The Ultimate '33 Hot Rod

Today. Horsepower takes on a one of a kind car and engine project.

We got our hands on the original kit, 33 Hot Rod for factory five racing.

The chassis here is serial number 001

that will help of their build team. We're gonna transform this prototype development mule into a potent show car one that'll start Ford's display at this year's

SEMA show.

Now it'll be a

combination of vintage styling,

race car engineering

and for power Ford's brand new Eco friendly 5 L Coyote. Before we get started though. Here's a behind the scenes, look at how these high tech bodies and chassis are built.

It's no secret. The guys at factory five are certified car nuts.

But Dave Smith, the president and co founder needed a little extra prodding when it came to green lighting. The 33 Hot Rod project. I had driven a friend's hot rod. It was a 33 and had a big 502 motor. It was a great car and when I went to stop, it was, it was a terror

and I kind of got a bad idea about hot rods that they looked good. But they didn't perform.

And our charter fact five has always been technology and performance and technology enables performance. So Jim

kind of convinced me that he could make a hot rod handle. He says, Dave, I can make a sports car and he, his only requirement was he wanted freedom of design. We were able to start from a clean sheet of paper

and, and do we wanted, we knew we wanted to do in board coil overs because the car is gonna be at some points, an open wheel car versus sometimes gonna have fenders.

Uh So we forged our own spindles, came up with our own geometry. Basically made the whole thing from scratch to fit the rear system

to match the two

and the rear suspension was something we lifted out of our challenge series cars. So when we design our suspension, basically, what we do is we have a software program where we map it out, then we design all the components on solid works,

we can fit them to the chassis ahead of time, make sure there's no clearance issues, make sure the geometry is the way we expect it.

And basically everything is working before we even start to assemble the first model. There are a lot of great design tools out there, but they get in the way of the design.

The best tools in the world are the ones that the engineers and designers don't even realize that they're using C

AD and computers are just today's tools. You know, they're a generation removed from traditionalists, but they're enabling us to make cars that perform and look good.

And uh they're the modern tools of a modern craftsman, but we're still craftsmen

only after the design has gone through rigorous testing in the virtual world.

And the real world does it go into production?

It all starts with the solid works design jig.

It acts as a template to ensure the frame is put together accurately. Every time

CNC high grade tubing is hand assembled and tack welded into place.

Some of the larger substructures are welded on the robot to streamline the process

laser cut components like this door hinge fit together like puzzle pieces

and then get welded into place.

Once it's all together, the frame is meticulously finished welded by hand

and then it's off to get powder coated.

Meanwhile, the fiberglass body panels are being laid out

cured and trimmed.

Everything comes together in the assembly area.

C and C aluminum panels are bent and put in place

and then the body is dropped on.

Finally, it's all loaded up and ready to be sent out to the next lucky owner and builder.

So I'm just really happy to talk to me into the project. I mean, this car is really delivered on the performance side

and from an engineering standpoint, I think it's pretty impressive. It shows what we can do.

Yeah, thanks. I I really do think that this is our spin on a hot rod and that's, that's, you know, kind of been the theory all along is that, you know, we just keep building the things we know how to build. And

if we like them, hopefully other people like him too

as a mule. That chassis has been tested with all kinds of V eights but nothing like what we're gonna throw at

it. It's Ford's brand new 5 L Coyote crate engine in a minute. We're gonna take a closer look at

it,

dyno

it and install it in our 33. Keeping that show rod all Ford.

It's also gonna wear a new body. Now, paint is one of the ways you can actually personalize your 33 when you buy it as a kid.

There's one just like this down the hall in the muscle car shop.

In fact, those guys have been at it hard laying their own special paint treatment. You'll see the results later. When we drop the body on the chassis,

we're about to bear down on the performance part of this project.

The real fun

is just ahead. Stay with us.

The factory muscle car wars are on again with Ford GM and Chrysler. Each battling it out to prove they've got the best modern day muscle machine.

It's a battleground for performance and horsepower and now Ford has really raised the bar with its new 5 L Coyote for the 2011 Mustang GT.

We not only have the crate engine, we have one of the brains behind it, Jessi Kershaw from the Ford Racing division,

but I think it'll make at least the 412. The Pony Wars are definitely on the brand X competition has 400 plus horsepower engines. And while we've always done very well in shootouts against them,

uh we really need to have that number that over 400 horsepower number. And the way to get it was to bring back the 5 L in a four valve configuration.

