$500 Junkyard Supercar: It’s Alive... Again! (Project Jigsaw #41)

This week we continue Project Jigsaw, our 1960's inspired supercar project based on a Porsche Boxster. We diagnose the previous issues we encountered that ended up with a fire in the engine bay! Additionally, we finish our cooling system (sans radiator fans) and take the car for a spirited drive! Come along as Tony and Ryan problem-solve the complex engineering behind this project, and take jabs at each other all along the way!
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Merch: www.cruciblecoachworks.com/
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#vintage #porsche #racecar #hotrod #restoration #fabrication #v8engine

[@CouchBuilt]

Careful removing the ceramic boots after they’ve been installed for a while. The terminal can rip out as I’ve had that happen on a couple. Dielectric grease and some back and forth wiggling as it’s removed seems to mostly mitigate that. They were warrantied, but not ideal when you don’t have a spare.

[@CrucibleCoachworks]

Noted!

[@zzzires5045]

100% cast your own valve covers. Make em something that looks crazy

[@CrucibleCoachworks]

Oh if we're casting them, they'll be crazy. 😁

[@zzzires5045]

@CrucibleCoachworks but what will the boss read? Jigsaw? Hopefully not still Ford;)

[@halosenpekka1090]

Uuu! And add the Crucible logo with ”prototype” to it 😎

[@EternalGamingNet]

Great to see jigsaw driving again! So fun seeing both the mechanical and body progress.

[@1nvisible1]

*@**20:09** Grommet that hole, lol. Same on my F150 lasted 61 miles.*

[@fourcam150]

21:39 that shot is perfect! 👌

[@YouBuildItYouBreakIt]

"Because he was a body guy, and we know how they are." Never heard a more relatable statement on KZbin before. 🤣🤣

[@Sixxoh66]

Thanks for sharing and letting us into your shop. You guys work well together.

[@CrucibleCoachworks]

Thanks for watching!

[@thomasamstatter2744]

Finally after 2 weeks of waiting. Already looked forward to it all week. ;)

[@Framo60]

To be honest, I like the original valve covers because they tell things as they really are - [Jigsaw is a Porsche] powered by Ford.And in terms of design, they go well with a 1960s inspired supercar. :-)

[@donmonojam]

Very nice! Remeber Dereks wise words: Every project start with a boiling battery =)

[@tatwo_]

Jigsaw is back! Let's get jiggy with it.

[@alman6581]

Love this project guys - keep going - we are watching.

[@faroironandcustoms6577]

Fel-Pro has a steel impregnated valve cover gasket for SB Windsor that is awesome. For whenever you rebuild!!!

[@k.s5079]

Watching your video's after work filles great ❤

[@chunkdaddy4733]

Thing looks like hell raiser at the end with all the clecos stickin out of it.

[@CrucibleCoachworks]

Haha! We thought the same as well!

[@nathanchalecki4842]

Love it!!! I'm not convinced that your air bleed will work rather than getting airlocked itself (actually I'm positive it will just flood with water and refuse to let air out of your high point). Probably much more reliable to replace that (beautifully formed and welded) bend of tube with a threaded boss and bolt

[@larrycluness5438]

I was just about to ask the question regarding this very issue. I also don't think that small pipe will actually do anything positive. As you say either put in a threaded boss so that when the system is being filled it can be open thus expelling all the trapped air in the radiator then screw in a set screw or fit an expansion tank in the front boot at the same height, if possible, that the expansion tank at the engine is at. They're still going to get trapped air unless the pipe that comes off it is running uphill all the way to the rear!

[@CrucibleCoachworks]

Tony and I talked about this at length actually! We believe it should work as we modeled it off of same concept Porsche used on OEM Boxster system. The overflow lines ran from the front rads, down under the car and back up to the overflow tank in the same location. So in *theory* it should work - time will tell however. 😅

[@thenotsonicecanuck]

Cut the tops of the valve covers off, then get plates machined with the crucible logo and text on them, and then weld those to the rest of the valve cover. Clean the welds up, Powdercoat them and then you have custom valve covers.

