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Old 07-03-2013, 02:24 PM   #1
TKat13
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TKat13's Mach1 Build Log

Figured I would share my on-going build log with the guys/gals at M1R, the folks here have seen my car go through most of its stages so why stop now.

Reason:
Car is slow.
(98k miles, still runs better than new, but still slow)

Logic:
I was either going to buy a new car or take that down payment and put towards rebuilding the Mach into the car I have always wanted. Eventually, I chose to apply the money to a rebuild. Bottom line, I have yet to get tired of the Mach, this is the first car that I have kept this long and I still enjoy it. Other than it being so slow. So, I am setting out to resolve the core issue I have with the Mach.

Answer:
Make it fast, but still retain daily driver status. It will be a real daily driver not one that could be a daily.

Budget:
Let's just say I have already blown the initial budget, it was set at 10k, lets just say it will be less than buying a new loaded GT. I am fortunate enough to have this opportunity but this is only because I have not had a car payment since 2009. I am the original owner. In other words, I have been saving for this moment.

Turning Wrenches:
I take pride in doing as much as possible myself to the car. However, I am also smart enough to know when it is best to enlist the experience of the pros. I would like to say I have done everything, but that is and will not be true. HPP in Lewisville has been a huge help in selecting parts, building the pieces of the puzzle that I cannot afford to mess up and of course Manny will be tuning it. However, I will do the install of everything in very cramped area of my garage.

Log Plan:
I will keep the next post updated with as many specifications as possible. If I change my mind as I have done many times then I will update the main post of the log. Well, that is the idea anyway.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 07-03-2013, 02:41 PM   #2
TKat13
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TKat13's Mach1 Build Log

The Plan:
Replace the Motor, Transmission, Driveshaft, Rear End and add a power adder. I met all but one of this forum's requirement to post here so 3 out of 4 wins.
I will add more details as I progress, please be patient.

Motor (HPP Built Longblock):
Teksid Block .20 over
Forged Stroker Crank (5.0 for final displacement)
Forged coated pistons, w/file fit rings, compression spec'd by HPP, 9.8:1 I think)
Oliver Billet Rods (budget buster)
ARP bolts and Head studs throughout (wow, I learned bolts are expensive)
Heads fully ported
Custom HPP spec'd Billet ground Turbo Cams
Canton 9 quart oil pan/pickup
Billet oil pump gears

Transmission:
TH400 built
HPP Spec'd torque converter (turbo application)
Hurst Quarter Stick Shifter
Trans brake
Prothane Trans Mount - 7-1604-BL
Lokar Dipstick - TD-3350400FM
B&M Super Cooler - 70274
Aeroquip Startlite -6AN Hose - FCU0620
Aeroquip Fittings -
Pressure relief valve, drains back into trans pan.
New driveshaft for this application
Summit G4890 9" fan
Derail adjustable thermostat controller/relay
Tee Fitting for temp sensor

Rear:
31 Spline Moser axles
31 Spline Diff
3.08 Ford Racing Gears
All new bearings, races etc
Ford Racing Girdle
Axles tubes welded with HPP support arms, also tubes straightened by HPP
Wolfe Race Craft lower control arms
Prothane Rear Upper Spring Isolators
Rearend Gear/Diff Install by HPP, rest by me.

Power Adder:
Upgraded to Precision 76mm Turbo. 70mm turbo
On3 kit, forward facing with larger intercooler.
Headers ceramic coated
Hot side of turbo ceramic coated (hate rust)
Boost Controller
Electric Cut-out on down pipe

Fuel System:
HPP Triple Hat - More info soon, this is the big momma of fuel systems. I do not want to buy a fuel system twice so just going big first.
Three Walbro 465lph pumps, E85 safe.

Interior Upgrade:
O2 Gauge
Boost Controller Gauge/interface
Pioneer DVD Radio and Amps ( Did I say this was a full make-over?)

Front Suspension:
UPR K-Member (really wanted MM but not compatible)
Prothane Steering Rack bushings.
UPR A-Arms
MM Coil-Over kit


Misc:
Poly Motor Mounts from LMR
Prothane TH400 Transmission mount + Custom built cross beam.

