9 SEP 2026 - Radiator

 While installing the electric headlight conversion kit, I discovered that the radiator has a leak on the passenger side lower corner.  Looks like maybe the lower radiator outlet is leaking at the radiator.

 So, before it gets worse, I will begin purchasing components to replace the radiator.

• I already have a replacement 3 row aluminum radiator.
• on hand - AN6 fittings/adapters - hard line to AN6 male ends - two   
• water pump fan spacer - not sure of thickness yet, radiator needs to be installed to check
• two AN6 double male end hoses for the transmission to radiator connections.
• Upper and lower radiator hoses and clamps
• transmission fluid
• radiator fluid 

7 Sep 2026 - Electric headlight conversion kit

The relay that is used for the kit is a 40 amp SPDT with an LED to indicate status and a mounting tab.

 

 

 

7 Sep 2026 - Electric Headlight Conversion Kit

 The passenger side wiring harness needs to be shortened about 24" and re-terminated. 

 While that section of the harness is removed, I can remove the +12 volt wire and properly wrap with a plastic wiring loom cover and use tessa tape to seal things up.

 The mounting location of the control relay is good but the wiring for the trigger wire from the car harness and the kit harness needs to be re done to tidy up the wiring.

 All runs of the wire loom need zip tie mounting tabs as well as using zip ties to secure kit harness to stock wiring harness.

 Need to get better battery terminal blocks that have taps for the various +12 and ground connections. 

6 Sep 2026 - Electric Headlight Conversion

Today the installation was completed.  The kit works very well.  I adjusted the headlight doors to align them to each grille.  Tie wrapped the kitcwiring loom to the frame.  I connected the battery, started up the cougar then went for a test drive.  Test drive was about 15 minutes, everything checked out good.  I still need to setup the headlight wiring looms so they do not get caught up in the actuator's movement.

5 SEP 2026 - Electric Headlight Conversion Kit

 Found out that both battery terminals and battery cable terminals had just enough corrosion to prevent functioning of the electric headlight actuators.  After cleaning up the battery terminals and battery cable terminals the kit worked.

 Installed the actuators, and installed and connected the wiring harness.  The engine bay headlight relay power wire was re-terminated with a two pin Deutsch connector that is connected to the blue trigger wire which has a corresponding two pin Deutsch connector. The ground wire for the harness is attached at the top mount of the external voltage regulator.  The power wire for the harness is connected to the battery + cable.  The power wire is in a plastic wire loom conduit.

The relay for the harness is fasted to the driver side engine bay just in front of the windshield washer reservoir.

After connecting the battery cables, the kit was tested and it works.  The headlight doors need to be adjusted to take up the slack in the adjustment rods.  The headlight wiring near each actuator needs to be more properly secured, I don't want those wires getting caught up in the actuator rods. 

 

 

3 sep 2026 - Electric Headlight conversion kit

Removed the wiring harness and actuators to test on the work bench.  I used an ATX power supply that I converted to a bench power supply.  I connected the red wire from the harness to +12 and connected the black wire from the harness to ground on the power supply.  The blue wire is the trigger or coil control.  I connected one actuator to the passenger side connector of the wiring harness, then I touched the blue wire to +12.  The actuator worked like it should.  Moved the actuator to the driver side connector of the wiring harness.  Placed the blue wire to +12 and the actuator worked.  Then I did the same process with the other actuator and it worked.  All components of the kit are functional.

1 Sep 2026 - electric headlight conversion kit

 Replaced all weather pack connectors of the kit with Deutsch DT connectors.

 Now I need to connect the components and check functionality. 

29 AUG 2026 - Automotive Electrical Wiring

 The Deutsch DT series of connectors is ideal for headlights, headlight actuators.

 While installing the connectors to the wiring loom of the electric headlight actuator kit, I damaged two pins on the 4 pin connector on the driver side headlight actuator.  Ordered a Deutsch DT kit with a crimper.  I will rewire the actuators and wiring loom of the electric head light conversion kit and use Deutsch DT 4 pin connectors.  The Deutsch DT kit will be here in a couple of days or so. 

20 AUG 2026 - Electric Headlight Conversion Kit for 67-68 Mercury Cougar

 Last week I ordered an electric headlight conversion kit for the 67.  It arrived yesterday.  Package contects are a left and right actuator, and a main wiring loom.  No instructions.  Don't see that as a big deal right now, it looks pretty straight forward to install.

  

2 May 2026 - Radio Bezel

 Recently purchased a replacement radio bezel from national parts depot.  I do not have a radio that fits that bezel.  I created an insert in the area where the radio would be installed.  Now I can store the garage opener, radio remote in that spot.  I also created two inserts to cover the location of the radio knobs.

 Working on scanning the dash area to create a replacement radio bezel.  Current scans are not promising, so I'll have to spend more time on scanning techniques.

 

13 APR 2025 - Aluminum Radiator parts

 Here is a link for parts...

 https://www.lyonsperformance.com/ford-trans-cooler-line-p-544.html

Another link

https://www.dynamicracetrans.com/Ford-C4-Trans-Cooler-Line-Kit

Another link

https://swperformanceparts.com/products/a-team-performance-braided-flexible-stainless-steel-transmission-cooler-hose-line-and-aluminum-fittings-kit-for-gm-ford-chevy

May need to get a fan blade spacer that is smaller than the stock 2 1/16" fan spacer. 

