Progress Photos 2020 - Part 1

For those who follow this blog, I would prefer to give more frequent updates. But finding the time, or simply remembering to do so when I do have time - is the tricky bit.

So the latest news is............

I recently had my much anticipated "final inspection" from the vehicle engineer. I have been delayed by the local government department (VicRoads) in regards to being able to fully register this car. The problem being that since i started the project, the rules have changed to limit engine size. I pointed out that I was given the green light when I started, and that I have not deviated from that project plan, and that a 1967 car would pass the new rule but my car with the same chassis wont, and, and, and - multiple other points.

The result is that I had to wait more than 6 months for a new official bulletin to be issued that allows my project to move ahead. That bulletin (limiting power to weight) was issued just a few weeks back - thank goodness. So here are a set of photos that depict what I have had to modify this car in order to pass the various tests needed to get full Victorian registration (not club registration).

• Noise Test.

I have had to add another muffler on each bank to pass the 96dB(A) limit that is in place for this car. The current exhaust setup is as follows.

• Extractors: 2" diameter primaries joining "4 into 1" that then neck down over about 12" into a 3" pipe. The extractors have O2 bungs welded in just downstream of the 4 into 1 join.
• Mufflers (primary): Just in front of the differential I have 3" diameter Flowmaster "FlowFX" units which have the offset inlet and center outlet.
• Mufflers (secondary): Squeezed in after the diff' and before the rear valence I have 3" diameter Flowmaster "Hushpower Pro Series" units.

The Hushpower units are nice as they are very compact, and there is so little room in the early Mustangs back next to the fuel tank, plus they have a heat insulation layer built in. But I have still gone to considerable effort to add extra heat shielding and also to clearance my fuel tank to provide at least a 50mm air-gap between these mufflers and the fuel tank.

• Fuel Tank.

The fuel tank modification required to add these mufflers (and provide clearance) was a particularly painful exercise. I'm sure you know the risks...... stainless tank construction, surge tank residing inside the tank itself, plus multiple baffles within the tank - so lots of spaces to trap petrol fumes. Yet I still need to cut and weld new "scalloped sections" into the tank, which is a recipe for a bomb.

My "safety" measure is to use my compressor, industrial vacuum, and even garden blower to clear it of fumes. This takes several hours. And just to make sure, I checked it (remotely) with an ignition source (a butane burner flaming directly inside the tank cavity). Only then did I start cutting/welding - and with my ventilation setup still running!
Here are some progress photos showing the new rear mufflers when first installed to meet the noise reg's. Then as the tank was scalloped to gain the clearance I needed and finally the heat shielding.
Now for the uninitiated, bending flat stainless plate to the meet the curved contours required is not easy. I built my own jig (two lengths of different diameter pipe) and pushed it around by hand.

• Registration.

Once I got the final inspection done I needed a set of documentation to present to VicRoads in order to get it legally registered. These items were:

• Engineering Certification slip (1 copy stays with the car, 1 copy is given to VicRoads)
• Tamper proof engineering sticker with the list of "Mod Codes".
• Original "proof of vehicle purchase" receipt.
• Dep't of Transport Vehicle Importation Certificate.
• Roadworthy Certificate.

Now things were going nicely until this bloody Coronavirus hit town. I had my VicRoads appointment booked, but they started cancelling services and mine was at risk. Learner driver tests were all cancelled in the week before my Monday test, but thankfully it all went ahead.
So ironically now that I am legal, I have nowhere to go during this lockdown! Well - I guess there is no law against what car you use to do the shopping, lol.

So what now?
I need to get the bumpers re-chromed, the front valence painted gloss black, and various interior items such as door trims, kick panels, run pinchweld, etc. Ah - and I also have some "sorting" to do now that it is finally running and I get to hear a rattle here & there, or I need more heat shielding in certain spots, etc. But these can happen over time and are purely cosmetic or comfort related.
What a journey, I have learned so much that if I did it again I would do it so much faster and no doubt a bit better. But this car is awesome to drive, so well worth the wait. This last photo shows the front as it currently looks. You can see the new spoiler I've added as well as the tow points for getting me out of the kitty-litter at a race track. I'm luke warm on the spoiler though as I think it takes away from the clean lines of the original car that I am after.