My 67 Cougar Build

[1Bad68Cat]

I started this build a couple years ago. It is a slow build. And I mean really slow. I have posted some pics of the things I did in other threads but figure I'll include them here.

I started with this:

https://i.imgur.com/6f7gZKJ.jpg

https://i.imgur.com/WTbJli9.jpg

https://i.imgur.com/nbNCjBo.jpg

https://i.imgur.com/xEL0v2j.jpg

[1Bad68Cat]

As I mentioned before I did some small things here and there. Here are a few pics of the front brakes I will be installing.

https://i.imgur.com/ED8xODt.jpg

https://i.imgur.com/VEcDMio.jpg

https://i.imgur.com/CClOYH1.jpg

[1Bad68Cat]

I did some prelimnary mock up with the coyote engine.

https://i.imgur.com/OnorvDb.jpg

https://i.imgur.com/T29xu1B.jpg

Along the way I built an engine lift fixture because I didn't feel comfortable with the lift brackets supplied with the coyote engine. I can see them bend as I lifted the engine. Getting the CG right also proved to be cumbersome with the supplied lift brackets.

https://i.imgur.com/NIiTvS5.jpg

https://i.imgur.com/cOuV4CN.jpg

https://i.imgur.com/0QyAyzo.jpg

[1Bad68Cat]

To date, I have mostly installed the front suspension. Still need to weld upper control arm mount gussets, top coil over mount, and and the down tubes. I'll tie the gussets, coil over mounts, and down tubes together.

https://i.imgur.com/bGDSXht.jpg

https://i.imgur.com/jJ6ANvK.jpg

https://i.imgur.com/hxsYnbc.jpg

[DavidBoren]

Coyote in a cougar, I don't see anything wrong with that. And it looks like you've got a good thing going with your front suspension.

What are your plans for the rear? Full floater 9" with a decoupled 3-link? Built 8.8" with an offset 3-link? Cobra IRS?

[1Bad68Cat]

Coyote in a cougar, I don't see anything wrong with that. And it looks like you've got a good thing going with your front suspension.

What are your plans for the rear? Full floater 9" with a decoupled 3-link? Built 8.8" with an offset 3-link? Cobra IRS?

I have a 9" already, but I plan to convert it to a semi-floater similar to what speed tech offers with theirs that use the c6 SKF hubs. I will be using a SRT8 setup instead because the wheel bolt pattern is similar to a Ford. I'll redrill the hubs for 5x4.5 since the SRT8 bolt pattern is 5x4.527. That way when I need to replace rotors I can go to the parts store. The holes are oversized in the rotors that I can use the 5x4.5 bolt cirlce.

[Justin@EntropyRad]

is beefcake! Kudos for the Coyote swap

[waynieZ]

Great project. This is going to be one fun ride! Nice job on the lift fixture.

[1Bad68Cat]

Small update. Fabbed up and tacked motor mounts in. Hope to finalize engine placement, then install both engine ans transmission so I can fabricate the transmission cross member.

https://i.imgur.com/SW6MXfu.jpg

[bonecrrusher]

What car did the 6 piston brembo setup come from?

[1Bad68Cat]

What car did the 6 piston brembo setup come from?

The brakes are from a 2013 Shelby GT500. With my build, I'm trying to use stock parts where possible so I can go to the parts store/dealer in an emergency.

[jarhead]

Very nice!

[bonecrrusher]

Very nice - I agree with sticking to factory parts where you can.

I disliked the Brembo/OEM pads with my CTS-V brakes - so I went with Hawk HPS pads.

[1Bad68Cat]

Another update. Mocked up my hydroboost to see if I can get it to clear the coyote engine. Results look promising. Used a reproduction Boss 429 Mustang brake booster wedge to tilt the hydroboost up. Still need to figure out what to do about the billet hood hinge interference and determine what the brake pedal ratio needs to be. If anyone has a later model mustang with hydroboost perferably the SN-95 (96-2004, prefer 2003-2004) variety would you mind telling me what the pedal ratio is.

https://i.imgur.com/TR9Z03r.jpg

https://i.imgur.com/4VUZwRM.jpg

[67XR7]

I guess a cougar is an okay choice for a build.

