aluminum primer with glass microspheres and calcium carbonate mixed in).

Earl

[narly1]

I built up the front lower arms last night. Still need to load the ball joints with new grease as I had to wash out what was in them before powder coating. Going to Lucas Red & Tacky. Just waiting on some colour matched touch up paint to arrive now. I need to fix up some missed places due to masking error.

20240723_073713[1].jpg

[progmgr1]

I couldn't get the link to work(?)
Keith HR #894

[narly1]

Try now.

[progmgr1]

yes, working now.

Are those parts silver / gray? What powder did you use?

Keith HR #894

[narly1]

The colour is Tiger Drylac Anodized Silver code 138/91021.

There is quite a variety of silver hues out there ranging from the whiter side to the blue/black.

This particular one is supposed to be one of their most common/popular and toughest formulations.

Earl

[narly1]

Built up these pieces last night.

The big snap rings for the upper ball joints tested the limits of my pliers but I got the job done.

I think I'm going to apply a coat of Nyalic to the exposed portions of the ball joints before installing them.

20240724_113601[1].jpg

Earl

[FF33rod]

For powder coating smaller parts, highly recommend the Eastwood kit...
This is a newer version of the one I got about 5 yrs ago. Super easy
(I might have done a larger part or two in the home oven when the Admiral wasn't home)
https://www.eastwood.com/eastwood-ho...-oven-kit.html

Prismatic Powders was an excellent source of a wide array of colours and coatings...
Steve

[narly1]

For powder coating smaller parts, highly recommend the Eastwood kit...
This is a newer version of the one I got about 5 yrs ago. Super easy
(I might have done a larger part or two in the home oven when the Admiral wasn't home)
https://www.eastwood.com/eastwood-ho...-oven-kit.html

Prismatic Powders was an excellent source of a wide array of colours and coatings...
Steve

We're going to need a bigger oven, LOL.

Earl

[narly1]

Not a lot of free time tonight as I had to pick up my one son after he dropped his car off for service.

I did manage to get the shocks built up though. The set screw threads in one of the collars were a little messed up so that took a little extra time time with a tap and oil.

Another thing I've taken to doing is to snip the corner(s) of the corresponding page(s) in the manual off once each task is completed.

Hopefully that way I won't overlook something.

20240724_221548[1].jpg

Earl

[narly1]

Over the past few days I've managed to clip the corners off of a few more pages in the assembly manual. Upper/lower arms and shocks installed.

Both loving and hating my powdercoater at the same time. That thick coat of beautiful silver he laid down made fitting these pieces a bigger job than I was anticipating. Pretty much had to spread everything a bit with threaded rod and nuts to get it altogether.

Earl

20240730_085317[1].jpg

[narly1]

So this is what I ended up doing to tighten down the lower ball joint nuts. There wasn't enough room to get my torque wrench in there.

You add some sort of extension that will fit onto the end of your torque wrench. Torque is nothing more than force times distance, so if you increase the distance the torque read at the wrench's indicator is less,. In this case the torque wrench was ~ 565 mm long and the combination wrench that I used as an extension was 295 mm long. So the indicated torque was 565/ (565 + 295) or 65% of the true torque,. The spec is 80-110 ft-lbs so I used 70 ft lbs so as to be somewhere in the middle.

20240730_220659[1].jpg

[narly1]

Who needs a gym membership when you have a hot rod LOL. Quite the workout this evening tightening down almost all of the front suspension components. Still have to double check the ball joint spindle nuts and put cotter pins through them before I'm finished. Don't want to look out the side window only to see a wheel passing me LOL.

Earl

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