Saturday, June 30, 2012

Self Motivation Milestone!

In the summer of 1972, I took the engine out of this car, and it hadn't moved under it's own power until yesterday at 6:22 PM.


40 years is a long time to wait for self-motivation.  The importance of this milestone is still sinking in with me.

Thanks to #1 Son for taking and editing this inspiring video.

Monday, June 25, 2012

So Close...

It's good to set challenging goals.  One way we know that they are challenging is that we don't always achieve them.  My goal this weekend was to get the car running, and moving under its own power.  #1 Son and I worked pretty hard, and we accomplished a lot, but we didn't achieve my goal.  It will have to wait until next weekend.
My first task was to finish the fuel pump installation.  I have yet to wire the pump to a switch under the dash... the switch you see here was left over from running the engine on the cradle in December.
After installing the front flex line, the fuel system is complete

Then I installed the drive shaft into the transmission tailpiece.
 I remember asking Mr. Mechanic if I should paint the driveshaft.  His answer... "You don't have to, but once the rest of the car is painted, you will want to."  He was right.
And bolted the new U-joint to the differential

Installing and adjusting the throttle linkage.  As I suspected, this required a lot of fine adjustment, and some minor fabrication.


Connecting the exhaust downpipes.
Uncle Packard offered some spare fiberglass exhaust wrap to use on the downpipes, as a way of further reducing the heat in the engine compartment.  I gladly took him up on the offer!  Later, I plan on ceramic coating the exhaust manifolds... which should lower the engine compartment temperatures by about 100 degrees!
Right downpipe and muffler, viewed from the front

The mufflers are directly under the driver/passenger's knees. 
Long, convoluted tailpipes take the exhaust back, over the rear axle, and out the rear bumper guards.  This long section is suspended between the muffler and the bumper with no additional supports.  Because I don't have the bumpers on the car, I've chosen not to install the tailpipes for the time being.  The car will be a little loud, especially in the cockpit, but should run OK for now.  Pretty good work for a Saturday.

Sunday I was very hopeful, but we got a late start and had a hard deadline.  I made the time crunch worse by wasting some time dry-fitting the cabin insulation.
Placing the floor insulation in the car seemed like a good idea...  But ended up taking too much time!
I thought it would make working under the dash easier, with the car out in the sun.  It did brighten things up, but also turned the cockpit into a solar cooker!  I didn't get a whole lot done with the electrical connections under the dash.  But I do have a good list of things to disconnect!

Meanwhile, #1 son was grooming and painting the radiator.  With just a few minutes to go, we installed the fan and the radiator in the car.

#1 Son installing radiator bolts.  There were a few issues, and we were tired, but it got in OK.
With the radiator in, what's left before starting the engine?
a. Sorting out the electrical to ignition and starter (and making sure everything else is disconnected, so I don't get any short circuits).
b. Flushing the block (again), and installing the thermostat, hoses and coolant
c. Put some gas in the tank
d. Checking fluids (oil, etc.)
e. (optional) hooking up mechanical oil pressure and temperature gauges, bolting to existing holes under the dash
f. Priming the fuel system with the electric fuel pump.

My hope is that we are only a few hours away from a running car.  Once it runs, I'll feel confident taking the car back to the painter.
Celebration shot
A good weekend.  We had some minor trials, but I feel blessed.  No, I didn't achieve my goal, but everything we did was consistent with my intention.  I'll take living with integrity over accomplishment any day!

Saturday, June 16, 2012

Restored Heart

As I gazed at the t-bird this evening before leaving Uncle Packard's garage, I got a surreal yet serene feeling.  Not necessarily a feeling of accomplishment, but a feeling that I have been blessed.  The engine is safely nestled in the engine bay, the transmission is connected, the brakes are done, the steering column and wheel are installed and working... this is becoming a car, becoming what it was meant to be.  I feel more like an observer, watching this happen, than the man trying to push this project forward.  5 men were involved today, each sharing a part in this project, each finding satisfaction in the relationship the day provided.

There is still a lot to do before this car runs: finish the fuel lines, install the exhaust, overhaul the electrical system, install and adjust the throttle linkage, install the radiator & hoses and fill with coolant, install a temporary seat.  But these are minor things, not major.

Sitting on the floor of the car, with the wheel in my hands, I realize how far I have come as a person since I first installed this engine in this car, 38 years ago.  I was pretty lonely then, and I didn't feel like I had anyone I could count on to help me.  I was insecure and depressed.  I wanted desperately for this car to run, but by the time I sold it I was just hurt and angry.   I was ready to move on, and bury my dreams for the car with other bad childhood memories.  I left it with a lingering sense of inadequacy, but I left it.  It took decades for the memories of my hopes for this car to wane, along with the vague sense of shame about how I handled them.

I am not the man I was then.  I have been willing to open up my hurts, to share them so that they can heal.  I have been willing to do disassemble, to wire brush, and to rebuild the parts of my character that needed it.  I have suffered some disappointments as replacement parts didn't fit.  Most importantly, I have been willing to continue, one day at a time, taking positive steps. Today, I am reminded that I have the opportunity to make a new start.  Not alone, but surrounded by people I know I can trust... my son, my uncle, my friend the mechanic, and another eagle scout from my son's troop.  