We integrated some new items to be able to have emissions, compliancy and fuel efficiency and have the performance for the torque and peak horsepower. Our throttle body position is on the front of the engine which is very different than the old four valves. We went with very lightweight components in the engine to because obviously weight is the enemy of both performance and fuel economy.

Uh We used a composite plastic intake manifold which

not only does it save weight, it also sheds heat. We went to a composite plastic valve cover which saved quite a bit of weight compared to the old aluminum valve covers.

And just the casting technology itself has gotten a lot better. If you look at the blocking, look at the cylinder heads, you see the rib

that was engineered into it.

So we have all the strength, in fact, more strength than any 46 block we've ever developed

but at the same time, we're able to have these cavities where we took material out

and we have pockets where we don't need the material. We have all the strength with the design of the block.

Well, like usual, we couldn't help it. We had to get inside to take a look.

The tall tubes are where the spark plugs are located.

It's got dual overhead cams with four valves per cylinder

and up front for total control of the cams. There's a phaser for each

on the bottom side. The pan gasket also doubles as the windage tray.

It's got six bolt mains,

a forged crank, forged powdered metal rods and hyper eutectic pistons. Now, here's something unique for a stock engine. It's got oil squirters for each piston. Certainly Ford racing is trying to step up with performance packs for handling and increased power. Uh We're working developing on an intake manifold for it, headers, uh CNC cylinder heads. I mean,

you name it. We want to have the gambit covered including uh a positive displacement supercharger kit.

This no doubt a TV, first putting one of these new five Os on

a dyno,

I've never even heard it run. So just when we hear it on the dyno, I'm,

I'm really, you know, excited for that to see what kind of numbers it puts out.

You remember Jim Shank

from factory five racing.

He was here when we modified one of their GMT super cars.

He not only designs and builds them, he races them too.

So, what's his game plan for the 33 today? This fun dude,

basically, what we have to do is convert the drive train so that it's, we were taking out a small block and now we're going to go with the new, the new 50, the engine mounts have changed and the fuel system has changed. The transmission is a trim

3550

that we had in the car before. So basically all we have to do is change the bell housing, fly wheel and clutch. So getting all that stuff ready for the new engine is the biggest thing.

And then while we're here, we, we could take advantage of the fact that the car is a part, clean up some of the parts, you know, plate, some of the parts because the car does have a lot of hard miles on it.

We're reusing the fuel cell wiring and brake reservoirs. Oh, and the horn, of course,

the nine inch rear end stays too

after we load it with stronger brakes to match that Coyote.

It's a pro plus system from bear. Starting with a billet backing plate.

The axles go back in now along with the differential

clip and spacer,

this floating self aligning caliber bracket eliminates the need for shims

followed by massive 14 inch two piece slotted rotors

and powder coated six piston calibers that use the same pads as the Corvette C five and C six

put it in a heated chrome. We sent out all the suspension pieces to Steve Tracy at advanced plating

ate it where it won't oxidize for a cool brush, nickel finish on the front. Those pieces are exposed. So that, that'll give us a good look. That's some beefy stuff man.

While Andy finishes out back.

Perfect, the front, upper control arms can go on first. We're upgrading the shocks to these adjustable aluminum body pieces. From Coney.

Notice how they install inboard just like the Indy cars.

Next lower control arms can go on followed by the spindles. The inboard shocks are fantastic. They get the shocks you in out of the wind. You know, they're they're concealed completely by the engine sides. We can control leverage rates and spring ratios and that kind of thing by the length of the arms.

Finally, the bear pro plus front brakes again, 14 inch rotors and six piston calibers you ready

with the control arms installed, the rear end can go up in place

and these factory five guys are really making some progress

down the hall. So is Rick

who's moved on to the tiny brushes

and when we come back, you'll get to hear this coyote how stay tuned

today on horsepower. We're saving factory five's hot rod mule from the pasture,

transforming it into a sea of show car with show stopping brakes,

satin nickel plated suspension pieces,

not to mention muscle car Rick's trick paint job for

Power Ford's all new 5 L 32 valve Coyote.

The challenge has been, how do you install it?

There is a little bit of a mystery to it with late model fuel injection, especially when you have electronic throttle control. You have variable cam timing, you have this pedal that isn't physically attached to anything.

And what we're able to do is develop our kit

um for a fairly easy install with done right. Performance. We always say we can never remove the mystery, but we think we've done a pretty good job of removing the complexity and they did that with a simple box and harness that powers everything including the Ford's computer, which does all the rest. I'm not pretty sure it's 6800 and

68.

All Mike has to do is decide how far to push the pedal with its new engine.

The advertised horsepower

412. But we think it's got a bigger power potential than that.

And we're about to prove it.