[@Tj930]

Quite a handsome, little beastie. Coming together nicely

[@halosenpekka1090]

Sooo happy to see your dynamics again 🎉 The front looks superb in live, at the end of the vid ❤️‍🔥

[@trentmiller8127]

Tony, those pushups need some work. Charles Atlas would be sad. Seriously though, it takes a special breed to build a car like that. Great job so far and, like everyone else on this channel, I cant wait to see the finished product.

[@JurisTruedge]

You might want to watch your temperature in the engine. The thermostat does more than regulate flow of water. It also offers a restriction to slow the coolant to the radiator allowing the radiator to remove heat from the coolant. This may not be so much of a problem with the relocation of the engine and using the aluminum tubes for coolant transfer. Just something to keep in mind for testing. Btw I love the work you’re doing. I wish I was a bit younger and had bunch more ambition, I’d try and do o this.

[@agerrgerra1361]

I've heard this sort of thing before, but unfortunately it's a myth that a slowing the flow will improve the cooling, because you're trying to keep the engine cold, not the radiator. If you slow the coolant flow it will definitely cool the water inside the radiator more, which will keep the radiator colder. On the other hand, the slower flow means you're also heating the coolant inside the engine more... meaning the engine will get hotter. It's true that the coolant entering the engine would then be a little colder, and the coolant entering the radiator would then be a little hotter... but it's not enough of a difference to equal out in the end, the slower coolant flow is still always worse. I've worked on coolant system design for vehicles before, and both the math and actual vehicle testing show that slowing the coolant flow will never improve cooling, and faster coolant flow is always better (though there's a limit to how much flow gives any improvement). Thermostats do restrict flow to allow an engine to heat up faster when it's cold, but they open up fully to allow for more cooling if the engine is getting too hot. Some vehicles have restrictors in the coolant loops to balance the flow through different paths, too. Some vehicles may also have restrictors in the coolant loops at certain spots to ensure there's higher coolant pressure behind them, which can reduce cavitation.

[@JurisTruedge]

@@agerrgerra1361 It will all depend on how efficient the system is. If you do not allow time for the heat to transfer to the coolant it will not get rid of the heat properly. I have seen this happen on my vehicle. I know it happens. I don't know how efficient their system is, so I told the guys to watch their temps is all. in a perfect situation you would be correct.

[@ironmonkey1512]

Ahh, the 15% complete milestone. The end is in sight!

[@tomschultz2833]

I'm hoping your going to build some serious power into that 5.0!

[@thebr0wnhornet]

This thing is awesome! Can’t wait for the bumper and side panels to get worked together, it’s so rectangular now and drives me crazy bc every thing else flows so well. 😂

[@peterbonnez]

Excellent....

[@travis.808]

"When 900 years old you reach, look as good, you will not."

[@Hexearth]

I swear like 2 months ago you just installed the engine and did the front clamshell frame, it’s so weird seeing the car so good

[@brandenagee9934]

Sounds like Christmas light clinks!

[@mathiasnkristensen]

Beautiful car. I just wish the windshield was a bit lower and more tilted to give it that real oldschool racecar look. It'll probably look great anway though.

[@TP-3000]

The Pord Foxster is coming on well

[@warrenhorby]

If you want to get the cooling system right and air bubble free take a look at a Fiat X1/9 or Lancia Scorpion cooling system. I have owned both for decades and cooling air bubbles have NEVER been an issue or over heating .

[@steveseeger]

Could you do the whole body in straight steel with no paint? Probably really hard but it looks so good right now with no paint!

[@ozenfant_ozn]

looks like hellraiser in that last shot.

[@kieren7763]

There are 2 things garunteed about old Ford motors they start after 20 years no problems but the valve covers will leak 2 weeks after fixing them

[@84eurospec911]

After long thought and consideration, I have decided that this build will need some type of ITB setup… for the esthetic of course

[@brentspang9092]

I think your radiator vent needs a vent which will need a vent…ventception!

[@noke1785]

classic german tork-spec gag: nach fest kommt ab. (after tight follows loose...) what u sayin´"gutentight" ??? ^^ made my day ^^

[@nuclearmedicineman6270]

It's alive!!

[@aaronburratwood.6957]

Freakin awesome‼️ Per usual.

[@quakxy_dukx]

Gutentight sounds like what I assume Texas German (an actual German dialect) sounds like

[@CrucibleCoachworks]

Now I gotta look up Texas German lol.

