TeamCapri

General => Build Threads => Topic started by: ReedStemen on March 21, 2014, 12:11:23 AM

Title: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on March 21, 2014, 12:11:23 AM
Hi, my name is Reed. I'm in my early 20's and have owned about 10 cars. My dad and I work on cars for fun and fix up old clunkers. My current daily driver is a silver 1991 Mercury Capri. I'm the third owner and bought it right at 100,000 miles. This was never supposed to be a project car, just a daily for me to get by while working on my 1991 Toyota supra turbo project. As fate would have it, it soon became a project when the auto transmission went into nuclear meltdown mode. I have spent one month and $650 on swapping a 5 speed in my dad's garage, and it has been a great experience. I had been doing other work to the car before this and it has turned into my daily driven project car that I now enjoy more than my supra in terms of "fun factor". I names this car "Project Personal" as I have learned many life lessons from this little car... More so than other sports cars I've rebuilt in the past. The realization set in of how lucky I am to have a dad that cared to show me how to work on cars and is willing to help me. I realized how nice it is to have family and friends whom are willing to loan me their cars when I didn't have a car to drive. I realized how lucky I am to have a girlfriend willing to put up with my shenanigans. Finally, I discovered that a car needs to be build the way the builder wants, as many people will not like and/or criticize the work. This is why I am building this little car up for me and the way I like it. This is Project Personal. I will be uploading pictures of stuff I have done to the car and will be adding as I make more changes.

-Reed
Title: Re: Project Personal - Reed's 1991 Capri
Post by: grantduffield on March 21, 2014, 03:34:17 AM
Reed -

First things first:  Welcome! 
I suspect folks are going to be very interested in the automatic to 5 speed swap.  I know I am. 
Title: Re: Project Personal - Reed's 1991 Capri
Post by: Chicken on March 21, 2014, 11:40:14 AM
From the lessons you've shared in your post, it sounds to me that you're ahead of many project owners.  Good for you!
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on March 22, 2014, 01:32:51 AM
Ok fellow Capri people, here's my little hotrod. Paid $1100 and I put $500 into some new tires on used 15" wheels as soon as I got it in summer 2013. This replaced my Buick century which was having many mechanical issues. Ironically the guy I bought it from had bought a Lexus SC400 off of me... Small world. Downside to car was/is a salvage title from a wreck and rebuild and auto trans, but it's all good.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/95B64459-9E6D-4CA9-BF67-8D126152D961_zpszqcjylta.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/95B64459-9E6D-4CA9-BF67-8D126152D961_zpszqcjylta.jpg.html)

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/E12FC715-FCE5-44CB-BDEC-0B2A555AC955_zpsa3of0wn8.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/E12FC715-FCE5-44CB-BDEC-0B2A555AC955_zpsa3of0wn8.jpg.html)



(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/3B3D9148-8E41-4D78-9D93-5F03FED6C53E_zpsthgqei3f.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/3B3D9148-8E41-4D78-9D93-5F03FED6C53E_zpsthgqei3f.jpg.html)
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on March 22, 2014, 01:52:48 AM
If my pictures aren't showing up right let me know as I'm not much of a "forum guy" and will probably mess something up. Anywho, I put a couple thousand miles on the car right away. The previous owner had recently replaced the upper engine mount, ignition components, fluids, fuel filter, and a few other bits and pieces. It was running pretty good but I can't drive a stock car... Tweaking (not to be confused with twerking!) is necessary. First up over fall season was this pile of goodies.


(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/8B09B026-CF60-486C-9D07-C09EA4F37943_zpsl3clgh4j.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/8B09B026-CF60-486C-9D07-C09EA4F37943_zpsl3clgh4j.jpg.html)

Auto trans fluid and filter, auto trans pan gasket, spark plugs, new rotors and pads, cadence audio door speakers, mobile one high mileage full synthetic oil, purolator oil filter, hidden antenna modification, full LED interior modification, and a new headunit.