[RidiCat69]

Have an 03 cobra pedal assembly here, measured out to a 5:1 brake pedal ratio.

Like your build!! I have a 69 Cougar I'm doing a slow build on also.

[1Bad68Cat]

Have an 03 cobra pedal assembly here, measured out to a 5:1 brake pedal ratio.

Like your build!! I have a 69 Cougar I'm doing a slow build on also.

Thanks RidiCat69 for the info. Would you mind sending me the measurements you took. I want to eliminate any possible rounding errors when I calculate where my pivot point will need to be. I'm a little surprised, I was thinking it would have been closer to 4 than 5. Also, did you take your measurement from the center of the pivot to the center of the pedal pad or the bottom of the pedal pad? I've seen illustrations showing both. Thanks again.

Robert

[RidiCat69]

No problem, Robert.

I retook measurements for both ways and you can decide which to use.

Center of pivot to center of pushrod lug is 2.75"
center of pivot to absolute bottom of pedal pad is 14.25".
this is what I got 5.1:1 ratio with.

Center of pivot to center of pedal pad is 12.75", giving a ratio of 4.63:1

Ryan

[RidiCat69]

What pedal setup are you looking to use?

[fleetus macmullitz]

Very interesting build. :thumbsup:

[1Bad68Cat]

No problem, Robert.

I retook measurements for both ways and you can decide which to use.

Center of pivot to center of pushrod lug is 2.75"
center of pivot to absolute bottom of pedal pad is 14.25".
this is what I got 5.1:1 ratio with.

Center of pivot to center of pedal pad is 12.75", giving a ratio of 4.63:1

Ryan

What pedal setup are you looking to use?

Thanks Ryan. I am using the power brake pedal for the 67 cougar. Right now the pin is lower than the hydroboost rod. I will move the pin and also likely the pivot so that the arc of the pedal matches the direction the hydroboost rod travels (currently it travels up at an angle because of the wedge). I believe the stock 67 ratio for power is around 3:1.

Robert

[RidiCat69]

Oh wow! Didnt know they were that low! The had an 04 Cobra as a daily for a few years, loved the hydroboost. Had good pedal feel without being over assisted. Did a 70 Mach build recently and used the stock pedal setup. Got a needle bearing setup for the stock clutch pivot rod. Don't know what you're doing in that area, but it's much smoother than the bushings if you haven't already done so.

Finally getting settled into my new digs, and trying to get back to mine. Only other cougar on here right now from a brief search. Keep the updates comin!

Ryan

[1Bad68Cat]

Oh wow! Didnt know they were that low! The had an 04 Cobra as a daily for a few years, loved the hydroboost. Had good pedal feel without being over assisted. Did a 70 Mach build recently and used the stock pedal setup. Got a needle bearing setup for the stock clutch pivot rod. Don't know what you're doing in that area, but it's much smoother than the bushings if you haven't already done so.

Finally getting settled into my new digs, and trying to get back to mine. Only other cougar on here right now from a brief search. Keep the updates comin!

Ryan

Yeah, I was a little shocked too when I took the measurements. My brother had an 04 Mach I and I loved the brakes on it too. I was fortunate to find a used 04 cobra hydroboost for cheap and decided I would adapt it to my car. As for the clutch setup, I did install the roller bearing conversion. I used a Scott Drake kit. I hope to get the new wedge soon so I can modify my pedal accordingly.