Parts Left on the car from previous mods:
H&R Rear Race Springs
MM Caster/Camber Plates
MM Bumpsteer kit
MM Steering rack bushings (Update, could not use, does not work with the UPR K-Member)
MM Sport Struts and matching Rear Shocks
MM Full Length Subframe connectors
Magnaflow cat-back
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP

Last edited by TKat13; 06-04-2015 at 05:28 PM. Reason: Added Trans Fan parts
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Old 07-03-2013, 03:16 PM   #3
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Re: TKat13's Mach1 Build Log

Congrats! Im looking forward to reading about your build.
I just about have my Mach paid off. Then comes the task of saving for my build similar to yours.
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Old 07-03-2013, 03:37 PM   #4
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Re: TKat13's Mach1 Build Log

Step 1:
Buying the parts. This is more of a show and tell session. It is exciting to have parts show up. FWIW, I have purchased 90% or more of my parts from HPP via Brad, he has been either cheaper or at least match any price I find. The best thing is HPP really helps explain every part I buy through them. Very nice to have a face to a purchase. It is also nice to be within a few miles of their shop. I just can't say enough great things about how that entire shop has treated me through this long process. I have been buying parts since March.

Again, thanks to the guys at HPP, Manny, Brad, Brandon, Chris, Scott and Jay.

Here are some Suspension Parts:
UPR K-Member:


UPR A-Arms:


Front Coil Springs that come with the MM Coil-Over kit, these are 350lb


MM Coil-Over kit, this kit is very nice btw.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 07-03-2013, 06:43 PM   #5
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Re: TKat13's Mach1 Build Log

Your gonna love it! cant wait to see the power this monster will make. How much boost you gonna run?
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Old 07-03-2013, 07:10 PM   #6
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Re: TKat13's Mach1 Build Log

I'd go with a return fuel system and e85. quite a build! I'll be interested to see how it turns out. Thats quite a parts list.
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Old 07-03-2013, 11:06 PM   #7
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Re: TKat13's Mach1 Build Log

Quote:
Originally Posted by 02gtvertible View Post
Your gonna love it! cant wait to see the power this monster will make. How much boost you gonna run?
Thanks, I am pretty excited. I will run as much boost as the little turbo will put out, with Turbo cams I have been told the boost level will be less but more efficient. I would be surprised if it will even do 18. (it is a learning process for me on turbos) Next year I may upgrade to a better turbo as it will be an easy swap and I am quickly running low on funds.

Quote:
Originally Posted by Mach828 View Post
I'd go with a return fuel system and e85. quite a build! I'll be interested to see how it turns out. Thats quite a parts list.
Yes, it is a full return style fuel system and e85 is absolutely in the plan. I have been running it for over a year and love it. This is the main reason why I am over doing the pumps with the triple hat. At this level I will be pumping a ton of fuel.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 07-03-2013, 11:18 PM   #8
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Re: TKat13's Mach1 Build Log

Here are some pictures of the Turbo Kit. This is the On3 forward facing kit with the larger intercooler option. If there are specific pictures of parts that anyone wants to see just ask, now is the time before they go on the car.

Intercooler:


Another pic:


Turbo Kit Expanded view, in the bubble wrap is the slot style maf sensor and pigtail adapter. I let the tuner pick the maf sensor:

Pictures like this shows me how bad I need to clean my garage, yikes!

Piping:
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 07-03-2013, 11:23 PM   #9
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Re: TKat13's Mach1 Build Log

More Piping:


Turbo when I first unpacked it, literally. Pig tail, maf and mounting plate make another appearance:


I had the hot side of the turbo ceramic coated, looks better and will not rust.


With the flash on...
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 07-03-2013, 11:29 PM   #10
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Re: TKat13's Mach1 Build Log

Exhaust Headers as I unpacked them from On3:


Same Headers after getting them Ceramic Coated:

I should have not shown these, proof that I am the one that scratched the table! Don't tell the wife.

Moser 31 Spline Axles with 3" studs:


Ford Racing Girdle:
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 07-03-2013, 11:38 PM   #11
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Re: TKat13's Mach1 Build Log

Diff:


Here's the Mach letting Mother Nature supply the bath. View from my office at work, I caught myself daydreaming of building the car so I took a picture.