So this is how round one went: mediocre. Ok, I did a full refresher on the auto trans just to have it go into nuclear meltdown mode a month later. The auto parts store got me the wrong rotors and I had to wait a week for the correct ones to come in. Guess mine are the bigger ones? Also I found out about the poor engineering design of having the rotor on the backside of the hub which requires full disassembly. I decided not to install the muffler and enjoy the song of a strait side pipe. Bad idea. Improved LED interior lighting? Yes please! Until I shorted out a light bar by making a mistake on my wire routing and driving a screw through the wire.

So, not so hot on the first go, but I recovered.

Here we see the brake swap and bleeding in progress.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/7901BA6F-4305-422F-8139-F47F4335910D_zpshqmun9k5.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/7901BA6F-4305-422F-8139-F47F4335910D_zpshqmun9k5.jpg.html)



Cadence compared to factory. One was blown and the other was held in with duct tape. A little TLC got the audio squared away.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/4C1A8B93-7DB1-42D2-A553-68C82C12E350_zpsavnais3d.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/4C1A8B93-7DB1-42D2-A553-68C82C12E350_zpsavnais3d.jpg.html)
Title: Re: Project Personal - Reed's 1991 Capri
Post by: Rocketman on March 22, 2014, 04:45:02 PM
Fantastic project. Im glad it's giving you more than a mechanical education.
If you're indeed in Ohio I would highly recommend trying to make it to one of the big meets, the MACG is in Illinois this summer or the NECG will be in Eastern PA in late summer/early fall.

I'll probably be in western PA/ohio area for a Ford Festiva meet on May 24, if you want to come meet and gearhead with us. You'll meet some really neat people with your Capri. I'm hoping to be there in my red XR2 for once, lol

I'm digging the seats.
And yeah, the nonturbo cars sometimes got the bigger rotors, I haven't been able to figure out a pattern for that one yet. Measure first! :D
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on March 22, 2014, 11:06:42 PM
I'll try to make it to a meet! I'm on the north west side of ohio but I drive to meets, like import alliance in Nashville. Thanks for invite!

Just to add a bit more accent to interior I put black speaker mesh in the door panels rather than the factory grey ones. Adds a bit of contrast. They are held in with bathtub silicone.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/EFF8318F-8372-4165-A033-B9DC6D7C02D1_zpsewq3zkoq.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/EFF8318F-8372-4165-A033-B9DC6D7C02D1_zpsewq3zkoq.jpg.html)

Like many other capris, my glove box handle was broke off and it was a pain to open it. Roo sport to the rescue! Metal glove box handle for extra durability. It's great quality and works perfect.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/F550EB1D-DCE4-4B5C-B220-EDA6A79C8C68_zpsvdlmobwx.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/F550EB1D-DCE4-4B5C-B220-EDA6A79C8C68_zpsvdlmobwx.jpg.html)

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/83755719-57E9-4016-8795-F538B35C345B_zpsdeobnnwi.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/83755719-57E9-4016-8795-F538B35C345B_zpsdeobnnwi.jpg.html)


Smoked turn signals.


(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/038B06F0-DC37-4B9C-9970-5F66AE328933_zps9z1jtqhb.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/038B06F0-DC37-4B9C-9970-5F66AE328933_zps9z1jtqhb.jpg.html)

Title: Re: Project Personal - Reed's 1991 Caprip
Post by: ReedStemen on March 22, 2014, 11:23:24 PM
So I'm also into car audio... You know, the big impractical obnoxious systems that most people outgrow. I've not outgrown it yet. So I tried two sony xplodes I got for $20 and they weren't good enough. So I got this JBL competition series 12" hooked up on an audiobahn 1800 watt amp. This was an afternoon setup wih undersized wire and charging system, so it never really got anywhere. Also it was extremely impractical with the spare tire out and box fillng trunk.


