Bad Cat

Bad Cat
Officially Bad Ass

Friday, September 21, 2012

Former Glory

Royce came across a funny pic of Bad Cat at the Pumpkin Run Car Show last year. It's former owners and the car in all it's former glory are here, lower right:

The date of this is October 2011, and of course, the car has been through a lot of changes in the last year.

What a metaphor for all of us! We could all use a makeover and a recharge, couldn't we? It's not over til it's over, Friends :).

Tuesday, August 28, 2012

Some New Video Updates

We had to create two parts. Part 2 follows below.

I had a feeling we were going on too long as I was filming (filming? Do we still use that word?). I had Royce divide it into two vids (we never have the heart to edit it for some reason) and place it on YouTube while I worked on another project in the Project Room we put together over the weekend in our house.

Wine, projects, Project Room = happy K&R

Sunday, August 26, 2012

Blog Blurb

Sunday morning is our day off together and we headed out this morning on our bikes to the shop to see what Royce accomplished yesterday for the Cougar. We threw together another project vid which was fun and is uploading now.

We wanted to post to say that we decided a couple of weeks ago to go ahead and cancel our hotel reservations in Missouri for the EVCCon to open up the room to someone else who will need it. This has been a slight bummer. There were a few reasons we're pulling the plug; the main one being, of course, that the car will probably not be finished in time. The other reason, a huge one, is leaving the shop for several days is just not an option for us, or for our help who is counting on making money that week. The final one is financial. We live on a shoestring budget and spending money to travel that could go into the car just seemed like shooting ourselves in the foot at this point.

We are hoping to be welcomed to the Saturday events in Cape Girardeau if we can take off on Friday after work to drive west, and spend a little time looking around the car show for the day seeing what other conversion folks in the world have been up to.

It's cool. We're happy project people. Our plates are filled to overflowing. And there will be next year, and hopefully many local parades and shows in the meantime once Bad Cat is off and running.

Here is something neat:

It looks like something off The Borg doesn't it? Note to self: Post a pic of Royce's Borg costume sometime, it was so kick-a.

This is a brake proportional valve. It proportions hydraulic fluid pressure from the brake pedal to the front and rear wheels. It effectively delivers 60% of pressure to the front wheels and the rest to the rear. It reasons that the rear lifts causing inertia and the transfer of weight gets shifted to the front, so the pedal pressure is reduced to the rear to keep them tires from skidding.

Most of these valves for the Cougars and Mustangs are relatively expensive, ranging anywhere from $90-120, depending on whether it's new or used.

I found this one on Ebay for $25, shipped.

Our Cougar is drum brakes all around. Royce is switching it to front disc/rear drum because disc brakes are much more efficient at stopping vehicles. It's the best option for a performance car.

Sunday, August 12, 2012

New BadCat Video Update!

We hope you like it. Parts of it are a mess, we know, we know! We're busy people! :)


New blog post is coming! Fresh, new video and lots of information on where we are at and where we are heading. The vid is rough and staying that way because neither of us have any interest in editing it, so try to extract the good parts and ignore the shaky-shaky. K&R

Thursday, July 19, 2012

Hoping you had a chance to see Royce on this week's EVTV. If you didn't, here's a link to the episode:

This was a great surprise because we didn't think the video was working. Video just hasn't been our friend through this process -and we're working on that!- but this time it worked (mostly!) and this is the result. Good fun!

Monday, July 16, 2012

If You Build It They Will Come

"Ray. People will come, Ray. They'll come to Iowa for reasons they can't even fathom. They'll turn up in your driveway not knowing for sure why they're doing it. They'll arrive at your door..." -Terence Mann in 1998's movie "Field of Dreams"

Okay, baseball metaphors notwithstanding, we headed west to Missouri this weekend.

This is the Bill Emerson Bridge that crosses the Mighty Mississippi:

And on the other side, for those in-the-know, is Cape Girardeau, the unintended (or intended? :)) Holy City for home-EV converts and DIYers.

We went there with intentions of assisting Jack Rickard to work out some irritating bugs in his Escalade with the help of a portable automotive scanner to track down issues through the ECU; but unfortunately, with little time there was little solution.

In the meantime we had a nice visit and took this photo the morning we left:

Thanks to Jack and his lovely wife for the hospitality and visit! We look forward to returning in September for the EVCon :)

Now, you know there is no place like home...

And with the painting done on the Cougar (DONE done!), we've crossed another threshold and the Mechanic will get back to EV engine work this week.

Blogging Assistant will work on figuring out how to make the sound better for the next vid.

Sunday, July 1, 2012

Here's the Flavor of the Week :). Bob's '87 TVR Spins

New vid! And we know it's hard to hear. It was over 90F degrees in the shop so the fans are on HIGH. Just check out the overall vibe of tire spinning.

Monday, June 25, 2012

BadCat Series 4. Wiring Harness, Field Coils and Brushes, Oh My!

