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'80 SA 5.0 Build

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Old 12-02-18, 09:28 PM
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Another productive weekend. My parts I ordered last weekend came in and I was able to make use out of them.

The EGR delete was an easy install. A simple plate and electronic delete. If I wasn't so anxious to get this thing running I would have built my own and wired in some resistors. But this was a simple fix and allowed me to work on other stuff. The plug is where the $$$ is at because it keeps the CEL off.






The focus was mostly on the exhaust, however. I used these Walker ball flanges, O2 sensor bungs, clamps and some 2.5" pipe to mate to some flex pipe.




I slipped the 2.5" pipe into the Walker flange and drilled a hole for the O2 sensor. The O2 sensor bungs are from Summit. They are nice quality but are flat on the bottom. So it didn't exaltedly sit nice on the pipe. So I took a curved file and filed in an arch to minimize the gap and get it to hold tight.






I then used my novice welding skill to weld the flange, pipe and bung together. I can't say it looks great, but it will works.










After it was welded together, I bolted it on to the headers. The fit is way better than the X-pipe I was thinking of using. And after this task, it reinforces the fact that building my own exhaust with pieced together mandrel bent pipe would have taken me a long time and probably would have been over my head. So I am glad that I am going this route.








The plan was to jack the mufflers off the donor Mustang rotting in my back yard. But when I went out there to take them off a suddenly remembered that I threw them away some time ago. Oops. These would have been a no-cost option to get me by, so I guess I'll have to buy some cheap mufflers for my hacked exhaust.

So things are coming along, and my Christmas wish may come true after all. I have set a target date of 12/19 to start it for the first time. Between now and then I need to:
- Finish installing hanging mufflers.
- Modify and install the O2 sensor harness.
- Added oil, coolant and fuel.
- Check for leaks
- Plug in the gauge/switch cluster a made a while back
- Figure out a couple of fuses rating for circuits that Ford originally had fusible links on (I can't find any sort of Ford cross reference on the internet).
- Do a key on test.

So its totally doable.
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Old 12-05-18, 10:51 PM
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A little teaser - I did a little shopping today.

I'm thinking the car will actually start this weekend.


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Old 12-06-18, 11:21 AM
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anxiously waiting. just remeber on a fresh build you want to take it to redline, say 7,200 RPMS for the 1st five minutes

then put oil in it
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Old 12-06-18, 11:07 PM
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Originally Posted by ATC529R View Post
anxiously waiting. just remeber on a fresh build you want to take it to redline, say 7,200 RPMS for the 1st five minutes

then put oil in it

Ha Ha. Good advice. Should be an epic first start following that advice.
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Old 12-07-18, 05:52 AM
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I had those same mufflers!! and I used those hangers. Hangers were good mufflers not so much. I prefer a chambered or larger magnaflow style
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Old 12-09-18, 11:13 PM
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Well gentleman - she runs!!!

But I had to work my *** off to make it happen this weekend. Saturday was spent finishing up the exhaust. There really isn't much room under these cars to do this, and I struggled with finding spots to bolt the hangers onto. I didn't want to drill holes in the floors for temporary exhaust. The rights side I just about said f#%@ it - and hung the rear of the muffler with a bailing wire - lol.

Today things started off really well checking off miscellaneous loose ends. I took my time doing the electrical checks to make sure it was all good. When I went to build fuel pressure I had a fat leak coming from one of the hard lines. The leak was caused by a poor double flare I made a year ago. So I had to cut some tube off, re-flare it, and remake a steel braided hose.

When I went to start it, it did not want to fire. I finally was alerted to the problem after a few tries when I got huge backfire from the exhaust - timing. I discovered the I stabbed the distributor 180 out.

After fixing that - she fired right up and sounded great.

There are some other things I need to go back and take car of. I'll share those at another time because I am beat.

Thanks for all the support folks. Next hurdle - getting driving.
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