(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/2E62A588-0793-43A1-A875-620E95633F48_zpspdayd8fi.png) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/2E62A588-0793-43A1-A875-620E95633F48_zpspdayd8fi.png.html)

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/D0EB4A37-D3C4-4AA0-B476-CD5A9A96749F_zps06g0qmui.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/D0EB4A37-D3C4-4AA0-B476-CD5A9A96749F_zps06g0qmui.jpg.html)

By this time I had a low quality DUAL headunit got for free as my factory radio did not work. I recently trade the sub and box for a nearly brand new pioneer double din headunit I've been wanting and I have yet to install it. I did relocate the battery to the trunk, installed a C&D gell cell industrial battery ran 0 gauge wire to the front with a 120 amp fuse and 0 gauge ground. Here you see a mockup of a little soundstream t5 10" that will be much more practical in this little trunk.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/41072777-830C-4C5F-8C65-6665D97D31E6_zps1qxkrne8.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/41072777-830C-4C5F-8C65-6665D97D31E6_zps1qxkrne8.jpg.html)


(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/BFAC48C9-5738-4DE0-B5D5-50EC9A702F3D_zpsrtnehwal.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/BFAC48C9-5738-4DE0-B5D5-50EC9A702F3D_zpsrtnehwal.jpg.html)


(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/2DC314F8-6DD9-409D-A040-DB860EED0A5F_zps9rirtuit.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/2DC314F8-6DD9-409D-A040-DB860EED0A5F_zps9rirtuit.jpg.html)

Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on March 22, 2014, 11:31:39 PM
Four 12" led light strips. Two under dash, two on upper windshield surround behind the sun visors. The stock lighting was terrible and I could see nothing at night. Problem solved! I also wired an additional grounding switch parallel with the door jam switches so I can turn them on from the dash... An option the car was missing from factory. Nice for looking at maps or instructions.


(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/6C3B2147-45EA-4BD1-B77E-0E58BF783D0A_zpspkmqj4mq.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/6C3B2147-45EA-4BD1-B77E-0E58BF783D0A_zpspkmqj4mq.jpg.html)
Title: Re: Project Personal - Reed's 1991 Capri
Post by: Chicken on March 23, 2014, 10:17:50 AM
Good work. Have you seen the optional rear view mirror with map lights built in. I can get you one next time I see one.  The wire that runs to it is a PITA to get the connector out from behind the dash and all the obsticals there.
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on March 24, 2014, 12:52:37 AM
Yes I have seen those and have one out of a modern Ford I was going to install, but the LED strips behind the visors are placed in a convenient location so they're not blinding in the line of sight. Thanks though!

So now here's the good part... 5 speed swap! Basically, the auto trans was on its way out. It was not until after I bought the car that I found out how poor of quality the auto transmissions were in these cars. When I did the first round of maintenance I had replaced the transmission filter, fluid and pan seal. I figured this would help the transmission with its minor shifting issues. Unfortunately, the slicker Lucas Oil fluid actually made it slip worse. I finished of the trans by buying a DelSol and towing it home with the Capri. Oops! I was not going to put another one of these slush boxes in, so I started planning my attack at a five speed swap.

For anybody interested in doing a trans swap, here's how to attack it. First, determine whether you want to spend $500-$700 on everything for a N/A transmission swap, or $600-$900 for a turbo XR2 5 speed. Rocketman can explain the differences better than me, but basically the Turbo 5 speed is beefier with a bigger flywheel, tougher clutch, different differential, and mechanical clutch. The N/A version is smaller, thus handles less power and has a hydraulic clutch. My money numbers are based off of the assumption you are in the same positions as myself; no personal connections, no existing parts, purchases from junkyards and buying a brand new clutch and components. Pricing will vary by location (I am in Ohio). I settled on a N/A swap as in my area the turbo transmissions alone were $400 and the N/A's were $200-$300. I am on a tight budget with school and wanted maximum efficiency with small drivetrain components, so this route made the most sense to me. Also, swapping in a cable operated clutch is a bigger pain under the dash than the hydraulic counterpart. Working under the dash is no fun.