The '11 GT belongs to a buddy at work. There are 7 people in the office, two of them have '11 GTs, one has a '99 GT 2 Valve that makes 730 RWHP and of course my Mach. The guy that owns the '11 next to the Mach also has an 8k Mile '03 Cobra and an '88 GT. I think this group has an affinity to ponys.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 07-04-2013, 02:38 AM   #12
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Re: TKat13's Mach1 Build Log

wow this looks like a fun build..subscribed.
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Old 07-06-2013, 01:31 PM   #13
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Re: TKat13's Mach1 Build Log

Quote:
Originally Posted by TKat13 View Post

The '11 GT belongs to a buddy at work. There are 7 people in the office, two of them have '11 GTs, one has a '99 GT 2 Valve that makes 730 RWHP and of course my Mach. The guy that owns the '11 next to the Mach also has an 8k Mile '03 Cobra and an '88 GT. I think this group has an affinity to ponys.

That would be nice having a bunch of friends or co-workers with the same taste of cars. Everyone at my work bashes on American cars. They like to drive torque-less euro cars and none of them will race me when I call them out.
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Old 07-06-2013, 04:08 PM   #14
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Re: TKat13's Mach1 Build Log

Looking forward to your build.
Similar circumstances for me. I would love a new 5.0 but I have not grown tired of the Mach either. Have a few plans myself...

Good luck with the build
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03 Torch Red Mach 1

Stainless Steel Systems Adrenaline Series
18x9 - Solid Gloss Black FR5's
Nitto 555 g2 275/35r18's
MGW Shifter With Mach1 Shift Knob
4.10's & 31 spline Mosers and 31 Spline Posi
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Old 07-06-2013, 09:22 PM   #15
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Re: TKat13's Mach1 Build Log

That build looks intense! That'll be crazy. Are you in the Lewisville area? I'm literally about 10 minutes away from HPP. I don't think I've seen another single Mach around here though.
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Old 07-06-2013, 11:28 PM   #16
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Re: TKat13's Mach1 Build Log

Looks like a lot of fun. I went the other route and added a lowish miled Whipple Terminator to my collection. I figured I might as well have another car while I was at it. I'm sure you're going to get more performance out of the deal. Looks like a ton of fun. Congrats! Make sure you get some good vids!
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Clutch Replacement Vid
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http://www.youtube.com/watch?v=GmL1KBmWyhg
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Old 07-08-2013, 03:45 PM   #17
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Re: TKat13's Mach1 Build Log

very nice!!!!
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Old 07-08-2013, 05:07 PM   #18
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Re: TKat13's Mach1 Build Log

sweet build so far! keep it coming!
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Old 07-09-2013, 03:28 PM   #19
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Re: TKat13's Mach1 Build Log

Quote:
Originally Posted by brtnstrns View Post
Are you in the Lewisville area? I'm literally about 10 minutes away from HPP. I don't think I've seen another single Mach around here though.
I see very few as well, I work about 5 miles from HPP. Certainly helps being that close.

Quote:
Originally Posted by XSELLR8 View Post
Looks like a lot of fun. I went the other route and added a lowish miled Whipple Terminator to my collection. I figured I might as well have another car while I was at it. I'm sure you're going to get more performance out of the deal. Looks like a ton of fun. Congrats! Make sure you get some good vids!
Congrats on the Cobra, I actually considered this as well. Those Cobras have held their value well. I am sure the first vids will not be too exciting, it will be much more car than I am used to and will adjust the boost as I get more comfortable with it. I will use an eboost2 controller. But, I will share them.

Quote:
Originally Posted by Alex302 View Post
very nice!!!!
Quote:
Originally Posted by bleedingfordblu View Post
sweet build so far! keep it coming!
Thanks guys, it has been a long time coming.

As a quick update, I just ordered the TH400, Shifter, bell housing, converter, flywheel, dipstick and all the other related items. So this completes my drivetrain purchases. Now just waiting on delivery.

The heads are near completion and I hope to post some pics of the porting job. To keep my car on the road I started with known good heads.

Now the bad news, it appears as work has me booked for a large amount of travel over the next few weeks so progress will slow. But, that is ok as I am waiting on parts anyway.

