WhitsEnd Transformation

[WhitsEnd]

Old vs. new. I went with the standard LX shocks and springs. I hope I don't regret it with the weight of the FE and a C6, but I absolutely don't want a stiff ride either.
This remains a truck for utility, so no canyon carving.

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The bearings in the hubs felt good, so they remain. Again, I hope I don't regret that after replacing everything else.

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BEFORE AFTER

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The motor is next on the list, so when this brand new water pump showed up for sale on the FE Forum, I snagged it. Someone bought it and never used it. Not cheap, but I planned on a new water pump anyway and this will take a few pounds off the nose.

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My plan was to keep the calipers and simply rebuild them. Afterall, a rebuild kit with all the seals and hardware is only about $20.

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What was I thinking?

Rebuilt calipers with new pistons, seals, hardware and powder coating..............$45!
Original FoMoCo castings too.

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The theme continues...I wanted to keep the steering rack, because it looked like it had already been replaced once. Well, that idea died a quick death as I was cleaning it and found the passenger side boot was full of steering fluid from a blown seal.

New rack was purchased with return shipping label for the core from the Rack Doctor. Their rebuilds are extensive and a good value too.

Here is the new rack installed and the old one almost ready to box up for core return.

[WhitsEnd]

I bought a 6" X 24" pice of 1/4" steel plate to fabricate the lower control arm mounts. Since I mounted the Crown Vic crossmember 5/8" below the frame, I have that much more of a gap between the frame and the control arm mounting pads. After thinking about the various options, I ended up with a plan and fired up the plasma cutter.



Damn, I love that plasma cutter.

I used the digital level app on my phone and dialed in the bushing to 35 degrees and tightened it down. With the plate in position, this is what my plan looks like in cardboard



I decided to tie it into the factory cab mount bracket and two of the plates actually wrap under the frame and will be welded across the bottom. The rear plate will be welded to the bottom of the frame and the cab mount bracket. Probably overkill, especially since it's 1/4" plate.

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So I got busy cutting the supports and started mocking up the driver's side.
That last shot was pretty dark, so this one gives a better view of how it will tie into the cab support bracket. The nuts will be welded to the plate as well.

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The red outline is roughly where the barrel of the bushing is located underneath. The dotted lines are where the hangers will be welded. The design intent is to centrally locate the load, have sufficient X, Y and Z force mitigation and oriented such that no water can get trapped

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Didn't finish welding up the mounts as planned (wife talked me into purchasing and setting up new outside Holiday decorations). We'll have to wait for that update.

On another note...one thing that I have been unlucky in locating is a new steering column that is required because of the transmission change to automatic. I finally found a guy on Craigslist parting out a truck and arranged to go get it this morning.
That's good news and bad news. Since I was having trouble locating a column, I had started planning to automate the shifting with a linear actuator and dash mounted buttons. With a little Arduino programming, this was about to be a cool project with total cost under $200. Since I located a steering column, the push-button shifting project will have to wait.

[Manny]

Man you been busy it looks great!! The front end looks fantastic with paint. As for the spring weights i think you will be okay. Fe's are heavy but a aluminum intake manifold shaves off a ton, and the aluminum water pump will help too. Add some headers instead of manifolds your back towards full cast iron small block.Keep it up she looks fantastic!

[hfdco4]

GREAT WORK SIR!

[cdnwillyg]

Nice work!

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I've been away for a couple weeks, so not a lot of progress. I got the lower control arm mounts welded in and I'm very pleased with the result.
I ended up abandoning the middle support I had mocked up because it was just redundant. With the front and rear bracket welded in, I tested the mount with a 3lb mini sledge and it was as if I hit the frame directly.

Previous mock up photos were of the driver's side, these complete photos are of the passenger side.

Here you can see how it is tied into the cab support bracket, as well as reaching under the frame and welded there as well.