Now that you have decided what swap to do, here's what you need: Transmission, manual axles left & right, slave cylinder, 36" hydrolic line with two inverted adapters (available at most speed shops), clutch master cylinder, clutch pedal WITH bushings, metal sleeve, cylinder push rod, safety switches, and the ubber long pedal bolt. You'll also need a flywheel specific for the N/A 5 speed and a resurface job, axle nuts, new clutch, new pressure plate, new flywheel bearing, new throwout bearing, shifter assembly including the shifter, floor mounted bracket, stabilizer bar, shift bar and whatever hardware is needed to bolt everything together, axle output seals, and a rear engine main seal if you want to go about swapping it out while everything is apart.

Important Tips: Buy an Exedy complete clutch kit as this is a great quality kit and includes the clutch, pressure plate, throwout bearing, and flywheel bearing. For the clutch pedal, don't buy just a pedal off of ebay as most don't come with the little bits and pieces needed to use it. Find a junk car and rip out everything from the pedal box that is associated with the clutch pedal. if you can, get the ubber long pedal bolt out that holds the clutch pedal and brake, otherwise you'll be paying $20 for a specialty bolt from fastenal or finding a hardened 3/8" bolt from the hardware store. This is no easy task, trust me. it's a weird bolt. For the hydrolic clutch line dont screw around with trying to get the factory hard/soft line thing to work. Buy a 36" premade braided stainless steel soft line and have the shop order the specialty adapters to bolt it onto the master cylinder and slave cylinder. Make their life easy and take yours in for them to see. Also, your pedal box is ready for the clutch pedal, and the firewall is ready for the master cylinder... just unbolt the block off plate. No modifications necessary. Another tip, have someone help you. Most of this work is "awkward" and is much easier with an extra set of hands. When you're working with hardware on this car, alot of threads are fine thread... 1 pitch, not 1.25. This includes the nut that holds the shifter stabilizer bar to the rear of the transmission. You can reuse the flex plate bolts on the flywheel as they are the correct length. Remove the starter from the bottom of the car... it's much easier. label bolts and organize parts so everything is easy to put back together. When slipping the transmission onto the engine, have someone kick/push from the wheel well area while someone else hangs over the fender and juggles & twists the trans to get it to slide on. This was the most effective method for us.


Sitting patiently to be resurrected.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/3EB73CDD-EA91-4F1C-AC5F-66146B223954_zpsaacby2ui.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/3EB73CDD-EA91-4F1C-AC5F-66146B223954_zpsaacby2ui.jpg.html)

The horsepower robbing slushbox is out.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/0F18E02A-5C5C-4BB4-B88F-EFECEB90569A_zps7n4vn9bk.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/0F18E02A-5C5C-4BB4-B88F-EFECEB90569A_zps7n4vn9bk.jpg.html)

Flex plate removed, ready for a flywheel.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/0AC3ACF9-8AC0-4B5E-863C-14EE625AA7B4_zpscbzgq5gu.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/0AC3ACF9-8AC0-4B5E-863C-14EE625AA7B4_zpscbzgq5gu.jpg.html)

This hideous eyesore will soon be gone.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/600C18C5-8485-471F-AF5B-4940FEB2442B_zpsoh3xx2ia.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/600C18C5-8485-471F-AF5B-4940FEB2442B_zpsoh3xx2ia.jpg.html)


One final thought on this project... don't be intimidated by it as this job is fairly strait forward as long as you have the tools, time, and a location. This took me four weekends to complete working partial saturdays and full sundays. I had around $650 in this, but many of my parts were new and I had very poor parts availability in my area which drives up cost. The biggest challenge is finding the parts. You WILL be traveling for hours and have a decent amount of money in gas. That is, unless you find a complete donor car, which those are becoming more rare with every year.

Goodnight all, I'll be back with more pics and info in the coming days.