Robert

[1Bad68Cat]

More updates. Brake pedal mod for adapting an 03 cobra hydroboost to the cougar pedal support. I replicated the pedal ratio from the cobra.

https://i.imgur.com/fPdiqAR.jpg

https://i.imgur.com/jYwmTZY.jpg

Pedal support setup with hydroboost, S197 mustang hydraulic master, and roller bearing conversion

https://i.imgur.com/fPaM5Iz.jpg

Used parts from the S197 mustang and adapted them to the cougar clutch pedal.

https://i.imgur.com/I4aVXFD.jpg

Hydroboost mounted using a reproduction Boss '9 mustang brake booster wedge to clear the coyote engine.

https://i.imgur.com/9Bx9t75.jpg

[RidiCat69]

Sweet deal man! The wedge seems like it will add quite a bit of clearance. Keep the updates comin!

[1Bad68Cat]

Sweet deal man! The wedge seems like it will add quite a bit of clearance. Keep the updates comin!

Thanks Ryan. Your measurements on the cobra brake pedal helped immensely. I do have a lot of clearance between the engine and the hydroboost. You can see in the picture below. This is with the engine set at 3 degrees down and not having to shift the brake assembly towards the driver's side like I've seen in other builds. I can get to 2.5 and still have plenty of clearance. Only issue I have now is clearing the billet hood hinge shock which I never really liked because it limits the height the hood can be opened. I have an idea that will solve those 2 problems.

https://i.imgur.com/pcDqfp6.jpg

https://i.imgur.com/qmTLou0.jpg

[ADiCarlo]

This is going to be amazing.

Much win.


Sent from my iPhone using Tapatalk

[WSSix]

Nice work! Glad to see you making progress on the car.

[RidiCat69]

Updates? Hell has frozen over since I worked on my coug the past 2 weekends straight....hasn't happened in months... :poke: eh?

[1Bad68Cat]

Updates? Hell has frozen over since I worked on my coug the past 2 weekends straight....hasn't happened in months... :poke: eh?

Lol. No updates on my end either Ryan. Been helping my brother with his 66 mustang. His car is much closer to completion than mine. I have some pictures of it if as proof I did some work. :lol:

https://i.imgur.com/9zJOQLk.jpg

https://i.imgur.com/PGC9eqA.jpg

https://i.imgur.com/GqUUz5l.jpg

I'm hoping the color evened out or the phone pic just gave it a greenish hue because it was suppose to be matte black.

[1Bad68Cat]

A few updates. Was able to roll the car out of the garage this weekend on it's own suspension. Finished welding in the upper control arm gussets, upper shock mounts, and frame boxing plates. Still need to weld in the down tubes and shock tower delete plates, but I will first fab up the transmission cross member so I can return the coyote motor to my buddy.

https://i.imgur.com/7kPq9Sb.jpg

https://i.imgur.com/TkZwpeT.jpg

https://i.imgur.com/jlCbqTv.jpg

Hope the car is not sitting too low once the real wheels and tires are on.

https://i.imgur.com/lgQvbpb.jpg

[WSSix]

Man that motor is huge. It looks good in there though. Congrats on getting the car back onto its wheels.

[1Bad68Cat]

Man that motor is huge. It looks good in there though. Congrats on getting the car back onto its wheels.

Thanks Trey. The motor sure is big. I believe it is even wider than the boss '9 motor.

[1Bad68Cat]

Fabbed and installed my transmission cross member

https://i.imgur.com/U8wQFuC.jpg

https://i.imgur.com/FpfAs02.jpg

https://i.imgur.com/Vcm5utA.jpg

[jarhead]

Nice job on the crossmember! Where did you get those rubber bushings, I would like to use that ice on my 68 Torino.

Thanks, Joe

[Spiffav8]

Nice job on the crossmember! Where did you get those rubber bushings, I would like to use that ice on my 68 Torino.

Thanks, Joe

Right!

[1Bad68Cat]

Nice job on the crossmember! Where did you get those rubber bushings, I would like to use that ice on my 68 Torino.

Thanks, Joe

Right!

