Mercury Cougar Owners banner

21 - 40 of 53 Posts

·
Registered
Joined
·
133 Posts
Discussion Starter #21

Well I finished the headlight door adjustment and got the lights all in and tested. Doors were sloppy when the were open until I installed the repro bushings on the center brackets. Now they open and close solid. No door movement when open or closed. Still bang a little bit but I’m not sure if that’s normal. You can hear it in the video below. Anybody that has the Cat Headlights installed it would be appreciated to know your thoughts.


https://youtu.be/zql6HqQSJlM





 

·
Registered
Joined
·
133 Posts
Discussion Starter #23
Small update on my progress. The grille is completely removed and packed up for delivery to the powder coat/painter. I'm waiting on a few pieces to finish out the packing. I hope to deliver it on Wednesday. On another note, I want to throw out a big thank you to Don and the crew at WCCC. THANK YOU! They have been fantastic through this process with parts and advice. They have stood behind everything they sold me and at times have shipped extra parts when I was trying to get pieces to fit properly. If you look back to the beginning of this thread you will see I started with a non-original grille. Don was able to source a complete grill including brackets and hardware. Pretty certain they are sick of me and I'm the bulls-eye on the break-room dart board but they haven't said it out loud to me!

Grille removed.jpg

Grill Boxed.jpg
 

·
Registered
Joined
·
133 Posts
Discussion Starter #24
I had a headlight door with a broken stud that I was able to use as a test piece with the powder coat/painter. After blasting it they said they think they could powder coat it but all the imperfections from the chrome peeling would show through. So I am going to have the cast parts body worked and painted and the metal parts powder coated.

Grill Blasted 1.jpg

Grill Blasted 2.jpg
 

·
Registered
Joined
·
133 Posts
Discussion Starter #28
Small update on my grille replacement. While waiting on the paint/powder coating (very slow...groan) I have finished the car side harness for the lights and headlight door motor. I have also made up a new hard line and bracket for the relocated AC drier. I striped out and integrated the Cats Headlight motor harness directly into my harness. I ran the power feed through the passenger fender well area into the cabin and tied it directly into a spare location on my fuse panel eliminating the inline fuse in the Cat Headlight harness. I love the mesh split looms! They are much easier to work with compared the the split corrugated plastic. As mentioned in a previous post the trigger for the motor relay is fed by the parking light circuit. This enables the headlight doors to open and the halos to light when the parking lights are turned on.

IMG_0573.JPEG

AAW Panel.jpg

IMG_0589.JPEG

IMG_0590.JPEG

IMG_0588.JPEG
 

·
Registered
Joined
·
133 Posts
Discussion Starter #29
On a side note. When I was emailing back and forth with the Cats Headlight people about stripping out their harness and tying it directly into my panel they had suggested connecting the motor power feed to an accessory powered circuit so if I turned the car off with the headlights on the doors would stay open when the accessory power was killed with the key. This would allow a way to hold the door open when you need service or work around the headlights. I thought this was a good idea especially during the reassembly adjustment process but I didn't like the idea of the door possibly being left open by accident if I shut the car off before turning the headlights off. So to achieve the same end I made a small switch harness, using a 3-way switch, that can be plugged into the power/relay feed in the grille area and allow manual or auto function of the headlight door motor when I am working on the car. When the switch is set to "open" just the doors open and stay open without the headlights coming on. When the switch is set to "auto" the doors open and close with the headlight switch as normal. When it is in the center "off" position the doors stay closed. I just simply unplug the weather tight connector and plug this harness inline then remove it again when I'm done.

IMG_0584.JPEG

IMG_0586.JPEG

IMG_0587.JPEG
 

·
Registered
Joined
·
2,172 Posts
Hey ... yes .. it is me again ..... Your wiring is looking great, as always. That is great planning ahead the with the service switch ... you should sell them to the Cats people ...
 

·
Registered
Joined
·
133 Posts
Discussion Starter #31
Thanks again nd. I’m surprised they don’t have something already because they were the one to give me the idea. I’m sure they are floating around this site. Maybe they will see it.

I picked up the cast grille pieces from the blaster and dropped them at the painter today so some progress is happening! The blaster said they should have the powder coat work done by next week.
 