-Reed
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on March 27, 2014, 10:55:06 AM
New front engine mount and transmission output seals. Mount is to a 323, a little different... you'll see why later.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/427D87DE-67BB-42ED-B027-FB80EB8CC8CA_zpsqyr2nybw.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/427D87DE-67BB-42ED-B027-FB80EB8CC8CA_zpsqyr2nybw.jpg.html)

N/A flywheel, resurfaced by Kalvinator Engine in Wapakoneta Ohio. http://www.kalvinatorengines.com/

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/94CBB2C7-8CDE-447B-9E61-250DAB0A0D06_zpsjiaqaz0d.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/94CBB2C7-8CDE-447B-9E61-250DAB0A0D06_zpsjiaqaz0d.jpg.html)

Different length axles for manual trans. 88 Mercury tracer axle will work for right side. Had to drive four hours round trip for these bad boys but they were right price and joints were fresh.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/DF7DAD97-F5E9-42A6-A4DB-71C8CC32BCC3_zpseqslqsij.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/DF7DAD97-F5E9-42A6-A4DB-71C8CC32BCC3_zpseqslqsij.jpg.html)

#racecarstatus

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/B14C1C29-5225-4E71-90FE-2C2909427238_zpsw9sh2odj.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/B14C1C29-5225-4E71-90FE-2C2909427238_zpsw9sh2odj.jpg.html)

Stripped and ready.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/AD95D461-ABE0-4C8F-877E-19A857FDA03F_zpsjmkck6az.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/AD95D461-ABE0-4C8F-877E-19A857FDA03F_zpsjmkck6az.jpg.html)

Manual plate painted and bolted in.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/E3A4D6B6-21EC-464B-B767-A875AEA29262_zpszvkhlwlu.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/E3A4D6B6-21EC-464B-B767-A875AEA29262_zpszvkhlwlu.jpg.html)

Brand new Master Cylinder, pretty sure I got it from Dorman. Firewall already has provisions to bolt it in, nothing custom.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/A196ED82-448E-4EFD-AE16-1D79144D3BF9_zps1dkeyy9z.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/A196ED82-448E-4EFD-AE16-1D79144D3BF9_zps1dkeyy9z.jpg.html)

Baby clutch ftw.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/EF77E932-105C-451B-B05D-ADA17860CB50_zpsmtetoqzu.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/EF77E932-105C-451B-B05D-ADA17860CB50_zpsmtetoqzu.jpg.html)

More to come.
Title: Re: Project Personal - Reed's 1991 Capri
Post by: Chicken on March 28, 2014, 02:32:10 PM
You're gettin lots done and done right.  How are your leather seats?
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on March 29, 2014, 12:40:09 AM
The seats are super comfy and add some much needed support and low fitment to the car. I have not worked on repairing the leather on the driver seat yet, but it's in the near future.

Sourced the shifter lever components from a '94 for $120. more than what I wanted to pay but I had already spent a couple hours and $70 in gas looking for one so I just dealt with it and spent the cash. Soaked in PB blaster, cleaned it up a bit and got it working smooth.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/6AB183FA-1120-4A8B-844C-4D01CA4E54FD_zpsxhye5zii.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/6AB183FA-1120-4A8B-844C-4D01CA4E54FD_zpsxhye5zii.jpg.html)

Manual trans in.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/B65DB082-08C9-4667-BE95-F7D687336009_zpsfppe6myr.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/B65DB082-08C9-4667-BE95-F7D687336009_zpsfppe6myr.jpg.html)

Here's some side work. Cleaning and painting bits and pieces. Also replacing none structural hardware with all stainless.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/970E6545-3037-44C8-B625-8D6E3CCBBA54_zpscz0lklud.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/970E6545-3037-44C8-B625-8D6E3CCBBA54_zpscz0lklud.jpg.html)


(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/3E78ADE7-648C-4B2E-9A9D-9D966B37E856_zpskelqzfcj.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/3E78ADE7-648C-4B2E-9A9D-9D966B37E856_zpskelqzfcj.jpg.html)

This valve cover is not racecar status.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/6D6BC358-A66A-4039-B45F-A4B90AD3C8B1_zpskjiioq29.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/6D6BC358-A66A-4039-B45F-A4B90AD3C8B1_zpskjiioq29.jpg.html)

