Factory Five Build

[PSYCHO]

Well been crazy busy with family visits and such but finally got back into today by dropping the body on to see where the motor was going to sit. Unfortunately it was sitting too high because the intake was pushing the bonnet up by an inch or so out with plasma cutter and mig and managed to drop it by the required amount and still left about 4mm clearance on the harmonic balance thus far. And now that's where the real fun began starting with the gearbox, I mounted the box outside the car and then proceeded to drop it in as one unit (But) the box is so damn long I couldn't get it up on the rear crossmember and clear the tunnel/firewall and to top it off the OHC's were hitting on the front body support rail.
So messed about for several hours trying alternative solutions but came up short or should I dare say long Lol. So separated the gearbox and shoved that up into position strapped it up dropped the motor back on the floor shut the shed door went and sat down and just cracked a can because tomorrow is another day.

[PSYCHO]

So today after having a good look at the front crossmember i could see that once the gearbox is hooked up i reckon the harmonic pulley would be too close for comfort so i thought it would be a good time to notch it out some.

[Jethrow]

Hi Psycho,

just to throw it out there, I have a LS3 and a TR6060 and I was no where near having to notch the front cross member. Are you sure you do not have the motor too far forwards? And I was able to install these already bolted together. I put the gearbox support in after the gearbox was in position.

[Aussie Mike]

Could you have got away with a smaller under drive harmonic balancer? The one I put on my LS1 is about 1.5" smaller than the original.

Cheers

[Three Peaks]

I'm pretty sure the FF5 kits weren't really engineered to handle the 5.4 engine due to the extra width.
I'll be interested to see how you install the steering bits, headers, and the footbox so you still have room to use the pedals.
Lots of pics would be helpful for many guys wanting to use the 5.4 powerplant but haven't gotten over these hurdles yet....

Bob

[albanycobra]

Im pretty sure you need 10mm clearence to a rotating part

[PSYCHO]

Jethrow no the motor isn't too far forward it's just the size difference between ford and Chev donks and the TR6060 is out of a FG so the rear extension is ridiculously long, when I refer to the gearbox and the rear crossmember in my previous post it's not the mount its the structural cross beam I haven't even mounted the the gearbox mounts.

Mike I did consider that option but as the crossmember is so large I thought it would be easier to notch it than try and remove the the pulley in the end I think AlbanyCobra sums it up the best you need 10mm clearance all round the motor.

Thanks for the feedback fellas I really appreciate your thoughts and opinions

Regards Psycho

[PSYCHO]

Bob you are right with the size of the 5.4l yes I have had to slightly modify the foot box and even the pedal box I have spaced the motor back over to the left hand side as the US push it couple of inches to the right hand side, the steering is not so much of an issue with out the headers fitted but may have to change once i start to fabricate them I have a few pics in my albums and a lot more still on my phone, once I get more time I will upload those mods

Regards Psycho

[damage]

Originally Posted by PSYCHO

the TR6060 is out of a FG so the rear extension is ridiculously long, when I refer to the gearbox and the rear crossmember in my previous post it's not the mount its the structural cross beam I haven't even mounted the the gearbox mounts.


Regards Psycho

Why not change the rear housing on the box to T56 and move the engine back. This would make your weight exchange a lot better and reduce understeer from having the weight transferred backwards a bit. This would also assist with gear shifter position.

[Aussie Mike]

You could probably swap to the main shaft and extension housing from a GM T56 for a shorter box. Most of the parts are interchangeable in the T56 box.

Cheers

[PSYCHO]

Ok so a few modifications today first was the pedal box support that was way too close to the head/ rocker cover


Then had a look where the gearbox will finally sit and that’s not looking good at all so I will need to look at maybe a remote shifter or modifying and relocating the shifter to the inspection plate or as Mike pointed out maybe changing out the rear housing.




Now to look at the passenger side and low and behold the starter motor is the next issue looks like I have to cut that support out and relocate it.








Oh I’m going to need to modify the kick panel so the starter motor will have to intrude into the foot well LOL



My new toy arrived yesterday all I need to do is learn how to use the Tig now HAHAHAHA

[Mrs flatchat]

There is another bell housing with the starter tucked up under the block where they used to be -- if thats any help.
The one you have is the "Aston Martin" version go for the "American " version -- apparently

[guye]

Originally Posted by PSYCHO

Love the steel caps footwear psycho!

[PSYCHO]

I was waiting for some one to pick that up nice one guye

[Aussie Mike]

Chinese Safety boots. I spent a lot of time working in China back in the 90's. So many building sites I saw where guys just wear shorts and flip flops and they are welding or wiring up reo, pouring concrete etc. Ouch!

[PSYCHO]

A small update nearly finished the passengers foot box will have to make up a cover for the starter motor






Received my new 7’ brake booster and XA master cylinder


Time to make up some booster brackets with a slight angle






Quick squirt of wrinkle paint just need to drill the holes




Regards Psycho

[itempany]

Keep the pictures coming. Its looking good. What is your opinion on the kit overall?
Ian

[PSYCHO]

Thanks Ian,
The kit is very comprehensive and would be very easy to complete if you stay with in FFR's parameters BUT as we all know everybody is different and customising to ones own taste is what keeps us all individuals and very busy lol. Wow that sounded a little deep heheheh
Thanks mate

Regards Psycho

[PSYCHO]

Received my Gearbox parts yesterday and spent last night looking on the internet to see if I could do it myself so hear it goes.







Taped out the whole area put a rare earth magnet under the shaft my god are they strong nearly lost a finger when it found the shaft. The grinding went well.



I knocked the small plug out of the end so I could remove the shaft for drilling



Drilling went very well took it nice and slow and sprayed plenty of lube



A little bit of persuasion and on it goes



Time to put it back together







Job done took 4 hours and I couldn’t see a single iron filling any where

[jcraigau]

Looks great! I'm bring mine over to you...