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1969 Bronco Build

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  • #16
    Now for the moment of truth...
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    Perfect!




    The fit on the engine side was so perfect and tight, I had to slide the adapter in very squarely or it could get stuck, but lined up right, it just slid right on.





    I also checked the starter clearance. Just enough.


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    • #17
      While the guys at work were machining the bellhousing adapter, I was at home working on the crank adapter. I already had to redesign this once after sourcing material proved to be difficult. Now it's a little smaller. The crank adapter proved to be a challenge to manage all the tolerance stackup over all the features of two adapters plus flywheel etc. After giving some thought to the manufacturing approach, I got started.

      Starting out with raw stock...



      ...I faced the part (after dialing it into the lathe), punched the center bore which located the 2nd crank adapter, and turned the counterbore that locates the adapter to the crank. Tolerances for the critical features were all sub-thousandth of an inch. I was aiming for 0.0003 or less deviation from print.




      Turning the hub face for the starter ring




      A-side completed.



      And test fitted
      Last edited by Digger; 03-31-2019, 11:10 PM.

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      • #18
        Now things starting getting frustrating. I spent the first 5 hours of the 2nd day trying to get the part dialed back into the lathe. After trying a few different configurations and switching measuring tools, I got it as close as possible. After reading the factory calibration report, I am at the limits of what this lathe can do.




        After finishing the B-side and measuring runout, I moved the part to the mill to punch all the holes.





        More holes




        And counterbores




        What a mess.




        After tapping all the holes, the finished product



        Checking bolt fitment vs the model





        Finally, checking fit on the engine

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        • #19
          That's some great looking work.

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