That's better! Even treated it to some new grommets and seal.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/89DA2EEF-C727-47E4-B4CA-791F956D43A1_zpshm6byd1c.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/89DA2EEF-C727-47E4-B4CA-791F956D43A1_zpshm6byd1c.jpg.html)
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on March 29, 2014, 12:54:23 AM
Shifter in.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/59939FD9-5812-4B37-8253-848463A20892_zpskrojklsp.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/59939FD9-5812-4B37-8253-848463A20892_zpskrojklsp.jpg.html)

Got that third pedal hanging, huge thanks to my dad for his help with this one. I did not hook up any safety switches, I'll just remember to put it in neutral before turning it over to save hours of wiring and hanging under the dash. Found some OEM replacement covers for the pedals.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/52F9149A-5FAE-43F4-B134-0F7EFD38A337_zpso0oiur94.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/52F9149A-5FAE-43F4-B134-0F7EFD38A337_zpso0oiur94.jpg.html)

36" Allstar Performance Braided clutch line installed with special adapters.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/00D1276A-7D1D-4964-A33E-1A718D13372B_zpscwbhc7n5.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/00D1276A-7D1D-4964-A33E-1A718D13372B_zpscwbhc7n5.jpg.html)

So the airfilter was shot. Rather than replacing with a factory style filter, I removed the entire airbox. The compartment looks cleaner, the Spectre filter has a lifetime guarantee and is washable, and I can actually hear the growl of the little 4-banger. Maybe a bit more power too?

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/D2EB338C-F9FB-4ECA-9E8C-AB6073BB78C3_zps4hidanho.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/D2EB338C-F9FB-4ECA-9E8C-AB6073BB78C3_zps4hidanho.jpg.html)

Custom intake bracket made of an old exhaust bracket and modified to tuck my ignition coil nice and neat.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/D056ACBE-51E2-4523-89D1-D3116310FB21_zpssmtpc9rd.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/D056ACBE-51E2-4523-89D1-D3116310FB21_zpssmtpc9rd.jpg.html)


Title: Re: Project Personal - Reed's 1991 Capri
Post by: Rocketman on March 29, 2014, 07:07:03 AM
I am surprised you kept the auto assembly and just added the clutch pedal to it - the manual assemblies have a much narrower brake pedal to fit in the middle. What that easier to do?

Nice valvecover! I am hoping to have a re-designed trim plate available soon to cover the plug wires
Title: Re: Project Personal - Reed's 1991 Capri
Post by: 94daves on March 29, 2014, 01:36:03 PM
Great pictures and descriptions.  I enjoy reading about your project and seeing it progress.  I like how you're taking the time to clean and improve as you reassemble.  Your valve cover looks great.  How did you clean it?
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on March 29, 2014, 10:41:55 PM
The pedal box or whatever it's called is a bit time consuming and irritating to remove. The auto pedal box is the same thing, even has the mount hole drilled. When I pulled the clutch pedal from the junkyard Capri I pulled everything I could involving the pedal, but didn't even thing about the brake. I'm used to it now but I need to cut the brake pedal down so people don't smash the brake when they go to shift... Although it is funny.

Thanks for the kind words 94daves! I used aircraft grade paint stripperand a wire wheel on a drill. There were a lot of splotches left and I had to spend about 45 minutes with a paint scraper. I sprayed high temp paints; primer first, metallic aluminum second then lightly speckled it with gunmetal grey and coated in clear.

Rocketman I am interested in the spark plug cover plate. Have pics? I like a clean engine bay and mines a work in progress, lmk price and info please!
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on March 29, 2014, 10:50:40 PM
Interior light switch. For anybody curious the advance auto parts touch dimmer switches fit right into the dash like factory. Unfortunately they work like crap, so I ripped the guts out of mine, drilled a hole through it and mounted up a rocker switch.