The engine arrives at Uncle Packard's garage in Mr. Mechanic's truck.

Yesterday's work prepared the engine compartment for the engine.  Note that the steering column and battery are installed.

All hands were involved swinging the engine into position, so we only thought to take a picture once it was almost in final position.

This is what a Thunderbird engine compartment should look like! 

Returning an engine to a car is soothing to the soul.  There is something inherently right about doing this.

#1 son really likes the glass bowl fuel filter.

A shot from the radiator's point of view.

Carburetor installed.

Temporary air cleaner installed.  I have a stock '57 air cleaner that I can install once it has been re-chromed.

The valve covers sort of match the new master cylinder.

I spent several hours under the car hooking up the speedometer cable and shifter.
Celebration shot!

Just like an old-time barn raising, and engine can't be installed by one man working alone.  The most important aspects of my own recovery also couldn't have happened if I attempted them alone.  There are things that men just know have to happen in a group, and we are inexplicably drawn together during those occasions.  I'm delighted that I had the opportunity to share this event with men who are meaningful to me.

Monday, June 11, 2012

Brake System Victory!

My #1 son and I went back to Uncle Packard's garage this evening.  I picked up two new rear brake cylinders from Autozone for $20, and some more brake fluid.  Installing the rear cylinders took less than an hour.  I then tightened the rear hardline to flex line fitting... the tubing was fine, just very hard to tighten.  I tightened the elbow fittings on the master cylinder... they were pretty loose, no wonder they leaked!  Once more tightening everything, then we bled the system again and tested... no leaks!  Or, I should say, nothing obvious.  This is a completely different feeling than last night!  We went home feeling victorious.

There is a lesson here for me.  Last night, I was tired.  The leaks were disappointing, but I really needed to stop and get some rest.  I'm very glad I did.  I was glad to have the company of #1 son and Uncle Packard, even in the disappointment.

Today, the answers to fixing each of the leaks seemed obvious, and straightforward rather than daunting.  The additional cost was minimal, and we finished the job quickly.  Tonight, we all shared in the victory... bleeding the brakes is a 3 person job.

I'd like to say that praying for serenity last night and this morning made a difference, but my prayer wasn't conscious.  I just focused on acceptance, and asked for discernment.  Before I was in recovery, I would have been extremely unpleasant when faced with this kind of setback.  I probably would have made some very poor decisions in that mental state, and possibly broken something or hurt somebody's feelings.

My attitude and actions last night clearly indicate that I'm not the man I used to be.

Uncle Packard also affirmed me last night, when he told me that my father didn't ever exhibit the perseverance, judgement, and tenacity that I had shown in restoring this car!  I am not like my father.  That is a huge thing for me, and even though I love him, it is a blessing to hear.

I am at peace.

Brake System Dissapointment

I installed the brake lines over the weekend (6/9-10) with #1 son and help from Uncle Packard.  This was a bigger deal than I thought, including fabing a bracket to position the control valve outboard of the battery tray, making several runs to the auto parts store for various brake lines and connectors, cutting and double flaring several sections of brake tubing, bending up and installing 5 different brake lines in the engine compartment, spending hours under the car installing poorly-fitting rear hard lines, cutting and fitting a brake push rod to the new dual master cylinder, self-bleeding the master cylinder, then bleeding the power unit and each wheel. 

New chrome master cylinder in place, next to the stock battery tray.

The combination valve (proportioning and residual, a must for disc-drum systems) tucked away outboard of the battery tray.  #1 son made this suggestion, and it's a very good one!  This should keep the valve away from the exhaust heat.

Top view of master cylinder, combo valve, and battery tray with heat shield in place.  The brake fittings from the master cylinder fit through new holes in the battery heat shield.

Stock power assist unit in front of the battery tray.  Front circuit must go from master cylinder to the power unit, then from the power unit back to the combo valve.

Front line from the power unit connected to the combo valve.

Power unit with both lines routed below, neatly tucked away.

Double flaring brake lines sounded intimidating, but was actually pretty easy.

Rear line from the master cylinder going into the combo valve.

Front brake line from the combo valve goes to the left front junction.  Flex line under the junction goes to the left caliper, hard line continues across to right side flex and caliper.

Front line from the combo valve, from the engine's point of view.

Rear line added in place from the combo valve.

I added heat shielding to all the lines at the rear of the engine compartment.  This is near the exhaust, and it gets pretty hot in there.

New fuel line, after wrestling into position.  I cut this line to add an electric airtex fuel pump.  It wouldn't have fit if I didn't cut it.

Rear brake hardline, before installation.  It didn't fit very well, and was very hard to install!

Rear hard line to flex line.

The rear hard line in position.  It is very tight in there.

Bleeding the master cylinder prior to bleeding the brakes.