[@bentnbroke]

Best channel I'm subscribed to! ❤❤❤

[@norcalonline1]

Awesome work. I hope we see some period correct white vinyl low back seats and interior. Also, what are the thoughts on the eventual wheel choice? The Magnum 500 would look great and give it a nod towards the Ford power plant.

[@gafrers]

Great work. Beautiful body isn't 100% of the final result. 👌👌👌👌👌👌

[@theheadone]

You got the roloc bristle discs in action this week I see! :)

[@craftybear01]

The UK torque setting for cam cover bolts is TAF. Not sure how to convert that to bushel thumbs or whatever is used on your side of the pond.

[@YouBuildItYouBreakIt]

Have you guys considered running something like a micro-squit with a trigger wheel so you can delete the distributor cap?

[@SideshowBen206]

In general I think the whole 180° headers thing is kinda meh. However, for this specific project it would really work. Making that 302 sound like a flat plane V8 would certainly Puzzle some folks.

[@williamaguiar14]

I used that gasket few months leaked only after a few miles

[@SideshowBen206]

So Will has to do 10 pushups every time he gets caught with his phone in his back pocket. Should Tony do 10 pushups every time he has to look for his reading glasses?

[@TheNorthernmunky]

I could be wrong, but would it make sense to put the spring inside the pipe, rather than the pipe in the spring! The spring inserted on the inside of the aluminium tube, stops the pipe collapsing

[@danielgreenaway1587]

Oh I didn't open the bottle, great help guys. Pea meter ftw

[@johnbarker5009]

The engine in this car is so easy to get at, why wouldn't you do some of the work now and come back for a rebuild later? Especially since you're surrounded the distributor area with a sickle-shaped saw blade. JK guys, I still think this is an absolutely amazing project.

[@rage.exe0205]

what are your plans on the doors? Do you plan to build it ground up or modify a boxter door?

[@tomcoryell]

Are you going to put in grommets where your lines pass through the sheet metal? Chafe is a bad thing! Oh, and how old is Tony really?

[@CrucibleCoachworks]

Yep we will be!

[@tomcoryell]

@@CrucibleCoachworks I figured you guys know your game, but I would feel bad if you lost a coolant line because I didn’t say something.

[@Nihil1st1347]

Interesting build! I only wonder how other car youtubers emphasise the argon shileding gas to proper weld tubes and you do without.

[@CrucibleCoachworks]

We use argon!

[@TipperaryArmouries]

Hope you flush the rad of all the metal left from drilling

[@trillrifaxegrindor4411]

cast your own itb's and intake..........this car definitely wants them

[@m1kalD]

Nice.....

[@slatanic1968]

Polish the car when finished

[@TheMdt1970]

i'm guessing this customer isn't paying by the hour? episode #41 and we're still on the front end.... lol

[@bigdadgigachad3042]

Gambler500 guys dropped the ball by adding Ryan and not Tony. Matter of fact, Tony should be a mythical character in the game, head to toe in movie reference clothing and attire. Maybe he even flies. Show your respect to your elders, Gamber guys, Tony is 70 ffs 😂

[@billlichirie14]

😁👍

[@plokmko0]

The wide and low front air intake doesn't make sense functionally let alone cosmetically with the cheeky smile look. wouldn't it be better to have 3 ducted air intakes in the front. one each for brake cooling and one for the radiator ... 🤔

[@lansonfloyd4687]

Serious question. How are you getting around the law (I presume for all of U.S.) that the engine of a vehicle must be the same age or newer than the chassis. Is it just N/A for a build like this?

[@JurisTruedge]

I don't think there is a law about the age of the motor compared to the car. However depending on which state there in a inspection sticker may be needed for the Emissions of the insured vehicle. Meaning if it's registered as a boxer, it would have to meet emissions for that year. That could be a problem. However thier are also different laws dealing with "MODIFIED" vehicles as well. Those i have never looked up.

[@aaronburratwood.6957]

I went to Cancun on vacation once and I had the runs everyday.

[@dermus7529]

The least appealing part of the build so far is how gross the engine bay is... Everything else is awesome:)

[@Ladyoftheroundtable]

Surely mounting the coolant overflow closer to the radiator would have been better