I am going to make my best attempt to run a build thread on my latest project. I am more of an observer than I am a poster so bear with me. I am by no means an automotive expert and have no formal training in the field. I simply love to fabricate and "build" from start to finish. I have some skills developed from my maintenance career with Ontario Power Generation and I try to put them to good use. I make many mistakes and often take one step forward and two back but never loose my vision and I am always moving towards it. Take a look, do not be shy to comment or point out my misdirection's. I know that to some this may be a sacrilegious move on a Merc coupe but it was a way to keep a car that had become apart of me, my wife's 1994 Lincoln Mark VIII and build a car I had always dreamed of owning. I will start with a couple of starting point pictures and a picture of where I am at this point. Over the next few weeks I will fill in the dots as my fingers are getting sore. Thanks, Rhys.
I bought this from fellow Ontario Rodder fatchuk, he had my interest when he said the previous owner was James Dean, he forgot to mention it was James Dean from Cambridge.
A friend in Stockbridge, Georgia found this coupe for me.
The Lincoln jumped on the frame machine, positioned, checked, rechecked, double checked and then locked down.
I grabbed my favorite tools.
And here we are today. I will post some more this week in chronological order.
That is a problem with most street rods as we get older we get used to creature comforts and the rods just don't have it.This is going to be a very cool car I can just see it now cruising down the road seat tilted back music on low ac blowing cold a little rumble out the exhaust Keep us posted!
I had two issues with the 94 Mark VIII and the Merc merge, wheelbase and track width. I decided to take care of the wheelbase issue first. I had the Merc at a wheelbase of 118" and the Lincoln at 113" (I had both vehicle's factory manuals with amazing dimensional drawings). I needed some working room so I stripped the Lincoln down to get it. As I mentioned, good drawings and carefully positioning on the Blackhawk frame machine would make the wheelbase changes easy. The frame machine is Blanchard cut true and the spacing on the fixture sections are indexed perfectly.
Finally, a bit of working room!!!!!!!!!!!!!!!!!!!!!!!!!!1
A bonus with the Lincoln was the air ride on the IFS and IRS, unlimited ride heights with minor modification to the computer system. While the IFS was on the frame machine I removed the engine and transmission (another bonus with the Lincoln, one of Fords4R70W AODE transmissions and the all Aluminum modular 32 valve 4.6L engine) to get access to the K member. A good place to start with the 5" wheelbase increase was making the opposite move back with the engine and transmission. Finally some fabricating.............................
Fabricated a fixture to move the mounts back properly
Motor mounts boxed in................. but steering rack and linkages??????????????? More next post.
I used Tig wire to layout the steering linkages. I made a few attempts to get the least critical angles with the geometry and required clearances. I had the chassis welded to a fixture on wheels that I could bolt back to the frame machine. I had to place the chassis, motor/tranny with exhaust manifolds and the dash with the steering column on the frame machine a number of times to check geometry and clearance. I had to purchase a double "D" U-joint, "D" shafting and a "D" to the correct spline of the steering rack U-joint to fabricate the linkage. I also added a support bearing to the linkage to keep everything firmly in place. Next the sectioning of the front frame horns for the 118" wheelbase.
Shortened the factory length of the shaft by removing the seal weld, trimming it down and re welding the fit.
Dash back in to get proper steering column position
Exhaust manifolds back on to check clearance.
All "D" shafts were then drilled through for retaining bolts, finish welding on the support bearing and final boxing of the motor mount. I also had to fabricate a relocation plate for the oil filter housing clocking it out 90 degrees.
Well I only worked out in the garage for three hours this morning with the heat. Man that kicks the crap out of you. So I had time for more posts. I had kept the engine in position relative to the chassis or more importantly to the firewall so that I could keep the original drive shaft length, wiring harness length, etc...... So now it was time to increase the wheelbase out from the 113" of the Lincoln to the 118" required for the Merc. I had to keep the front suspension in position relative to the K member before I "Z" cut the front frame horns and increased the required 5". I made another fixture that was welded to the K member. It was doweled and flanged so that I could remove it as required.
I had a ton of spot welds to drill out to remove the strut towers or supports.
Strut towers cleared out of the way to begin laying out the frame horn cuts.