Joe/Curtis, I bought them through Off Road Warehouse. From what I remember they are just bulk bush kits. Another alternative would be to buy bushings from energy suspension like these and use the appropriate tube diameter.

http://energysuspension.com/universal-products/link-flange-type-bushings-universal-mounts-isolators.html

[1Bad68Cat]

Christmas came early.

https://i.imgur.com/jNMxClx.jpg

https://i.imgur.com/ctT5Zdk.jpg

https://i.imgur.com/sVQ5FgI.jpg

[rustomatic]

That's a nice package!

[WSSix]

Merry Christmas!

[1Bad68Cat]

Just a small update from the weekend. Decided to cut the firewall out to make clearance for the Charge Motion Control Valves (CMCV) on the back of the intake. I didn't want to move the engine forward for the clearance because it would have created an issue with the steering linkage and oil pan. I figured modifying the firewall would be easier. I just wanted the firewall to remain looking "stockish" after the mod. I think I accomplished it. Still need to complete the metal finishing though.

https://i.imgur.com/23BsRej.jpg

https://i.imgur.com/fGouNng.jpg

https://i.imgur.com/V8nGwsl.jpg

[67XR7]

keep up the good work, Look forward to seeing your progress!

[1Bad68Cat]

Dressed the welds and retest fit the engine over the weekend.

https://i.imgur.com/CWsqIgD.jpg

https://i.imgur.com/w39YmXe.jpg

Barely enough clearance. I may massage the area a little more just in case.

https://i.imgur.com/07HPgFy.jpg

[jarhead]

Nice work!

[Tuske427]

Looking awesome!

[anarchy99]

That is a good looking engine. Looks right at home in there.

[98ssnova]

What if you just radius the corner of the cover? It just plastic right? Might be easier.....

[1Bad68Cat]

What if you just radius the corner of the cover? It just plastic right? Might be easier.....

Sorry about the confusion. I was actually referring to the CMCV behind the engine cover. I have about .125" clearance right now. But now that you mention it, I may also radius the engine cover too.

[syborg tt]

Great project.

I'm looking forward to seeing and hearing this car when you get it running.


Marty-mj
www.garagescene.net www.syborgtwinturbo.com www.2ndcamaro.com

[1Bad68Cat]

A few updates. Fabricated the mount for the coyote control pack power distribution block and closeout panels for the shock towers delete. Also picked up a steering wheel along the way.

https://i.imgur.com/ZgywbiB.jpg

https://i.imgur.com/BmrqeEF.jpg

https://i.imgur.com/S23ajYC.jpg

https://i.imgur.com/rOXIAxx.jpg

https://i.imgur.com/byb1BmA.jpg

[1Bad68Cat]

New valve covers for the coyote conversion. Machining begins today. Excited what it will look like in person.

https://i.imgur.com/MG57wWG.jpg

[jarhead]

nice!

[WSSix]

Post finished pics! Looks like a great design.

[1Bad68Cat]

Post finished pics! Looks like a great design.

You ask and you shall receive. :hapdance:

https://i.imgur.com/ui2CnUv.jpg

https://i.imgur.com/iduHqqb.jpg

[67XR7]

New valve covers for the coyote conversion. Machining begins today. Excited what it will look like in person.

http://i1096.photobucket.com/albums/g322/ricasas/67%20Cougar/14808658_10209339581183337_770229581_o.jpg (http://s1096.photobucket.com/user/ricasas/media/67%20Cougar/14808658_10209339581183337_770229581_o.jpg.html)


was this something you created in CAD and then had availability to the equipment to make it happen?

[1Bad68Cat]

was this something you created in CAD and then had availability to the equipment to make it happen?

For most of my car that is what I've done. I use SolidWorks or Pro-E to design my ideas. However in this case, the person machining had been making coyote covers already and was willing to make custom ones. I just provided him a picture of the script and logo which he plugged into whatever program he uses.

