Hey everyone, hoping to get some thoughts to get me through winter project #1 - subframe connectors. I recently ordered a set of Mike Maier subframe connectors (I would post a link, but it appears I can no longer find the Cougar connectors on their site https://mikemaierinc.com) and they look AWESOME, fit snug, and contour perfect. One problem…where the '68 fuel line crosses over the rear subframe…
Hoping someone can confirm the '69 fuel lines on a Cougar are like that on a '69 Mustang and don’t cross the subframe until up in the wheel well?
I have searched here and mc.net but coming up a little short on a specific answer of how to get around the fuel line and subframe dilemma on my '68. Any help is much appreciated as I try to tackle this project.
At one time I had Total Control Products subframe connectors on my GT-E. They are made from round tubing and do not interfere with the fuel line or the E - brake cables or anything else.
Thanks Royce - but I already have Maier racing connectors.
Thanks for confirming Leon.
I pulled the trigger on a set of '69 fuel lines and will see how they fit on my '68. I will document the install (successes and hurdles) for anyone else that decides to install longer subframe connectors like Maier or Tinman.
After removal of the fuel line I was able to get a better feel for how the Mike Maier connector was going to fit…
As promised, this is documenting the hurdles in which I face with my 68 Cougar, hopefully it can help make a better product or help others with their install. Mike and Dillon at Mike Maier Inc have been great to work with, emailing and calling to discuss the fitment issues.
The driver side continues to be difficult:
It is hitting the braket for the parking brake cable on the front subframe. Mike has only built a few Cougar connectors, the mass majority of his production is Mustang, but he did recall that there was a 2 year design that had the parking brake cable plate in the way and I am guessing that it was 1967-8.
Connector continues to want to be where the fuel line is, particularly where it exits the front torque box. We are going to pull the front line and see if it will reinstall once the connector is dry-fitted up properly on the subframe.
The passenger side sits great and really shows how much this is going to tie into the subframes and solidify the chassis, I believe far more than the connectors that attach right at the end of the subframe.
After talking with Mike last week, we decided to trim up the front plate to slide the whole connector forward to take up the gap at the back of the front subframe. Should still have plenty to weld with the bottom plug weld and a stitch on the edges of the plate.
So using the old line I bent it to better align with the replacement and then started test fitting and putting a slight bend to it, and it fits pretty well. Still need to do one last bend - but it has plenty of clearance to get the rubber hose on and off with the connector in place. And while everything is out, gonna hookup shopvac on one side of the torque box and blow compressed air on the other side and see if we can get all of that dirt and crud out before doing the final fuel line install.
'69 rear fuel line does not align well with the '68 body length…so I think I might be in the market for yet another set of fuel lines and then perform the connection piece that Mike recommended for his solution on Mustangs (segment from front fuel line to rear fuel line after it crosses the rear torque box).
I think the final real issue I have to deal with is the angle of mount #3 on this driver side connector - it touches at one side but leaves 1/4" on the other side of the mount.
Completely agree Royce! Hoping the communication with Mike Maier might enable an enhancement to the connector and continued vendor investments into the Cougar.
I think that 3rd mount will just need to be removed and rotated slightly to get the good contact on the rear torque box for a weld.
After talking with Mike again, he sent me the draft instructions they have been working on; following those with a block of wood and a jack, things look good.
So it is time to start prepping the metal and I notice a small area of rust in the bottom of the driver’s side front torque box…well, now is the time to address it! What is that saying about worms in a can?!
A little bit of wire wheeling and its not too bad:
So we can easily open that up and replace that small area…no problem. You should have seen the mess that came out of the torque box! Fortunately, all of the debris and moisture settled in the lower portion - a camera placed into the box shows everything else looked nice and clean.
As I look a little closer, I don’t like what I see on the frame rail, and a screwdriver running through didn’t build up my confidence either. Fortunately it doesn’t look too bad and we should be able to patch that easy enough. There is no weight on the jack stand, it is there just in case…
My brother and I were able to weld up the small slit in the subframe and feel pretty good about the overall integrity of the torque box. We didn’t have the confidence to weld the 1/8" subframe connector plates to the ~14 gauge subframes, especially with the limited room under the car (life is easier with the right tools - like a 4-post lift just for this operation), so I have located a local shop that will be doing the welding for me. Car goes in next Thursday for that, and then I can put the fuel lines back in and clean it up for some nice spring drives.
Overall the Mike Maier subframe connectors were a great fit - the 2 areas of issue are:
the front mounting bracket on the drivers side needs pushed back about 1/2 inch - I have been working with Mike and will supply the dimensions from my 1968 Cougar to see if he will make the adjustment.
the 3rd mounting bracket on the drivers side was 3/16" below the torque box. There is thoughts that someone hit something there or used it as a jack point because of the “changes” to the fuel line - so we welded in an additional plate in-between.
Welds look good though:
Now I can return to the rerouting of the fuel line and see if I can get some road time before the heat sets in…
Fuel lines were able to be installed this weekend, cut the rear line where it would have crossed the rear torque box and ran a 46" section of straight fuel line (after putting in a slight jog) to connect the front and rear fuel lines. I did have to bend some of the front fuel line so that it would get around the 2" subframe connector on the outside of the front-subframe. Overall it came together pretty well, doesn’t leak, and was a great weekend to finish up this project. My son wanted to run down to the gas station for the maiden voyage, which we then decided to take the long drive home - turning a 2 minute drive into a 20 minute cruise between a father and a son…what a sweet benefit to this hobby!