5" out ahead of the front suspension gives you 5" before the front suspension and with a quick slide on the indexed bolting of the frame machine with the K member fixture the required 118" wheelbase is achieved.
Everything checked and butt welded back together. The strut towers were then put back onto the K member with the fixture and plug welded back into their new position.
Here are my accomplishments today. I had to pie cut the floor at the tunnel to achieve the correct dash height. I manged to butt weld in the missing metal on the passenger side. That's all for now, next set of pictures will be the perimeter frame that was fabricated to tie the front and rear sub-frames (similar to a GM G-body frame), Rhys.
Excellent Workmanship Rys.. and thanks for all the time to make a pictorial for us appreciated big time..Sure glad I sold that car to you..I know it's in good hands..
Some random pictures. I stripped the rear sub-frame down and sent it out for sandblast and powder coating.
All new bushings and wheel bearings, upper and lower Aluminum arms glass beaded and the sub-frame reassembled.
Chassis on the frame machine at the onset of the perimeter frame install.
Perimeter frame attached to the front and rear frame rails. The frame was a pain to fab and install and the pictures are pretty boring so................. All the skin attached back to cover front and rear attachment points.
I get what you are doing now I thought you were doing the old style,putting the front and rear in the merc frame, but this is a helluva lot better idea.When it comes to width are they close or do you have to narrow,widen the dash? You need to put a set of valve covers on that I had on my roadster it confuses the hell out of people.
Widen or narrow you say v8deuce, well that's exactly where I was going with my next set of posts. So the wheelbase differences have been all sorted out and a perimeter frame fabbed up. The next was the track width issue. v8deuce is correct, the Lincoln has a wider track width than the Merc. I did not want it to look like a Hot Wheels car with the tires stuck way out in the wheel wells and back spaced rims were out of the question with the large rotors and calipers so i made another sacrilegious move. I widened the Merc right down the centre. This also allowed me to use the Lincoln dash without cutting it up. First things first though, body was braced and the floor cut out.
Body off to the sandblasters to find all the rough spots and give it a nice protective coating.
Body back and attached to the frame machine with a fixture all true and level.
Adjusters made to evenly move it out for the big cut.
The big cut. I will let everyone get comfortable with this before I post the metal work. Thanks, Rhys.
Yes poncho62, it will have a modest chop (3" to 3-1/2" on the vertical). Front glass is no issue as it is all flat glass. The rear will be the original from the 49 sedan so rear glass will be OEM. I will just have to widen the pie cuts a bit more than usual on a regular chop. Here is a picture of the back window going in. Is everyone ready for the grafting of roof metal?????????????????? Rhys.
I cut a rather wide section in the center for the grafting as seen in this picture. This was to keep the correct contour of the roof with the new metal.
Everytime I see a chopped roof I always look for the dip in the middle that so many guys make when the z is put in to add metal but my hat is off to you and your talent as I'm sure that roof will be perfect with a slightly rounded contour side to side and front to back and all this in a house garage!Amazing! Remind me not to pick a fight because your arms must be as big as Thor's handling the weight of that hammer for a couple hours at a time
I get what you are doing now I thought you were doing the old style,putting the front and rear in the merc frame, but this is a helluva lot better idea.When it comes to width are they close or do you have to narrow,widen the dash? You need to put a set of valve covers on that I had on my roadster it confuses the hell out of people.
Randy
I love that set up in your 32. I saw a picture of a 31 coupe with a similar "modular" in it with the timing chain "bulge" of the valve covers slightly stuck out of the side curtains of the hood. There is a nice 31 coupe for sale http://stcatharines.kijiji.ca/c-cars-vehicles-classic-cars-1931-Ford-Coupe-Barn-Fresh-W0QQAdIdZ495642252 nearby................. no.......... I need to finish this first. One day though, Rhys.
With the roof back as one I really wanted to complete the chop but I had to hold off the urge. I needed to get the integrity of the body sorted out and all the door, quarter and front fender gaps set. Why invest a bunch of time in chop work when you don't know the potential of the vehicle. I love sandblasting my vehicles it reveals everything. I ended up cutting off the bottom two feet from the front of the body at the "A" pillars and about a foot from the bottom of the rear and back end. I have a ton of pictures of the body structure repairs (not sure if you want them posted, some might be bored with all the pictures?) but I will start with what I uncovered.