416,

power,

411 ft pounds at 4400.

And we didn't hit the, we didn't hit the rev limit there.

Hey, how high can we rev this with a quick confirmation of where the rev limiter at? We're ready for one more. Run.

7300. He says

he says we were brand

it like that

all day.

All right,

I was limited there. Yep.

465 and 68 4 13 at 49.

Yeah.

Yeah.

No, it looks really good

and the consistency is really what you want, right? You have the flat torque, you want horsepower under the curve

and you want consistent horsepower. So I'm very

pleased with this.

We've also got some powerful bling for the 33 Greening auto company made us a one off custom set of five piece wheels painted by Rick Bacon that Jessi Greening will assemble. The inspiration came from the old Ford steely wheels that had the beauty trim ring and just a snap in center cap, outer barrel, inner barrel. And we put those together and then we slide the wheel center together. Once the beauty ring is placed on the center, then we slide that into place and then bolt everything all together

and then we put a beat of silicon on the inside to seal the seam up. It's ready for tires. I think it's going very good, especially with what's Rick's done with the body and everything else. It's a perfect match.

Oh, man, I don't think uh we could have picked out a better color. That was the same theory, Wayne and Pam mcgriff from M and M Hot Rod interiors supplied to the upholstery. What have you done here?

Well, we kind of changed them up a little bit and kind of made him a little more contemporary

and uh

covered them with an ultra leather, kind of give it the old hot rod look. I like it. I like it. I think this will be nice,

which they were in

next. We get to see what the chassis looks like with a new engine. After we finish reinstalling the engine mounts and bolting up a new center force. Plus

you're good since it's been home to several Ford engines.

The last one being a 4.6 L.

This one mounts like a direct replacement. There

we go.

Ok.

You thinking

this is gonna do it

and that's in there, isn't it?

Yeah.

Well, you know what it is is basically

the body was designed around that engine. So it's as tight as it could possibly get

ready.

This trim,

Tko five speed has been here before as well.

Only the bell housing was changed for the 50, again an easy fit.

Well, guys, you're looking at about 250 man hours and some really teed off wives.

There you go guys.

She's done. Polish painted.

Try not to bang it up too bad. All right. That looks sweet. Yeah, it does. That, that looks really nice.

Yeah, the first paint job is free. You wreck it. The second one's gonna cost right on, man. Be careful with it. Great. That looks fantastic. Thank you guys.

No time for talking in Andy's book.

He's mounting the electronics under the dash to get started on the wiring.

Mark's jumping ahead with the gauges

and this old mule is a lot closer to the spotlight. Once again, we really have been through a lot with this car. We've tried a bunch of different engine combinations. It was, it was really one of the original cars that we showed people when we first came out with a product.

So it's, it's neat to kind of see it

get reborn and something that, uh, that we can show off again.

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Thanks for hanging with us because we're hanging late to finish off this 33. Yeah. Water tamp and oil pressure

bolts are tight on the drive shift. Now, time to check out our wiring skills.

It's in here. That just seems tight. Yeah, this is, this is loose.

Ok.

That was the gear that time you guys,

so that

don't work whatever that is. It's not working.

You too

start shooting, fire out of this side

time for the body

you ready?

Come down in the back,

easy,

easy.

It's a good thing. That body has some flex to it.

That's what it takes to get it over and down on the chest.

I need a value

that

I'm kind of hoping that since we've had it together once before it'll go together fairly easily again.

Well, the checkered flag is definitely inside.

Although the remaining work is tedious,

it's also very satisfying.

I love this car. I think that this is just,

you know, uh the best looking hot rod we've done to date.

I mean, it really is just the, the choice of parts, the paint jobs, everything on the car is just

out of the park. But

while it has the classic designs,

their technology and the suspension is very modern and it's great to put a late model power train like the 5 L engine in there, that's light,

it's high rubbing,

it's gonna make great power and great torque. And um you know, I think it's gonna be, it's gonna be a heck of a lot of fun when they get it done.

One of the most exciting things I think for me and all of us at the factory is, is not when we build the prototypes and we, you know, we get the finished cars, but when we start to see what other people can do with the car because really that's what we're building. We're not, we're not building cars, we're, we're building the start of a project for someone

and, and what they come back with as an end result of that project is the most exciting part of the whole deal for us.

They got a distinctive design. So everybody will remember it when they see it,

but it also communicates a message of responsibility. I mean, underneath that, that's water based paint, that's an emissions legal carb program engine. I mean, that's a, an engine you can drive and be proud of.

That is the future of hot rodding.