·
Registered
Joined
·
133 Posts
Discussion Starter #32
It's been a while since my last post. I have had a few issues getting on board with my painter but that is all finally worked out (Thanks Don). I picked up the powder coated brackets and hardware a few weeks back and I picked up my newly painted grille yesterday so I am ready to get back to work. But first .... vacation. lol

I have done a few things while my grille was incarcerated at the paint prison. I installed the new bracket to relocate the AC drier and recharged the system to run cold again. I also installed black powder coated right and left eyebrow trim along with the hood lip trim (mine were shaved). I created templates from a pair of fender extensions to lay out the holes then used a dremel tool to route out the slots. Not sure why some pics are rotated.

IMG_0602.jpg

IMG_0610.jpg

IMG_0608.jpg

IMG_0609.jpg

IMG_0614.jpg
 

·
Registered
Joined
·
133 Posts
Discussion Starter #33
I did one other fun thing yesterday. I laid out the various options for the corral and emblem/Insert trim color combos to choose from. All the trim on my car is blacked out and I do not have any chrome on the car. So I sent a couple extra corrals and emblem/Insert pieces to be painted black and silver(silver to match brushed aluminum rim outer).

I'm liking the last option with the black corral and black emblem insert.

Painted Grille Combos 3.jpg

Painted Grille Combos 2.jpg

Painted Grille Combos 1.jpg
 

·
Administrator
Joined
·
13,577 Posts
I like the middle picture with the silver corral.

Dang! I missed out on perhaps selling a bunch of nice spares to you for this project (and I'm in NJ too). Oh well. Obviously I am not on the site much (like at all) these days.

Car looks great! I seem to recall you live in SNJ? Have you taken her to the track? Isabel's best was 12.9s ET @ 110 MPH, a couple of years back at the Old Time Drags event at Raceway Park in Englishtown before they permanently shut down drag racing :-(

I'm still enjoying Isabel, weather has been a problem though. Drove her to work today.

Regards,

Robert
 

·
Registered
Joined
·
133 Posts
Discussion Starter #36
I like the middle picture with the silver corral.

Dang! I missed out on perhaps selling a bunch of nice spares to you for this project (and I'm in NJ too). Oh well. Obviously I am not on the site much (like at all) these days.

Car looks great! I seem to recall you live in SNJ? Have you taken her to the track? Isabel's best was 12.9s ET @ 110 MPH, a couple of years back at the Old Time Drags event at Raceway Park in Englishtown before they permanently shut down drag racing :-(

I'm still enjoying Isabel, weather has been a problem though. Drove her to work today.

Regards,

Robert
Hey Robert I was wondering where you have been. I haven't seen many posts from you. Hope all is well.

The middle configuration is my second favorite. I will make my final decision once the grille is all back together and I can see the whole picture.

Yes I am in South Jersey and No I haven't taken it to the track yet.

Glad to hear you are still enjoying your car. I'm sure we will cross paths at an event sooner or later
 

·
Registered
Joined
·
133 Posts
Discussion Starter #37
Does anyone have a suggestion on the type of adhesive to use to reattach the corral to the headlight door grille? I’m thinking JB Weld but not sure. I welcome all suggestions.
 

·
Registered
Joined
·
133 Posts
Discussion Starter #38
Got back on the grille assembly this weekend. After searching the various forums I found a drill and screw method for reattaching the corral to the headlight door grill explained by 1969XR7Vert on one of the threads. As suggested I used 1/4" long #2 screws and countersunk them so the heads are flush. I used thread-lock on the nuts to keep them from vibrating off. I also decided to make a carbon fiber insert for the corral to match an insert I did on my fuel door. I'm really happy with the look.

IMG_0829.jpg IMG_0828.jpg IMG_0832.jpg
 

·
Registered
Joined
·
133 Posts
Discussion Starter #39
Got the grille all reassembled. The following pictures show the center section installed and aligned along with the brackets and the Cats Headlight motor installed.

IMG_0821.jpg IMG_0826.jpg IMG_0827.jpg
 

·
Registered
Joined
·
133 Posts
Discussion Starter #40
Here is another picture of the center section and one of the passenger side completed.

IMG_0824.jpg IMG_0838.jpg
 
21 - 40 of 53 Posts
Top