S197 Hybrid - 2006 Mustang with S550 guts

[zackmd1]

Hard to even tell it needs adjusting!
But man, your work is tempting me into eventually gutting out my S550 for S650/S750 internals!

That would actually be FAR easier since the S650 IS an S550... I would be willing to bet everything would literally bolt right in.

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[Ballistica]

Thoroughly enjoying this thread. Thanks for the constant updates, your work looks amazing!

 

[zackmd1]

Prelim fabrication of the S550 dash frame to fit in the S197. The S550 end caps were just too different to modify in any reasonable way to fit the S197 A pillars. What I ended up doing is removing the S197 end caps and adapting the S550 frame to fit. A bit more trimming left to do and I need the HVAC box to ensure proper alignment with the dash but it should work! In the end, the S550 dash should bolt in just like the S197 dash.

 

[zackmd1]

In case anyone thought I was joking about the 10 speed.... 30k miles out of an F150!

 

[zackmd1]

HVAC mocked up! The S550 firewall is SIGNIFICANTLY different from the S197. The HVAC box when indexed with the drain ports is 2" back from the firewall. The good part about this is that it gives me plenty of space to reroute the heater and evap lines to the OEM S197 locations. This will help avoid any major firewall mods.

With the HVAC in place, the dash does not need any trimming and indexes with the HVAC perfectly. Interesting thing about this is that based off of the S550 side trim, the dash is 1.5" farther back from the A pillar. So safe to say the S550 firewall and A pillar area was changed significantly as compared to the S197.

Next up is finalizing the dash frame once I have a center console to ensure proper alignment.

 

[JetGray_Mach1]

Looking awesome! Are you going to use the S197 door panels?

 

[zackmd1]

Looking awesome! Are you going to use the S197 door panels?

That is the plan. The S550 door panels are way too different in shape to work. I am actually surprised by how well the S197 panels fit with the dash.

 

[zackmd1]

Making progress on the dash frame. It appears that the dash is slightly farther back than it should be based off of the ebrake and console fitment. With that said, I am not changing the location of the dash as it will be easier to massage the console and ebrake then make firewall mods. The dash itself is still farther forward than the 06 dash due to its shape so no interior space will be lost!

 

[zackmd1]

I give you an S550 dash BOLTED into an S197! Frame is tac welded at this point. The idea is to continue assembling the interior to ensure there are no major fitment issues before final welding. Don't mind the console, it was left over from a previous project which is why it is cut up. I have a steering column, console, shifter, and ebrake handle on their way. I hopefully will be able to test fit them this upcoming weekend.

 

[Ballistica]

I give you an S550 dash BOLTED into an S197! Frame is tac welded at this point. The idea is to continue assembling the interior to ensure there are no major fitment issues before final welding. Don't mind the console, it was left over from a previous project which is why it is cut up. I have a steering column, console, shifter, and ebrake handle on their way. I hopefully will be able to test fit them this upcoming weekend.

Looking great!

 

[dbtgt]

I give you an S550 dash BOLTED into an S197! Frame is tac welded at this point. The idea is to continue assembling the interior to ensure there are no major fitment issues before final welding. Don't mind the console, it was left over from a previous project which is why it is cut up. I have a steering column, console, shifter, and ebrake handle on their way. I hopefully will be able to test fit them this upcoming weekend.

Following...
Nice work!

 

[zackmd1]

The console and shifter arrived! As expected, the shifter confirms that the dash/console assembly is about 1.5" further back than it should be. With that said, the amount of work required to move the dash forward vs the amount of work to move the shifter and ebrake back is not even close. In addition, the console still fits well between the seat and dash. Once the steering column arrives and I can confirm no significant issues are present with that fitment we should be good to go!

 

[zackmd1]

Steering column is in and looks good! I was worried about the distance to the firewall and the steering shaft being too short but thankfully the 2015+ models have a telescoping steering wheel so there is plenty of adjustment!

 

[zackmd1]

Tweaked the dash placement today to get it centered up and ready for final welding! Will be completing that tomorrow.

Talking with a few different tuners though and I might have to change my engine choice.... Ford changed the trigger wheel on each cam between gen 2 and 3... With the Voodoo being a gen 2 motor, this means that I would have to disable VCT if I want to run it with a Gen 3 PCM. With the 12:1 compression, marginal low end torque to begin with, I am not sure I want to make that compromise...

My backup plan I have been formulating would be to build an NA version of the 5.2 Predator. That uses gen 3 cams but without the high pressure fuel pump and are designed to fit in 5.2 heads. I would basically be creating a 5.2xs aluminator motor. That thing makes 580hp at 7800RPM. Down the road that also opens up the possibility of adding the 5.2 supercharger! Still have not made a final decision yet but I am leaning toward the NA predator motor at this point.

 

[zackmd1]

Dash frame is welded! Now on to the center supports and console parts.

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