(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/FE6FCAF9-BC11-40CA-8135-219AC1DF7DF2_zps5ojuyvwa.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/FE6FCAF9-BC11-40CA-8135-219AC1DF7DF2_zps5ojuyvwa.jpg.html)

Here's my all metal high current headlight switch to replace the broken factory one.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/655844AF-00C6-4F41-AE27-6ACE15CFBB2B_zpsann4zjoo.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/655844AF-00C6-4F41-AE27-6ACE15CFBB2B_zpsann4zjoo.jpg.html)

;)

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/25BEDF03-4A91-4FF3-B073-3B815C23FBFE_zps2f9bu9pf.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/25BEDF03-4A91-4FF3-B073-3B815C23FBFE_zps2f9bu9pf.jpg.html)
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on March 31, 2014, 11:19:17 PM
Before:

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/5DA4BC7C-A561-42F9-8451-D6E637E8DBD4_zpsrp4bn1kn.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/5DA4BC7C-A561-42F9-8451-D6E637E8DBD4_zpsrp4bn1kn.jpg.html)

After... still not washed, but it's getting there.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/DC5998D6-0B68-4D41-9474-A9DB7082F53F_zps67qma4vl.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/DC5998D6-0B68-4D41-9474-A9DB7082F53F_zps67qma4vl.jpg.html)

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/C060D311-062A-41A4-B578-6AC719705C18_zpsbjjtykk6.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/C060D311-062A-41A4-B578-6AC719705C18_zpsbjjtykk6.jpg.html)

Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on March 31, 2014, 11:38:22 PM
So I've been experimenting with high performance economy mods and driving styles with the Capri. I went from around 24 MPG with the auto to 28.5 average MPG on a tank with the new manual. I also surf around on ecomodder.com... check it out if you haven't, good info. My daily drive consists of about 60+ miles so I've been practicing more economical driving. Shifting at 2000 RPM every gear, coasting when possible, and some aero mods. I recently completed a front air dam made of modified lawn edging and full stainless hardware. Helped 55-70 acceleration power and off power coasting distance noticeably. Also blocked off small grill/driving light inserts with some duct tape but fiberglass is planned in the future. I also bent the license plate and mounted it up in front of the grill to stop some airflow (no temperature issues... N/A love lol). I have been coasting 4-6 miles on the daily, and that adds up. Last tank without air dam got 31.5 MPG average. Hoping to be around 33 with air dam and aero mods. Ecomodding turns into a competition. More mods planned.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/IMG_1939_zpsdd5ad027.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/IMG_1939_zpsdd5ad027.jpg.html)


(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/IMG_1942_zpsb9fafb1b.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/IMG_1942_zpsb9fafb1b.jpg.html)

Another aspect of the car receiving treatment is the interior. The back seat was useless so I ripped all that junk out including the seatbelts. I'm in the process of making a compartment area out of wood and I'll be carpeting everything. Also the spare tire will be moved to the cargo space for the in-floor subwoofer box.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/IMG_1935_zpsdf511bcf.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/IMG_1935_zpsdf511bcf.jpg.html)

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/IMG_1936_zpsb2905ddb.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/IMG_1936_zpsb2905ddb.jpg.html)
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on March 31, 2014, 11:58:42 PM
Here's an important tip for anybody swapping a five speed. The auto trans had a park ignition lockout that will cause the car not to start without it plugged in. Simply strip these two wires and twist them together to complete the electrical circuit and get the car to start. These were attached to a white three-prong plug by the airbox/cruise control module. There's a third wire there that does not have power, you can let that chill and chop the plug.

(http://i118.photobucket.com/albums/o113/reedstemen2/Mobile%20Uploads/IMG_1941_zpsf98e44ee.jpg) (http://s118.photobucket.com/user/reedstemen2/media/Mobile%20Uploads/IMG_1941_zpsf98e44ee.jpg.html)

I have not yet figured out how to get the "manual shift" light to stop flashing on the gauge cluster.
Title: Re: Project Personal - Reed's 1991 Capri
Post by: Rocketman on April 01, 2014, 02:15:46 AM
Did you pull out the automatic's computer out?

You should be able to get significantly higher than 33mpg. Russ's blue 94 (he's since sold) we had a high-comp N/A engine with a turbo, XR2 trans with .717 5th gear swap and bubbletop/F40 wing which aren't exactly beneficial but he/we got just under 40mpg with it.