A picture of the right side before I cut the inner and outer rockers out.
I made a ton of reference measurements using my smart tool (everyone should have one of these) and tape.
I made a billion of these measurements and wrote them all over the car and frame machine, you would be surprised how handy these datum points and measurements are.
I usually cringe when people say they're putting an old body on a modern chassis, but you're doing very impressive work here. Thanks for posting and please keep us updated. This is going to be an awesome car! BTW, how's the wife feel about you cutting her Lincoln up? LOL/
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My wife wants me to see things from a woman's point of view, so now I spend a lot of time looking out the kitchen window
Well I have time to post as I am off work today watching my girls (eight and eleven, they need a constant eye as they tend to get into a bit of mischief if I wander into the garage).
To answer Ragtop's question, my wife did not mind me re purposing the Lincoln. I bought here the car when it was four years old, she loved it. As the years went on it lost it's luster with the start of our family. At the point of having two toddlers to get seated in a coupe she was fed up with it. I started using it as a primary vehicle and just loved it. I could have kept it running forever and a day but with purchasing a new car in 2010 my wife wanted rid of it from the driveway. That's when I had the idea of combining the two cars, my daily driver and my next project.
I started to make body repairs at the back end, rust repair and further widening. I first filled in some pin holes in the taillight areas, I make all repairs with a TIG process, ER70 filler, as I find the finished welds are softer and easier to work or stretch.
I cut out the rusty lower taillight lower flanges and replaced them with new metal.
I cut out all of the rot and damage and replaced as I widened. Again, I left the original centre sections in to keep contour and filled on either side.
Thanks for sharing not only your build, but your thought process and detailed implementation as well. Blending new and old isn't for the faint of heart! Looking forward to your next installment.
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Nick M.
A journey in design and fabrication begins with a vision, a single pen stroke ... and in some cases the blow of a hammer.
The "B" pillar extensions, as mentioned above, were completed next. I started with the the right side by removing all of the poor metal and built it all back out.
The left side was completed in the same manner. The next series of pictures are the mating of the chassis to the body, my favorite part of the build so far. I will post that series shortly, Rhys.
I do not have many pictures from this stage but I will post what I have. I used a small gantry out on the driveway to hoist the body onto the chassis. I landed it and struggled to get the Blackhawk back in the garage with the low headroom.
Leveled out and shimmed out for a rough position
It was tight fitting over the perimeter frame with the inner rockers, I had about 1/16" clearance total when I brought the body over the chassis. I cut that pretty close.
I spent hours and hours truing everything up. I mounted the front fenders and rear quarter panels to get it centered on it's new 118" wheelbase. I also had to get a good sense of ride height so I mounted up some old tires to the size I would be running on my Caddy rims. I still will have a good bit of adjustment on ride height as I can set the original Lincoln air ride to a multitude of positions.
Then I grabbed my bead roller and some 20 gauge sheet metal and welded upside down, right side up and backwards to attach everything at the inner rockers to chassis. This sounds easy enough but for every run of weld it is a constant twist and shrink to the chassis and body. I had to readjust door and fender gaps a number of times as I went along.
The inner rockers were supported to the chassis with four structural members off of the perimeter frame on each side (that I did not take pictures of) and then the inner rockers fully boxed top and bottom to the chassis. That has brought me to this point (the outer rockers are just sitting in rough position in the picture). I now have the dash mount complete and the Lincoln firewall is welded to the Merc firewall. I am in the midst of bending up DOM tubing to support the strut mountts to the frame horns and firewall.
Next will be a series of pictures of front sheet metal repair. A bit unorthodox but the only way that I know how. You will laugh and you will cry. Any advice would be appreciated with methods, etc... I will leave off with a bit from last week, the finishing up of the trans tunnel. Thanks, Rhys.
So you have to do what you have to do. I had two less than perfect right front fenders. One on the car that I purchased from fatchuk and a second I found on the internet. These Merc fenders are few and far between so some fabing was required.
