Converting
a '79 Capri to '86 Mustang power
This is my 1979 Mercury
Capri. Basically the same as a Mustang (at least from '79-'86). I
built this car in the fall of 1993 when my '86 Mustang GT got totaled by
a little old lady. The Mustang got hit on April Fool's Day the same day
Alan Kulwicki was killed. After moping around for a while and finishing
my engineering degree from the University of Arizona (BSME), I built this
Capri using the totaled '86 Mustang, the settlement (about $6000), and
parts that I gathered in trade for labor. The labor involved rebuilding
T-5 transmissions, installing clutches, headers, cylinder heads, etc. The
hood, bumper reinforcements, bubble hatch all came from trades. Being cash
short but time rich, I gladly would work for parts.
The original '79 Capri
started as a brown 4 cylinder / 4 speed with carburetor, no A/C. Serious
P.O.S.
I gutted the '86 Mustang
and began the process of converting the Capri to EFI 5.0 / 5 speed standards.
This can be done but
will require lots of space, a bunch of stupid little tools only to be used
once, a lot of patience, and a reliable ride to the parts store. Don't
skimp on the reliable ride part. Multiple trips per day become the norm
with this project. Feel free to email me with any questions about undertaking
this and I will offer my meager experience. Having a donor car readily
availible is very convienent. It's astounding how many silly things reveal
themselves during the course of this project. For example, the bracket
to mount the fuel filter, computer location, inertia switch location, etc.
Begin the project by
admitting that damn near every part of the car will come off. Once that
premise is accepted, frustration will be minimized every time something
has to come out. Some highlights are as follows:
-
Electrical- Virtually the entire harness must be swapped from the donor
car to the recipient car. On my '79, many of the places where the EFI harness
had to go had no provisions to allow the harness to pass through or attach
to. In particular, the stock location to mount the computer has a brace
in the footwell that prevents the computer from fitting. My computer now
rests on the floor at the passenger's feet in a super trick pocket created
using a plastic bag and the expanding crack filling foam available from
the hardware store. With carpet over it, it's invisible and possibly safer
than the factory location. Also, the wiring to the fuel pump must be routed
to under the driver's seat and then to the back of the vehicle. An advantage
to all this is being able to route the wires where desired for a cleaner
appearance ( particularly under the hood ). The battery has been moved
to the back using a Moroso box and Flaming River Big Switch. I used #0
cable purchased from a local welding supply store and have had no charging
problems. The car also has 2 12" Hayden electric fans which work fine here
in Phoenix. NOTE: Do not skimp on the wiring. Many things will not be easily
accessible once the car is together and a bad connection can haunt the
car in the textbook example of electrical ghosts. Use solder whenever possible
and use heat shrink instead of vinyl tape.
-
Fuel - Because of the different requirements of the EFI, the fuel tank
was swapped along with the fuel lines to the front including the return
line and line to the charcoal canister that sits under the passenger frame
rail under the hood. Here in AZ, the emissions folks pressurize the tank
and look for the canister. My car failed once because the car didn't have
the canister. Mine's not really hooked up, the lines have bolts siliconed
into them where they can't be seen, thus "sealing" the system for testing.
Also needed are the tools for disassembling the factory EFI fuel lines.
These are a must to prevent damage to the fittings and are readily available
from most parts stores. I got mine from Checker.
-
Suspension - Assuming the car is starting as a 4 cyl (like mine did), all
the suspension gets swapped to the recipient car to deal with the increased
power and weight. While swapping the suspension, I installed Southside
lift bars and a Suspension Techniques rear sway bar. I bolted the Southsides
in which was a HUGE mistake. I had to weld them later. They wiggle worse
than a bowl of Jello. We also installed through the floor frame connectors.
These are seriously stiff. Made them from 2"x3" steel tubing cut to length
and then notched to fit over the front and rear subframes. They are tacked
into place and then the floor is welded full length to them.
-
Engine / trans - The basic swap is a piece of cake. My biggest problem
was the car had just returned from the body shop where we painted the engine
bay, door jambs, around the hatch, etc. So, I was paranoid about scratching
something I'd just spent a lot of time on. No clearance problems. ONE SNAG
was the flanges welded to the floorpan to mount the trans crossmember are
different on the '79 Capri. I wound up cutting the up the original x-member
from the '79 and welding the bushing ends onto the '86 double hump x-member.
Not tough but a nasty surprise when trying to bolt the trans into place.
I also had to notch the floor pan where the shifter comes through to access
the shifter bolts better.
-
Interior - I used the dash and doors from the '86 because I was putting
the A/C into the Capri and I had just spent a few days installing stereo
components into the '86 Mustang when it got totaled. Many thanks to Tim
Hawley for his labors installing the stuff in a car that got crunched just
a day later. Tim has an '86 GT with a lot of juice.
He's shooting for 10's. Tim also gets the nod for getting the back seat
re-covered in material to match the new Flofit seats. Flofit seats have
a serious quality control problem. I would NOT recommend buying them.
-
Brakes / 5 lug - This was done using the now-extinct Ford Motorsport M-2300-F
kit. This fit replaces the rear setup with new 5 lug axles and 10.5" rotors.
The front gets 5 lug 11" rotors. It comes with a new master cylinder, adjustable
proportioning valve, and parking brake cables. Pretty nifty but requires
the use of a flaring tool and at least a gallon of brake fluid by the time
everything is bled.
-
Body / exterior
- The hatch is from an '86 bubble back Capri. Obviously the "make it /
break it" item for most people. I happened to like the way it looked because
it wasn't another flippin' Mustang. Then I found out that bubble back Capris
won the IMSA championship in '85-'86. This was largely due to the reduced
drag of the bubble hatch which supposedly took the Cd from .47 for a Mustang
to .38 for the Capri. I also used sail panels from an Mustang SVO for a
cleaner appearance. The hood is from Bill Maier at Maier
Racing in Hayward, CA. Bill's a good guy to deal with and makes a helluva
nice hood. He offered choices in weight based on need. The hood required
only slight clean-up to remove some waves but fits very squarely and has
no warps. The doors came from the wrecked '86. Much thanks also go to Seth
and Chris at Photofinish in Tucson, AZ for the killer shine. They are truly
awesome to deal with.
That's about it.
Some dumb stuff was:
-
No hole in the firewall for the EFI harness above the climate control box.
I had to make this hole using a hole saw and Dremel.
-
The trans x-member requiring cutting the ends off the '79 x-member and
welding them to the '86 double hump x-member. The flanges welded to the
floorpan that the x-member mounts to are only about 3" apart instead of
the 6" on the '86 floorpan.
-
The bubble back hatch required cutting the catch post from the '86 Mustang
and welding it to the '79 for the new bubble hatch to operate.
-
There's no holes in the transmission tunnel to feed the harness to the
trans for the overdrive switch, cruise control sensor, and reverse switch.