Instead of messing with the engine compartment, I decided to spend time working on getting the pedals converted over to manual, as well as converting the old style z-bar setup to cable. I actually did this exact swap once on my last Mustang, and assumed (wrongly), that it would involve the exact same process. This would allow me to perform some of the steps out of order, since I'd previously figured it allllll out.
Shoulda known better...lol.
Anyhow, on to the pictures.
I started out by dressing the top of the manual pedal in preparation for having a roughly 3" structural (read: mild) steel extension welded onto it.
Here is said extension. Its actually just a piece of flat concrete stake cut down and dressed up a little. I always keep a few spares of the flat stakes around as they're a cheap source of mild steel for fabricating, guards for knives I make, and various other odds and ends. They can be forged/cut/welded into just about anything I might need.
Backed and trued to the clutch pedal in preparation for joining. I actually took it all apart again and widened the v between the pieces before I welded it.
Welded up, painted, and contoured to fit the cowl area, or so I thought. Turns out that either the pedal hanger on this car is completely different, or the under side of the cowl is. I ended up test fitting it like ten times, and regrinding about 3/4" off the pedal extension in the process. It fits now, but it was a hell of a piece of work doing it. Also pictured is one of THREE nuts I had to tack onto the pedal bracket. Apparently someone had twisted off all but one of the pot metal ones. Lucky me lol.
Roller bearing kit. Last time I used Mustang Steve's deal...but this kit from CJ Ponyparts (sourced from the Mustang Service Center a mile from my house) seemed to work nicely also. The main differences seem to be in the amount of support provided by the setup, the fact that this one uses the pedal shaft as the inner race for the bearing, and that this one also requires no fabrication skills (other than basic grinder work to remove the old pot metal bushings). The Mustang Steve kit is as much superior to this kit, as this kit is to the stock setup. Maybe in another 40yrs I'll have to rebuild the hanger bracket again lol. I'll be sure to use Steve's then =p.
Three pedals in the car...JUST like they should be! On a side note...this was a much more enjoyable process on the 68 (other than the repeated refitting), simply because the steering column was so easily removable. Getting that bracket and pedals in and out of a 67 is a rabid B!%*#!! with the column in place.
Speaking of the column...while it was out I took the time to sand down the primer and shoot it (and a few other loose parts laying around) with a nice satin black. I've decided this will be the main color for my interior, with gloss accents where applicable.
Anyhow, back to the clutch setup. I drilled a 1/4" hole at the upper rear (towards the driver) portion of the pedal extension...pushed a grade 8 stainless allen head through, and attached it to a 1/4" female rod end that I'd modified the clutch cable to fit. Basically I threaded the catch on the cable, and screwed the female rod end onto it with red Loctite.
This is the same type setup on my 67 Mustang, with a slightly different style rod end (captured ball). I went with a standard rod end this time for ease of fitment, and because that's what my local supplier had in stock.
Pretty basic stuff
Now here's a fun pair of pictures. The top one is the Mustang, bottom the Cougar. See any differences in where the cable is coming through the firewall? Yeah...me too. The extensions were EXACTLY the same length, and I actually had to grind some off this time around, as I mentioned. It's a bit puzzling, and rather annoying, since I'd planned to simply use a 3/8" thick aluminum brace as pictured above on the Mustang. Now I'm going to have to fabricate a bracket (like the one pictured first above...only, less flimsy) in order to stand the cable off of the slope in the firewall above the master cylinder area.
So there we have the pedal construction pictures. Next up, bracket construction.