I tried to repair the fender I purchased over the internet as the professionals would but I soon came to realize I lacked the skills that many on here have. Light bumping on dolly, off dolly, etc....... This is where you can laugh.
The fender that came with the Merc. The lower section had a brazed patch panel. It did what it had to do but I wanted a bit better repair.
Now you can cry. This was my approach to the repair, it works for me. I made a tool to un-flange and remove the back support
I decided to repair the rot first so I fabed up a patch panel.
I fabed up a punch and die to match the factory indentations.
Welded in the patch.
Now to get rid of the creased section at the upper end. I took the file along this area and found good straight metal.
Most would cry here but as I said this is the only way I can pull it off.
Checked it for gaps, fit, straightness, etc..... I had to wedge, pull and pop it however I could to get it there.
that's a neat way to do a car, modern handling and drivability with old car looks. ive seen a lot of gms grafted onto caprice s but widening the body is cool, makes it different and a real head scratcher since it wont be stock width. I would add some determination and patience along with skill on this one. theres a ford truck ive seen before that uses the firewall and engine from a more modern ford , its silver and about an early fifties I think. this method also saves you a lot of wiring hassles as you are using the linc dash and stuff
I would add some determination and patience along with skill on this one.
I hear you fatstax, I had a day like that today. When I started this thread I mentioned that I take one step forward and two back many days. I am trying to tie up the bracing on the front suspension with tubing but I have to make sure that I have clearance. I fitted the front sheet metal and mocked up the grille surround. I found that the front frame horns will need to be trimmed back a bit further than I thought. This will have me moving my radiator mounts back, shorten up my battery box and effect the compressor mount for the air ride on the right side. The front sheet metal also showed that I have to trim back the strut towers as well. One days work has brought me four more back in the hole. Good thing I am a patient and determined son of a beach, Rhys.
Mock up of grille surround to test fit hood for strut support clearance.
This actually shows the total amount I widened the car, 5-1/4".
There's gonna be a few pie cuts on this hood to get this to all match up. I can't wait. This hood will take me a good few weeks alone when the time comes.
Still a bit of leveling out of the front end but the good news is all of my strut supports and eventual tubing will clear nicely as shown.
I started the strut supports today. I managed to get it where I want it with the multiple compound bends. I think this is going to support the strut towers properly. I have it tied to my 2"X3" tubing perimeter frame at the firewall and the front sub frame. I have an additional piece bent to fit in from the front sub frame to the tower support at the firewall as well. The JD squared model 32 is working great for the bends. I still have a lot of fitting before I weld it in but its a start, Rhys.
I'm tired just from looking at the pictures. That is a huge project and good for you for sticking with it. You have done some really nice work there and I applaud you for it.
i had a Mk VIII a while back and just loved it. If your Merc has the comfort and performance the Lincoln had it will be a real winner. Good Luck..
Well........................ I have no real excuses for the lack of progress here. I managed to fab up a cart for my new welding machine by early November to put in a killer season of fabbing but life and the cold winter caught up with me.
The coal fired power plant that I work at burnt it's last scrap of fuel last September 19, 2013 and I have been heavily involved in the layup of the site. So over the winter I spent most of my time organizing my belongings and home for the sale and move. I did not want to get too deep on the car and make the move harder. I was expecting to be redeployed/relocated to a new site with Ontario Power Generation on March 21 with the rest of the plant staff but I have been left behind. I continue to work to layup the equipment with a small group of staff. I really have no idea when I will now be moved.
So here I am, in la la land, no location no date. With that it is hard to get motivated on the car. I have just been spending a lot of time with the kids hanging and having fun.
Pro Stock Johnny, I have read your threads on the HAMB and refer to them often for parts and suppliers. You have a great Merc by the way. I don't often post on the HAMB as this project does not fit the traditional approach.
I will be back on the car this holiday weekend for sure. I will post updates. Have fun with your rides this long weekend, Rhys.
Was just thinking of this thread after a member sent me a PM. It has been almost a year to the day since I last updated. I have relocated to Welland and all goes well, three months in the new house. I need to get things cleaned out of the garage (and get a shed up) and get this thing out of storage. Just so much to do and address when you move (everything seems get busted and broken on a moving truck). Hopefully soon if I don't sit around the pool too much, Rhys.