Ignition switch mod

As unsophisticated the mustangs were in 1999, they still had a few very interesting electronics on board. One of them is the Passive Anti Theft System (PATS). What that means is the car need to be started with a special key that has a chip inside. This days it's almost a standard for every car to have this feature. In 99, and I am sure Ford introduced it even earlier in some other cars, it was an innovation. The system is not very complicated and does not really have that many parts. The on-board computer ECU has at most 3 keys programmed. The key has a special chip inside. The last link in the chain is the ignition switch closing the circuit. The plan is simple you take the right key, stick that into the ignition switch that reads the chip, the ECU matches the code of the chip in the key to that stored in memory. If everything matches the car fires up!

Most of the time the builders of the custom cars can't be bothered with all this complexity. However, I have it already from my donor car so why throw it away? The donor ignition switch and lock cylinder are actually fairly far apart. There's a linkage that translates the turning action of the key into a sliding action on the switch. This parts are all made to fit on the mustang but would not fit behind cobra's dash. Let's make them fit!

This is how the housing looks like for the lock cylinder.

I have marked the blue line to cut off the excess of the material.

After some grinder action

Here you can see how I reused the linkage to connect to the ignition switch. The angle bracket here is temporarily. It's holding the parts together for now. Once I get closer to the dash mounting I will fabricate a real bracket that mounts to the frame behind the dash. 

The pinnacle of my engineering

Originally, I was looking at the assembled cobra cars and loved the relocated oil filter. It's part of the cool factor. Then I was doing though all the parts and was happy to see the relocation kit included from Factory Five. I even ordered a couple of K&N filters from Summit. However, when it came time to install, I learned that only small blocks and big blocks really need that. My mod 4.6 actually works fine with the original location of the filter. Normally, I would not mess with engine's oil system unless I really have to. In this case, I "really have to" :) For some crazy reason Factory Five includes the oil relocation kit that fits on 302 block as part of my 4.6 package. I had a disappointing chat with them to learn that I don't use that part but have paid for it. Factory Five for you! Oh well, Summit gets a next order for an oil relocation kit for 4.6 motor.

This is where things get a bit tangled. The location I have selected for oil filters is actually near the steering shaft and steering column. However, on the other side of the same location I was thinking of placing the power distribution box. Also just above that I have the coolant reservoir. It may look like all of this are very loosely dependent but you'll see what I had in mind.

First of all, my birthday has just past and apparently for a round number of 30, many people give much more cash then I expected. All that meant, I got a Lincoln Electric welder. It freed up my imagination for new level of parts fabrication.

Well, the welding machine is nice but it's only as effective as my welding skills. Let's see what I can do. This is the coolant reservoir mounting bracket. The reservoir bolts up with two bolts. The problem is the bolts are poorly accessible. The solution is to weld them to the bracket.

First attempt was recorded as a success. The weld is neat and looks good. Here's how the reservouir will look like in final position.  

Next one up is the power distribution box bracket. It was intended to fit on the mustang fender. I tried different locations but stopped at under the coolant tank on the x brace.(see above where the red wire is passing through). Let's modify the bracket

Now this is the end of the beginners luck. I present the proper "booger weld".

There's actually an inverse relationship between welding skills and grinding skills. Here's the proof: 

Now that bracket is drying up the new coat of paint. Meanwhile I need to crop a new plate that will be the mounting spot for the third coolant reservoir support, the power distribution box bracket and my oil filters. I used a peace of cardboard to create a template for the round tube frame.

The left is shape that the plate on the right should have.

From the front of the car

From the engine bay

Now time to bend the original support rod into the new shape

Cut it off and thread the end

Here's the mock up fitment of all three parts together. The rod above is serving as a mounting bolt for the bracket. I have exceeded my expectations here. :)

See how the dual oil filters look like in the engine bay. They are very accessible from the bottom and are high enough to be away from the dangers of the road.

This is the entire assembly ... assembled. I actually did measure things here. That power distribution box actually has a swing stile lid. That lid will open and follow the curvature of the coolant tank. This fact alone promotes this from a "blog post" to a "success story".

Yeah yeah, I need to clean up my parts, my desk, my garage, my room.