Brendon's '67 Firebird thread by Tuske427

8 minute(s) of a 286 minute read

I got a day or so in on my car last Labor Day weekend- most of it was spent painting the trim on my house.

My project was to add the DSE brake bracket to my car. I thought it would be easy, but I had issue after issue adding it. We all have those days, I suppose. I did fill in the old holes to help smooth out the firewall. I eventually got it attached, and added some metal underneath it, too.

Then I went to mock up my Hydratech brake unit, which for some reason doesn't align with the bolt holes. So I'm working with the folks at Hydratech and it's looking like I'll need to modify the DSE braket to make it fit.

On another note I did order my brakes through Kore 3 and I'm looking forward for those to arrive.

9-11-2011

This weekend I made a little progress. Following up from last weekend I got that DSE plate welded in, only to realize two things: 1- my Hydratech brake unit wasn't fitting, and 2- I didn't like the angle the clutch hydraulic cylinder was at. There's an old saying about measuring twice, cut once. I need to learn that.

I had a little guidance from the folks at Hydratech, so that is all taken care of. Good customer service there, btw. As for the clutch cylinder, I cut back out the metal I put in and made a groove in the bracket so I could bend it to the angle I wanted. I located a hole on the clutch pedal 3" down from the pivot point to reduce the pedal travel and help firm up the clutch feel a little. I also welded the foot plates onto the levers better. I didn't like how little the factory attached them.

After being temporarily side tracked with putting the column and wheel in, I also wanted to add a clutch pedal stopper as I don't want to bottom out the hydraulic cylinder. Raiding my scrap metal bucket I pirated a piece of scrap 2" square tubing and welded it onto the side of the pedal bracket. I originally was thinking about installing a rubber plug on the end of it, but then changed my mind to make an adjustable stopper. So I welded on a nut, and have a bolt with a second jam nut on there for adjustment.

I ran out of time today so it'll have to be assembled next weekend. I also shortened the pushrod extension so that is aligned to fit. Next weekend I'll also replace the metal on the firewall I had removed.

9-25-2011

I put in some time this weekend on my front fenders. Well, one of them, and only half of it. And I started it last weekend. I'm rebuilding them to accommodate the larger wheels I plan to use. I really had to get old school on these as I don't have an english wheel, a shrinker/ stretcher, or a gas welder. I don't even have a pellet bag. So I wrapped up an old bed sheet and got the hammers out. I started to build it in one piece, but that wasn't working so I cut it into sections and was able to rebuild the inner half. I may have to notch it to make more room for my master cylinder, but I'll deal with that when I have to. I'm now starting to build the outer half. I've made a template and cut the metal, but will have to wait until next weekend to fab that, and the fender itself. My plan is to relocate the fender attachments upwards so this will still connect to one another.

I also recessed an area in the bottom corner to make room for the hoop supports that will eventually find its way in the car.

10-2-2011

This weekend I was able to finish up the driver's side front wheel well. I built the outer half, as well as made the fender modifications to attach it. I removed most of the original mounting flange, added a double wall along the outside edge to restore strength, then made a new flange welded to the inside of the fender in a higher location.

Next I added some material to reduce the large opening the oem design had. I left some room in case I use the other DSE supplied bushings for the upper control arms.

Now the real trick will be to make the passenger side look the same. I'll do my best to follow my method of building the driver side to come up with an approximate close shape. I've just started to rough out the middle shape.

I won't be working on this next weekend so it'll be a couple of weeks before I get back to this.