Projects 1965 Comet Caliente Convertible Project

I got the cork gasket made and the inside bracket riveted in place (picuter1). I then had to take what’s in picture 2 which is 11.5 inches long and make it 6.625. inches picture 3 is the result. Oh yeh and the float needed to be a little shorter. I did not change any of the wiring or disconnect any of it in the process. Picture 4 is the finale product and picture 5 I jumped down into the tank to take a quick picture. The sock fits perfectly into the recess. I set the float a little higher to show the tank empty a little sooner to help with the no baffles problem. Now on to altering the trunk sheet metal to lower the tank 2 inches.

 

I am working on lowering the gas tank so the in tank fuel pump will fit. First picture is the stock configuration. The second is the mod to move the tank one inch forward, one inch to the right and 2.125 inches lower. The final picture is the tank set in place. I still need to weld it all in place but it fits. I found out that 2.125 inches is not enough and I did not want to lower the tank any more so the tank cover will be raised 5/8 inch on a frame of 5/8 square steel tubing to get the clearance for the fuel pump.

 

Jeff;looking good! WOW,that tank is clean,I should have charged you more for it!!! ROY.

 

Roy

I appreciate you taking care of the tank for all those years and selling it to us for our project. It has a new home now and a new life. There is still plenty of work to do before I fire it up with the new tank. Filler neck, expansion tank, plumbing, wiring, tank cover … I guess I better get to work.

 

I complete forgot to give my dog credit for helping out. Below are a few pictures.

 

Jeff;the dog really gets in there to help! Was there a cat in there?Jeff;I had offers for that tank but really wanted it to get used on a cool project and you and your daughters project is WAY COOL!!! Good Luck and keep the pictures coming!!! ROY.

 

I did the same thing with my T'Bird tank ('59 'Bird with an 87 roller cam 5.0 HO), but used the donor Mustang GT tank fitting (actually about 1/4 of the entire top of the tank), brazed to the top of the 'Bird tank. You HAVE to have a baffle, or fuel will slosh away from the pump pickup. The pickups/pumps are not forgiving of fuel starvation. With the large opening, you should be able to form one from sheet br*** or copper, and solder it to the bottom of the tank. That's how mine is done. Nice job.

Brian

 

Roy,

It wasn’t a cat but the next best thing a tennis ball was in the battery tray

Brian,

Thanks for the heads up. It’s nice to talk to someone who has done this. Do you have any more info on the baffles … height, width… I was thinking it would be more like a box around the pickup without the edges of the box sealed to allow fuel to fill up the box.

 

Jeff;I agree in that you need a baffle.I would think that either holes around the baffle or just attach it on the 'high' part of the ribs so fuel can come under in the 'low' areas.I would think making it big enough to fit through the opening and two or three inches tall would be big enough.In over 140,000+ miles I never ran out of gas or had any fuel pickup issues with that tank in my Comet! JMO , ROY.

 

The baffle in mine is sheet br***, about 3" tall, a circle that doesn't quite meet at the seam. The open area faces the side, so fuel can enter, but on acceleration or deceleration it doesn't slosh away from the sock. And, it's on top of the ribs, so it's also open underneath. It's about 8 or 9 inches in diameter, the open area is about an inch wide, if I recall. I had originally used the plastic baffle from the Mustang tank, but when I pulled the tank last winter to clean it after it's long sleep in the garage (it had rusted inside and fuel was varnished) the plastic baffle was found to have broken. My radiator shop owning buddy replaced that with the hand made baffle, repaired the completely rusted through left rear corner of the tank and re-sealed the tank.

Of note, I had used a Ford Tempo fuel pump, which was the right depth for my tank. It delivers the same pressure and volume as the V8 Mustang pump, I just didn't have to modify anything. This made it easy (once I remembered what pump/sending unit I used 18 years ago when I built the car) to replace the pump last winter when I found the old one was seized.

I like how you lowered the tank. I didn't think of doing that, I made an access cover, hammered to form a bulge to clear the hoses and a channel for the wiring harness. The 'Bird is so low, hanging the tank 2" lower would pose a problem...

Brian

 

Brian,

I understand about the height of the Tbird. My friend has a 59 all stock and it sits Lowwwww. I was a little hesitant to lower the tank in this car and it sits pretty high. I made a compromise and lowered the tank 2 inches and raised the trunk ¾ of an inch

Thanks for the specs and info on your setup. I will have to figure out what works for mine.