[1Bad68Cat]

Some minor updates to my build. I received the custom covers for my coyote conversion. Still need to decide how I want them finished.

https://i.imgur.com/3RySqLE.jpg

https://i.imgur.com/Jlayq4F.jpg

https://i.imgur.com/gNPHWYS.jpg

[1Bad68Cat]

I've been lacking on updates because I haven't had much time to work on the car, but the shell is at the body shop now to prep the car for my upcoming engagement photos. Of course it took a major life event to light a fire, but it's getting there.

https://i.imgur.com/4mkVdxf.jpg

Car at media blast. It showed good and bad. I was surprised to find out that the car was originally a vinyl top car. The good, the roof wasn't rotted out like other vinyl top cars. The bad, the quarter panel was replaced sometime in it's life, but the repair work is subpar. The body shop will work with it since quarter panels are hard to find.

https://i.imgur.com/ZOZBa4F.jpg

https://i.imgur.com/PwauZts.jpg

Car after epoxy showed even more dings I didn't see when the car was out in the light.

https://i.imgur.com/t81qL4T.jpg

https://i.imgur.com/pm4dzhh.jpg

One of the subtle changes. Added a GT-E "esque" cougar hood scoop. It will look similar the g-force cougar hood scoop.

https://i.imgur.com/VYorEIV.jpg

I also managed to find 18" wheels that fit my car and clear the monster 15" rotors from the gt500 brakes I'm using.

[WSSix]

Nice, Robert. Glad the car wasn't too bad after media blasting.

[1Bad68Cat]

Added some color. Still need to mask for stripes.

https://i.imgur.com/X2ANStp.jpg

[1Bad68Cat]

A few more updates. Body shop laid out the stripes, painted them, and cleared the car.

https://i.imgur.com/URvhrf5.jpg

https://i.imgur.com/niqdzFX.jpg

https://i.imgur.com/pR5IQX4.jpg

https://i.imgur.com/XefmwYd.jpg

https://i.imgur.com/1SO6W7n.jpg

https://i.imgur.com/Ww13m3p.jpg

https://i.imgur.com/TRDAADt.jpg

[1Bad68Cat]

A few updates. Still needs to be cut and buffed.

https://i.imgur.com/65hFdBU.jpg

https://i.imgur.com/kr5pIX7.jpg

https://i.imgur.com/eGC8OpU.jpg

https://i.imgur.com/ZlW3WH8.jpg

[Mikael A]

Paint looks awesome out there in the sun:thumbsup:

[WSSix]

Very nice looking. Great choice on the blues.

[cjsgarage]

I just love these Cougars.theyre not as common, but they’re pretty nice.

[1Bad68Cat]

Can't believe it's been 3 years since I posted to my build. Not much of an update. I got the car looking presentable (i.e. still not running/driving :lol:) for my engagement photos and that's about it. The car has been on the back burner as I haven't had much time to work on it. Hopefully that will change soon after the home renovation.

https://i.imgur.com/UqUv1H5.jpg
https://i.imgur.com/NOJ1VIW.jpg
https://i.imgur.com/QXKKByb.jpg

[camcojb]

Great looking car and congrats on your engagement!!

[Peter McMahon]

I love it!
Is the front suspension from a kit? What spindle does it use? and what master cylinder did you use? I have a 56 F100 Coyote with hydroboost [ 2000 mustang ] looking for options.

[1Bad68Cat]

I love it!
Is the front suspension from a kit? What spindle does it use? and what master cylinder did you use? I have a 56 F100 Coyote with hydroboost [ 2000 mustang ] looking for options.

Peter, the front suspension kit is an Art Morrison Sport IFS. It uses the Wilwood Pro Spindle. The hydroboost and master came from an 03/04 mustang cobra. Hope that helps.

[WSSix]

Congrats on the engagement, Robert. The car still looks great, too.

[1Bad68Cat]

Great looking car and congrats on your engagement!!

Congrats on the engagement, Robert. The car still looks great, too.

Thanks Jody and Trey. I should mention that I did get married 10 months later since the photo I posted was from 2018. :D