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BackMaltese Falcon: Phase One

Phase One

We will now be placing her on fixtures as she will lacking shoes and brakes for a few weeks during which time both her shoes and her brakes are having a color change.

Here she is be prepared for the many phases of this project to commence.

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Here we are inspecting this very cool looking Whipple supercharger as received for this gal. This particular unit was removed from another gal and even though there are very few measured miles on this unit we are still going to ship it to Whipple for a bit of a physical so that once integrated we are assured that there are no issues; it is as new.

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Here are removing the OEM brake calipers as we make them ready to be transformed. We noticed a large amount of rust and corrosion on much of the hardware likely as the result of her living near the Atlantic sea board. No worries as we will tend to these issues during the assembly processes.

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Here the driver seat was removed and then disassembled so that the back can be altered in such a manner that will make it more comfortable for this gal's owner.

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Here we are removing the OEM supercharger as we make her ready to received the new huge Whipple supercharger. During these processes we use liberal amounts of tape and protect materials so as to insure that no secondary damage is caused. Then once we begin the process of integrating the new Whipple supercharger we will use all new OEM gaskets and seals.

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Here we are fabricating and integrating reinforcement plates under the corners of her bonnet; these plates will prevent the fixed bonnet stops located on her cowl from inadvertently being pressed through the carbon bonnet; a problem that we have seen on more than one of the early production gals. Now these plates are being fabricated by us however they were in fact designed by Ford because they too experienced the same issue as such they integrated similar plates on the late 05 and all of the 06 model year gals produced.

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During the process above we have been tending to a comprehensive inspection during which all of her fluids and filters are being changed. We are also inspecting hardware to make sure that everything is in place and that the proper torque values are applied. As with most gals this gal has had several folks tend to her needs since new as such we want to make sure that she is by physically sound and can be safely exercised while in Texas at the rally.
We are working on numerous phases of this project with the following being tended to at this time; the battery charge port, the integration f Kip's cool carbon fiber/leather center console cubby, converting the OEM one piece front inner fender liners to the two piece system as created by Shadowman, powder coating the wheels a semi gloss black and then putting new Bridgestone tires, integrating the huge custom coated Whipple supercharger, and also integrating the custom vacuum/boost gauge as created by Michael aka FreeFlyer.
Here we are integrating the remote battery charge port system as created by Kendall aka CoolTech.

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Here we have installed this nice personal touch item at the request of her owner.

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Here we have removed the OEM magnesium center console and made it ready to have the cool carbon fiber/leather cubby integrated. During this process we use extreme care so as to insure that no secondary damage is caused; this is truly one of our favorite interior personal touches.

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Here we have taken two pair of OEM one piece fender lines and created the two piece system; the advantages of this system is that they are much easier to remove and install and even more important is the fact that the risk of secondary damage to the fenders is significantly reduced.

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Here are her shoes after being stripped and powder coated and the new Bridgestone tires installed; when we install them we also be using the very nice black one piece lug nuts as created by Derry.

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Here we have carefully removed the OEM instruments as we make ready to integrate the custom vacuum/boost gauge. The OEM gauge would not only present a skewed reading but also only reads to 15 PSI where as the Whipple with produce 19-20 PSI.

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Here we are preparing and installing the new huge custom coated Whipple supercharger; during this process we use all new OEM gaskets and seals so as to insure that there are no installation related concerns.

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Here we are modifying the Mafia and then integrating it in a custom plate as created by Shadowman. We disassemble the unit because it arrives with a shiny hard plastic coating over the wires which does not appear as if OEM as such we re-sheath the wiring with an OEM style mesh material and then once integrated on the custom plate that tucks neatly under the soon to be installed polished AccuFab throttle body it appears as if OEM rather than an add-on aka bulls-eye. We mount the custom plate to the throttle body with polished ARP bolts that match those being used to secure the Whipple supercharger.

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We have now completed several phases of this project and during the process sadly found a bit of minor damage needing tended to. While we were installing the custom two piece front fender liners we found that the driver side rocker panel has a crack in it; we have seen this before and in each case it was caused by one attempted to lift the corner of the gal improperly.
Here the custom carbon fiber/leather cubby has been fully integrated into the OEM magnesium center console and as an assembly it remains ready to be installed once we complete a few more interior tasks.

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Here is the rocker panel damage found; as you can see with the under body side spoiler in place one would never know.

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Here we have removed the damaged rocker panel and have made her ready to receive the new one once it comes out of the paint shop.

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Here we have installed the Safe Craft fire suppression bottle and the quick release mount; one more item needed for the activities at the upcoming Rally.

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Here we are adjusting the shifter cables. This gal had a Ford Racing short shifter as such we had to remove it and install an OEM shifter to complete the processes because the OEM Ford tool used to make the adjustments was designed around the OEM shifter. In the case of this gal one of the two cables needing a small adjustment.

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Here we are installing a fresh set of spark plugs; these are a performance series NGK spark plug and are also a bit cooler which works well with the increased power as created by the new huge Whipple supercharger.

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Here we have completed the paint and detail work within the gal's engine bay as we make ready to but this portion of her up.

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Here is her engine bay all button up and looking might fine; it is at this point that we can sense that she is getting anxious to go play.

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