 

I have been working a lot but this mod is not easy. There is very little room and nothing seems to work unless it is modified. First picture is my daughter working on the stock tank and the dog really doesn’t care at all. Second is a little mod to the gas tank filler section of the body. The third picture is the idea of the small expansion tank after several tries with other ideas (time consuming). After gathering several pieces from the mountaineer tank the last picture is what the expansion tank will look like after I get it welded up and pressure tested and yes that is an anvil made out of a piece of track from a narrow gage railway. I flow tested the mods to the filler neck and it flows adequately. I have made expansion tank so that the stock tank cannot fill all the way leaving room at the top of the tank for vapor and expansion area. Should be about a 16 gallon tank when I am done.

 

Jeff;what are all those fittings?Make sure you use hose that is rated for gasoline on all your connections! ROY.

 

Wire brush in a drill and no safety gl***es is a disaster waiting to happen. Ask me how I know.

 

x2, and shorts aren't a great idea either.

 

X3- I didn't realize I had a strand stuck in my eye until I blinked....

 

Ok you guys caught me. That picture is staged. My daughter had worked prior to that (with safety equipment) and was done for the day when I realized I hadn’t taken a picture. So I had her pose. Thanks all for looking out for us

Roy: The connections are from farthest to closest the pressure senor, vapor canister outlet (with safety valve) , the main gas filler tube and the gas over flow from the filler tube. I have yet to get all the hose I need for this so I will be taking a trip to “Hose Man” in Santa Ana.

 

Jeff;thanks for clearing that up!! I'm used to fuel systems for Carbs!!Oh yea,I use a full face shield now after having a bristle come off and stick in my cheek!!! ROY.

 

It seems the more time I have the slower I go. I have done a lot of fabrications and I’m happy with the progress but I wanted to be done with the gas tank by now and that’s not the case. I got the expansion tank done with the filler neck and all the other attachments (first picture). I got the filler neck mount that fits the Mountaineer filler neck welded in place (picture 2) and I got the baffle built for inside the tank. I still need to get the new hoses to hook everything up, attach the baffle to the tank, pressure test the system and make a cover for the expansion tank inside the trunk.

 

Jeff;it is looking good! I like the baffle for around the pump,should do the trick!! ROY.

 

Thanks Roy.

I got the baffle installed and then the tank put together with the new hoses and then pressure tested it. I found a couple of pin holes but not bad. I spent half a day at the wrecking yard stripping out seat belts from a 95 mustang convertible and the seats out of a Ford ******. I will adapt parts from the seats into the Comet seats like head rest which are removable a requirement from my daughter who hates the look of head rests. I will try and use the seat back lock but may just fab up the old style latch for that. I know I can use the rear seat belts from the Mustang but the fronts I’m not sure about yet. All in all a good weekend.

 

Jeff, wow I just spent at least an hour going through your thread from start to now. It is looking great. You do great work and your daughter has great taste.

My Dad has a 4R70W in a 66 Mustang. I figured the bump in the middle of the pan served some sort of purpose. Do you have any pics of your process in removing the bump? I'd like to have it gone.

 

Like um. I bought my wife a new 65 tudor hardtop when they first came out - very nice car, look good drive good. The 289 was great engine for the car. good luck on your project.

 

Arkieguide: Thanks. I was a kid in 65 but I sure remember the cars. This car did not have an engine, transmission, floor or half a sub frame when I got it so I turned it into a modern day Hotrod with parts from the wrecking yard.

LowHeat: Thanks for the complements we are having a good time with the project. I bought the transmission pan on eBay. It’s a 4R70W shallow pan. You will also need the correct filter to go with it (AutoZone). Search eBay for “4R70W AODE pan 2WD SHALLOW FORD”. You can also go to the wrecking yard and get one. I believe they are on previous year 4R70W transmissions. The bump in the pan does serve a purpose I’m not sure about the reason for the change in design.

 

Finally got the gas tank done and installed with all the systems hooked up. The car starts and runs great. Now onto separating the tank from the inside of the trunk

 

Jeff;looks good,glad to hear it all works!!Will you make the tank cover removable?You have a lot of connections that may need periodic adjustments.One step closer!!! Also,the Mercury Show is October 19th,at the same park as last year.I can't make it as I will be racing in Bakersfield at the CHRR. ROY.

 

Roy,

Yes the cover will be removable. Sorry to hear you won’t be at the Mercury show. Ri and I will try and get there. Have fun racing.

 

I got the tank cover finished pictures below. I am still working on everything that needs to be in place to separate everything having to do with the gas and gas tank from the inside of the car. Getting close but at least the car runs then back to the interior with seat belts and shoulder harnesses front and back and front head rests.

 

Jeff;looks great,that should be plenty strong! Should be able to stuff a couple bodies back there[just kidding]!!! ROY.

 

Roy

Thanks. Yes the trunk is big enough for that. I hopefully will not have a need for that. I am currently working on the third version of the filler neck entry thru the body and then I will build the cover for the expansion tank.