I learned a lot this weekend.  I learned that inverted flare fitting (iff) connections come in four different sizes, and that my master cylinder/combo valve uses all four.  I learned how to use a double flaring tool.  I learned that "made to fit" brake lines really don't.  But on Sunday afternoon, we had the entire brake system together.
one of the three leaks.  Bummer!
Last night about 10PM, we finished bleeding the brakes, and learned something else.  We learned that the brake system had at least 3 different leaks! We were pretty tired, and this was just too much.  #1 son and I drove home feeling pretty low.  My goal of installing the engine on Friday seems unobtainable.  The reality that I really can't fix everything has started to bring up old doubts and insecurities.

I thought about this at work today.  In the calm of my office, I realized that things really weren't too bad, and I could approach fixing these leaks systematically.  A call to Mr Mechanic confirmed that most custom brake systems leak when they are first installed, and each requires careful tweeking and adjustment to make it work properly.  Encouraged, I decided to take a crack at fixing the leaks tonight.

I also found out that my boss scheduled an important meeting on Friday.  The engine install will need to wait until at least Saturday.

Sunday, June 3, 2012

Brake System Plumbing

Today I focused on sorting out what to do with the brake pluming in the engine compartment.  Having disc brakes in front, I really needed to use a dual master cylinder... once circuit for the front, and one for the back drums.  Disc brakes require more pressure to yield the same amount of stopping force, so I decided to use the stock power assist unit on the front brakes only.  I also realized the need for a combination valve, to keep the ratio of front to back pressure correct and avoid rear lockup during braking.  All this means that I have a lot of custom pluming work to do in the engine compartment.  I didn't finish today, I really just started laying things out, and counting the parts I need.  My hope is to have the brakes together and working by this time next week, in preparation for putting the engine in the car.  The master cylinder is much larger than the stock one, and sits very close to the battery heat shield.  This will make connections difficult, because I need to connect on the battery side, away from the hot exhaust manifold.  I will also need to fabricate a suitable heat shield for the master cylinder, since the stock one won't fit.  The power brake unit sits in its stock location ahead of the battery.
I struggled with where to put the combo valve, but found a convenient bolt on the power brake bracket.  This location is easy to get to, but I suspect that it will be too close to the exhaust.  I've heard of other people mounting the combo valve under the battery tray, or on the battery side of the heat shield.  Since I plan on using a small optima battery, there will probably be plenty of room for that arrangement.  I will need install the battery, complete with tie downs and brackets, and then mock up the arrangement to check.  I expect to be cutting and flaring a lot of brake tubing next weekend!

Here's a shot of how close the master cylinder is to the battery heat shield.  Uncle Packard proposed drilling holes in the heat shield, and routing the brake lines on the other side, next to the battery.  That might work well if the combo valve is there, too.  I don't like cutting up the "stock" battery heat shield, but it's not a particularly valuable or hard to find part, and I think this simple approach might be best.

Because the parts all come from different sources and eras, the fittings are all different.  I will be able to adapt two of the brake lines I bought, but I will need to fabricate at least three new ones.  
 I will need to change the routing of the brake lines to go behind the battery heat shield and through the power brake mounting bracket.  This should provide good shielding from the exhaust heat.

Well, my 6 days of dedicated t-bird work has come to an end.  Am I satisfied?  Well, I had certainly hoped to accomplish more  I have one more weekend before my scheduled engine install.  Will the car be ready?  It will be what it will be.  The car clearly looks better.  It has all four wheels on it.  The parking brake works, and I can roll it back and forth.  I need to celebrate that new freedom.

I plan on installing the engine on the 15th regardless.  As I think about preparing for it, dozens of "to do" items keep popping into my mind... how do I get the steering wheel painted in time?  How do I get the drive shaft painted?  How do I get the electrical system ready?  What about the fuel pump?  What about the exhaust system?  All are legitimate concerns, but I need to restate my intention.  The engine is going in on the 15th, because I need to arrange for the manpower to help me do it.  Everything surrounding the engine can be installed later, at my own pace, and that's OK.

Saturday, June 2, 2012

Floor and Tank

Yesterday, I stripped and painted the floor of the cabin.  There was light rust, and only a few minor rust holes, which can be filled with seam sealer.

 I brushed on red lead rust destroyer.  This will be under the floor insulation, padding, and carpet, so the color really doesn't matter.

Today,  I started fitting together key pieces in the engine compartment... the battery tray & heat shield, the plate and rubber backing that seals the steering column, the brake booster, and the new master cylinder.  
 I will need some custom brake parts to make this work.  I'll try to place an order tonight, so I might get the brakes working next weekend.
 Uncle Packard and I installed the fuel tank.  It went in fairly easily.  Surprising, for such an inexpensive fuel tank!
 The fuel filler is in the middle of the lower trunk sill.  I'll install a large rubber grommet around the neck after the car is painted.
We checked that the fuel level sender unit is accessible from the trunk.

It was a good day, but I'm feeling pressure to meet my scheduled engine install date of 15 June.  The fuel lines set me back a bit, and I was hoping to have the brakes done by now.  Only one weekend left, and I really need the brakes finished, as well as at least the basic electrical.  I wanted to paint the lower dash, so that I would only have to install the steering column once... but that may have to wait.