Friday, June 28, 2013

Flip Down Gas Cap installation

The flip down gas cap itself is tricky to put together.  A good video is here:

The small screws that attach the gas cap to the car are different than used on standard gas caps.  They are recessed and short sheet metal screws.  I opted to get some from the local supply shop instead of paying the extra amount online.
There is a screw that secures the cap from inside the trunk for protecting from theft of the gas cap.  The screw hole is very hard to get to and didn't succeed in putting it in but it may not be necessary unless you are paranoid about someone stealing the gas cap.

The filler tube goes in from the outside and remember to put the gasket in between the flange and the car.

Trunk Lock

The trunk lock is fairly easy to install.  But first, you must install the latch, then slide the bar into the hole that turns to unlock the trunk.

The extension bar was quite long so it was cut with metal cutters or else it would snag on anything you wanted to put in the trunk.

Sunday, June 23, 2013

Taillight Panel Assembly

The first step to installing the taillights is to assemble the panel separately then install it onto the car.

The taillight panel parts.
The taillight parts include the Shelby lenses, the chrome bezels and the fiberglass taillight panel which I had painted the same color as the car.

Screw the threaded rods into the frame

The bottom part is the 1967/68 Cougar taillight bucket housing and can be purchased from:

It is a challenge to get the plastic lens to fit inside the fiberglass piece.  I did a lot of grinding with the round rasp file.

The frame that contains the threaded rods will finally fit through the slots in the fiberglass with more shaping with the round rasp file.

Inside view of the threaded rods poking through the back

Install the gasket onto the rods
Set the cougar taillight bucket onto the threaded rods and fasten with washers and nuts to secure the parts together.

The final piece all assembled and ready for installation on the car.

Saturday, June 22, 2013

Upper Vent Scoops/Air Extractors

Add RTV 100 Sealant to keep any water from getting inside the car.  Ideally this show car won't see much rain but it will happen. 

Functional Rear Brake Scoops

In early Shelby cars, the rear scoops were functional and I like the idea of scoops that actually do something rather than just looking cool.  Not a lot of information available on how the brake ducts were installed originally so I made my best guess from what was available.

Made a template from the fiberglass piece

Taped the template to the wheel well in the best fitting place

Drilled a pilot hole
Used a hole saw to make the bigger hole

Pre-drilled 4 holes in the fiberglass then placed the fiberglass piece and drilled through the metal.  Applied some RTV 100 sealant on the piece to keep out water, then, using a pop-rivet gun, secured it to the wheel well.

Pop rivets from the wheel well

The brake duct kit comes with a single long hose, need to cut it in half and hope both are long enough...

Secured with a really long nylon zip tie

Final epoxy black to finish it off...

Tuesday, June 11, 2013

Rear Valance and Backup Lights

Rear valance installed and new backup lights installed.  We tried to install the backup lights with the rubber seals but one tore and the other was difficult in fitting the light into the groove.  I think they look a bit ugly.  Installed the lights without the gaskets.  I think they look sharper.  Don't think there will be an issue with moisture since the lights are exposed in the back anyway.

Trunk Lid

Installed the fiberglass trunk lid.

The torsion bar works to open the lid but flexes quite a bit.  Some installations I have seen a center bracket holding the bar.  I will have to research if this will help and whether I can safely put screws in the fiberglass that will hold it.

Installed trunk weatherstrip.  After installation, the trunk lid doesn't close all the way, the weatherstrip may need to soften a bit before it settles, if not, it may have to be altered or replaced with softer material.