Not sure about going with an electric fan at this time...

 

Fan spacer 1"

https://www.jegs.com/i/JEGS/555/51190/10002/-1 

Fan spacer 1/2"

https://www.jegs.com/i/Derale/259/31500/10002/-1

 

 

28 NOV 2024 - Color Schematics/Diagrams for the 1967 Mercury Cougar

 

28 NOV 2024 - Super Tach II stuff

Considering replacing the MSD ignition system with a much simpler, easier and cheaper to repair system.  So I need to look into how to properly wire the Super Tach II tachometer that is currently installed with the MSD ignition.

Here are the wiring functions for the Super Tach II:

- Green to neg coil terminal

- Black to ground

- Red to switched 12 volts

- Blue for illumination ... tap off dash or accessories lighting

21 NOV 2024 - 351W stuff

 Heres a list of parts that might be needed when installing the 351W;

Hedman headers

#88300

Exhaust manifolds

D00e-9431-b Driver side

C90e-9431-B Passenger side

Current exhaust tubing size is 2.25" from the head collectors to mufflers

 

Alternator Mounting Hardware:

 

WCCC

=====================================

Adjusting Arm - Alternator - 351W - Used
Item #: 24595
$39.87

Mounting Bracket - Alternator - Rear - 351W - Used
Item #: 24793
$44.87

Spacer - Alternator - 1-5/8 Inch - Used
Item #: 23846
$25.88

Bolt and Installation Kit - Alternator - 351W - Repro
Item #: 31528
$18.00

19 Nov 2024 - 351 windsor ideas

Pieces / Parts needed to install a 351 windsor:

- exhaust manifolds / headers

- distributor

- flex plate, 28 oz imbalance. 

- harmonic balancer, 28 imbalance. 

- low/lower profile air cleaner

- mechanical fuel pump

- valve covers may need to be purchased.

- alternator mounting hardware specifically for 351W

- oil pan for 351W

- dipstick for a 351W

16 Nov 2024 - Thermostat

Replaced the 180 degree thermostat  with a 195 degree unit.  Did a test drive and no leaks so far.

 The 195 degree thermostat is a  Murry brand.  I will continue to drive the Cougar using this 195 degree unit.  If it runs well I will keep it installed otherwise I will install a 180 degree unit.

Still need to install the fan shroud assembly.

11 NOV 2024 - Parts n stuff

 

West Coast Classic Cougars

 

Drive Shaft - C4 or 3 / 4 Speed - Small Block - 2-3/4 Inch - 1 Piece - Used
Used C4 Drive Shaft 1967 1968 Mercury Cougar
Item #: 27529 

Leaf Springs - 289 - 4 Spd - Coupe - No A/C - Competition Handling - PAIR - Repro
Item #: 43010

10 NOV 2024 - Tools I might need soon...

 Harbor Freight

https://www.harborfreight.com/12v-brushless-cordless-3-in-cut-off-tool-tool-only-58629.html

From Amazon:

 Allstar Performance ALL11081 Koul Tool Kit for -6 AN to -10 AN Fitting/Hose

 

 

10 NOV 2024 - Radiator replaced

 Today, the radiator was replaced with a stock unit that I happened to have on hand.  Hopefully it will last.

Today the coolant level was filled and run tested in the garage, through three sessions.  Each session was 20 minutes of warm up and topping the coolant level in the radiator.  The third session didnt require any coolant.  Checked for leaks and currently everything looks good for a test drive.

I still need to purchase parts to install the aluminum radiator.  I have the radiator transmission line fittings.  They are 1/8" NPSM to AN6.

I need to determine the length of the braided hoses to use for the transmission.  I will have to cut the steel lines that connect from the transmission to the radiator.

I will need to use a thinner water pump fan spacer.  The stock one is too thick.

Parts on hand:

 

Earl's Performance Plumbing 

 

Transmission steel line to radiator transmission cooler in radiator

AT165056erl

6 AN, 5/16 in., AN6 to steel line fitting

 

Radiator to transmission

AT981662erl

-6 AN, 1/8 in. NPT, 

Parts to obtain:

AN6 female both ends, 12" braided hose

AN6 female both ends, 16" braided hose

 

AN6 female both ends, 18" braided hose

 

AN6 female both ends, 20" braided hose

 

AN6 female both ends, 22" braided hose

 

AN6 female both ends, 24" braided hose

 

water pump fan spacer - thickness determined by radiator thickness after installation 

 Summit Racing

 

10", straight, -6an,  female ends
6026-1-1-10BL

12", straight, -6an,  female ends
6026-1-1-12BL

16", straight, -6an,  female ends
6026-1-1-16BL

20", straight, -6an,  female ends
6026-1-1-20BL

24", straight, -6an,  female ends
6026-1-1-24BL

 

C4 to radiator transmission lines

https://www.lyonsperformance.com/ford-trans-cooler-line-p-544.html

23 Sept. 2023 - Replacement radiator has arrived.

Ordered a replacement radiator from Jegs, three days ago and it arrived today.  It is supposed to be a heavy duty version and a drop in replacement.  Since the radiator is at least 1" thicker, a shorter fan spacer will be used.  Need to order/buy replacement upper hose, lower hose, bypass hose, engine coolant and transmission fluid.