I hope to remove the rear end this weekend, strip it and take it to HPP to have the Axels welded in their jig. Once I get it back, sandblast and paint and rebuild everything including new bearings.

What is the best paint for the rearend? Looking for a Matte Black.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP

Last edited by TKat13; 07-09-2013 at 03:37 PM. Reason: finished thought.
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Old 07-15-2013, 10:56 AM   #20
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Re: TKat13's Mach1 Build Log

I had to take advantage of the 80 degree weather in Texas on Sunday so I removed the Rear and gutted it. I will be dropping off the rear to HPP today to have the Axels welded in a jig. As you can see from the pictures it is a bit cramped in my garage. The 'Cuda is consuming a good amount of space (this is the next project).



Here are the 4:10s coming out, 3:08s going back in this weekend.

Yes, they are for sale as well as the stock axels and diff, the diff was rebuilt about 20k miles ago.


And now it is empty. Not very exciting but I will post more as I rebuild the rear end.

Can't really work on it during the week so the Mach is out of commission until next Saturday.

My wife, the trouper she is attempted to help me lift the loaded rear on my stand, but it was just too much. At least she tried.


Now I just need to figure out how to remove the ABS rings from the axels, any ideas?
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 07-15-2013, 07:36 PM   #21
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Re: TKat13's Mach1 Build Log

I used a press to remove and install my abs rings
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Old 07-21-2013, 01:47 AM   #22
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Quick update, since I pulled the rear I decided I should upgrade the lower control arms so after much research I decided to go with a set of Wolfe Race Craft lowers. Recommended by HPP but after comparing them with others I was sold. Even better they are not only made in the good USA but close to home in Texas!

Here's a quick picture:


They are only 235.00.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP

Last edited by TKat13; 07-21-2013 at 01:54 AM. Reason: Trying to fix link to photo
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Old 08-19-2013, 05:42 PM   #23
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Re: TKat13's Mach1 Build Log

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Old 08-20-2013, 11:29 AM   #24
TKat13
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Re: TKat13's Mach1 Build Log

I finally ended my 7 week travel for business tour. It was a complete pain being away from the home for so long. I had a day here and there to work on the Mach but to be honest getting motivated was pretty tough knowing that the next day I was flying out to another location. Anyway, I got a little to report, but not much.

I did get my rear end housing back from HPP. I had the tubes welded up and had them add some additional bracing. One of my tubes were tweaked pretty good, but with their jig they were able to get everything back to spec.

This weekend I cleaned it up and painted it with a high-temp epoxy paint. 9 years of daily driving it pitted the metal pretty bad, not sure why Ford does not protect these things. Anyway, it looks much better.

The housing is empty and the rear cover will be replaced with a girdle style, I just used the stock one as a cover for when I sandblasted and painted it.



Welded tubes:


Bracing + (ugly toes):


Next in line is to fix my press, I forgot that part of it bent when I replaced my ball joints months ago. urg.. Maybe tonight I will stop by the hardware store and pick up some steel and get welding. 90% of the Harbor Freight press is good, that 10% is what failed and it is very easy to see why. Not sure why they used a different material on the press bar. (of course a good amount of this was user error...
.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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Old 08-27-2013, 02:06 PM   #25
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Re: TKat13's Mach1 Build Log

Update on the heads; took a couple quick pictures of the ported heads, the custom turbo billet cams also arrived this week.









Still working on the rear, need to adjust the pinion depth, when I went to pull the bearing off of the pinion I discovered that my press was a bit small for that huge pinion gear on 3.08s. So, I could not press off the bearing. Threw the towel in and HPP has the rear. They will set the pinion and install the diff/backlash etc. I will complete it from there. Bottom line, I am working to many hours and don't have much time left over. Hope to have it back in the car this week.
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Darrell
Black '04 Mach 1
Track Times (bone-stock w/drs):60 ft - 1.90 | 1/8 - 8.67
(100 shot,E85,4:10s,Street tire):60 ft - 1.67 | 1/8 - 7.88
New build - 750rwhp; not track tested (yet)
Mods: Build Log
Paint&Body
Tuned by Manny @ HPP
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