My old modded XR2 achieved 36mpg at one time on the highway. And my AWD capri with a bigger engine somehow managed an avg of 33mpg over a 1600 mile trip, figure that one out lol.

You can play with the TPS a bit, it will cut fuel sooner but it makes it jerky to drive as the power comes on/off suddenly. Tires & wheel combo make a difference, the smaller & narrower the better. Lowering makes a decent difference as well

Nice work, I'd like to do a front lip or air damn & some underbody paneling on my red XR2
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on April 01, 2014, 11:56:33 AM
My funds are limited currently but I would like to lower the car, replace the oxygen sensor, fabricate a fiberglass bubble top, and put a tubular header on to help with efficiency. I need to adjust my timing too which might help. My trans has .820 5th gear ratio so it's running a little higher RPM on the highway which might not help. fueleconomy.gov rates the car at 21 city, 26 highway, 23 average so I'm well above that atleast. I'm not sure how yours are so high? That's impressive. Either way it's better than my Supra's 14-18 MPG! Haha.

Oh an no I have all auto electronics. I tried to find a circuit to bypass to trick the ECU into shutting off the manual shift light, but I think it's integrated into the ECU's programming. I'll just pop the light out of the gauge cluster.
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on April 01, 2014, 12:26:22 PM
Here's the first test pull with the capri after the clutch break in period, much better acceleration than the auto provided. Seat of pants dyno says atleast a 5-10 HP gain.

https://www.youtube.com/watch?v=prUDKmA3keg&feature=youtu.be
Title: Re: Project Personal - Reed's 1991 Capri
Post by: Rocketman on April 01, 2014, 12:46:44 PM
The XR2 not only has a taller 5th gear but a taller final drive too, 3.85 vs the F's 4.105. My numbers are a little high but not unusual.

The N/A has shorter gearing to make the car feel peppier at the cost of top end, and it does have a small effect on overall economy it seems.
The ECU's & ignition timing are the same between both N/A engines, so that's not affecting anything.

Since your car was originally an auto, you have 9.0:1 CR (n/a manuals had 9.4:1, autos were 100hp and manuals were 116hp) and a different exhaust camshaft tailored specifically for low end torque. Grab an exhaust camshaft from a manual car and drop that in there, your powerband will feel a lot better and more natural with the 5spd, and your highway speed volumetric efficiency will shoot up and increase your MPGs as well.

I have a line on a tubular header, if you're interested PM or email me
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on April 01, 2014, 01:21:58 PM
That's some good knowledge right there, thanks for the info. I'll see if I can source one. Wouldn't a higher compression N/A have better fuel economy and power than a lower compression N/A? Or is the power difference and economy difference in the head? Is the block and rotating assembly the same?

PM sent.
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on April 01, 2014, 01:34:23 PM
I might be thinking backwards... is 9:1 considered lower compression ratio than 9.4:1 because there is less air being compressed? If so then my engine is likely losing efficiency because of a lower compression ratio and being naturally aspirated correct? would a manual B6 head swap increase compression ratio and improve MPG?
Title: Re: Project Personal - Reed's 1991 Capri
Post by: Rocketman on April 01, 2014, 05:11:51 PM
9.0:1 is lower than 9.4:1 It's not a huge difference, by comparison the XR2 is 7.9:1 CR Going to n/a pistons or custom higher CR pistons in the turbo motors is quite popular now, it improves off-boost economy and power

The heads are all identical. The compression ratio difference is in the pistons - The pistons have more or less of a dish in the center, meaning it breathes the same, it just doesn't 'squeeze' it as much. Higher CR does mean more efficiency but the difference isn't much between the two.

I'd say grab the camshaft from a manual B6D and call it a day. You could grab one from a 1.6L manual Miata engine too
Title: Re: Project Personal - Reed's 1991 Capri
Post by: ReedStemen on April 02, 2014, 12:06:27 AM
I've got some miata buddies, I'll try to source one. Thanks for bringing that up and thanks for the lessons! This tank of gas currently with the front air dam is looking promising, can't wait to fill up and check mileage. Ecomodding is a competition!