This is an update of a few things that have been cooking in the shop today. Royce wants to show you his new wiring harness (Found on Ebay via "Keep It Clean Wiring" ~ $148.95, shipped) and tell you about our GE motor upgrades (Helwig Brushes are $258, and the lathework and field winding is done by Royce. The field winding insulation was purchased years ago).

Tuesday, June 19, 2012

Speedy Update

I took Scruffy to the shop this morning... Scruffy is K&R's Janitor and general clean-up crew, and our youngest son, Steven; and so, while I was there I thought I would take a peek at the happenings in the paint booth where Bad Cat resides.

There have been a few minor cosmetic setbacks, but we have once again assessed our goals and one of them is not aesthetics at this point. We're going to find creative cover-up for the issues and call it a day. As Royce likes to say, "We're not body guys."

Anyway, our Visionary put the front grill and the taillight covers in place, just for fun. It was a little breathtaking I must admit.

That was a nice moment.

Film at 11.

Sunday, June 17, 2012


Royce is getting our car ready for the EVCCON in Cape Girardeau, Missouri in September.
Electric Vehicle Conversion Convention

I made our reservations today at the headquarters hotel. Thanks to Jack Rickard and Brian Noto for making that available to us. We are in!

Saturday, June 9, 2012

It's Beautiful

I don't have pics, yet, but came over to the shop to see if Royce was still breathing. He is and  applying the last of the clear coat.

The car is beautiful.

Wednesday, June 6, 2012

Getting Pretty

Can you tell that Bad Cat looks different? This is pre-paint. The body floor panels have been knocked out and replaced, the interior body is ready, the rust pieces removed from the exterior and replaced, body putty is finally done, and sanding, sanding, sanding is in the past. Royce will be doing a few minor repairs, putting on some inner fender liners and the hood. And we have the paint, the hardener, the paint gun. The paint booth needs cleaned, but painting is happening on Saturday. All day Saturday.

We have decided thus: No more cars that require bodywork. Ever. A lesson in love, but nonetheless, never, ever, no. Not ever.

Next pics will be of a beautifully painted and shiny car body (the color is a surprise!), and deservedly so. Thank you, Bad Cat. K&R

Tuesday, February 14, 2012

Cowl Repair And The Next Step

I finished the repair on the cowls today. I have a couple small areas beneath the rear seat that need to be replaced, so I'll do that next and then it's on to the rear quarter panels. 

 Until then, here are some pictures:

 Having coated this area with epoxy I feel confident that no water can get through. Sorry about the picture quality..
This is the outer cowl panel. I stripped off the paint, straightened some minor dents and started welding it back in place. I actually finished the welding today and ground them flush. Once they were smooth I coated the entire seam with epoxy. This should keep out all the water and dirt.

Sunday, January 29, 2012

Cougar Rust Repair 101

Well, my blogging assistant has been very busy so it's up to me to make an update.

As many of you know our shop has a guardian. She is a stray calico that we took in shortly after moving to our new shop location (a little over 5 years ago) and my kids named her "Rusty." While she has many others, I'll refrain from the more colorful ones, and let you know that in her honor my new project - a1967 Mercury Cougar-   has appropriately adopted her current pseudonym, "Bad Cat."

Well, Bad Cat has some "rusty" issues as many of these late 60's pony cars have. Over the last month and a half I've replaced the floor pans and seat risers; repaired the the driver's side frame rail; replaced the driver's side torque box; installed a passenger side torque box( Ford did not originally have a passenger side torque box on the 67 Cougar or it's sister car the Mustang); and added frame rail ties. These ties are an add-on which connect the front frame rails to the rear frame rails which increases rigidity and strength.

Another problem with the design of these cars was the cowls. The cowls were basically how you got fresh air to the heater and the vents. They were prone to holding dirt and leaf litter (check the pics below ~ nothing like 40 year old nastiness). Dirt and leaf litter hold moisture and moisture causes rust. Once the cowls rusted through, the rain water ran down the dash and onto the floor pans. There it would soak into the carpet until it finally rotted through the floor pans. There are plenty of replacement parts available for Mustangs, but very few for Cougars, so it's been a challenge for me. The new cowl sections were not available but fortunately the platform is the as the Mustang so I was able to get most of the parts I needed, although they required some modification because the Cougar is 3 inches longer than the Mustang. For the cowls, however,  I decided to move into the 21st century: I cut out the rust and welded over the openings. The new fresh air inlet will come from under the hood where I can filter the air coming in. I'll replace the old heater plenum with one of my own designs using ceramic heaters for the core. It's on the agenda after the rust repair is complete.

Meanwhile, enjoy some pics.....
 Passenger torque box..
 Front frame rail with new frame rail tie...
 Driver's side torque box...
 Driver's side outer kick panel...
 Driver's side floor to firewall....
 New driver's side floor pan....
 Driver's side seat riser.....
 Driver's side torque box...
 Driver's side front frame rail repaired....
 Driver's side frame rail rust cut out....
 Old floor pans, what's left of them...

 The Original Bad Cat  keeping warm on Assistant's new coat....(Hence the name, Bad Cat)....
 New floor pans.....
 Cowls with 40 year old gunk...

 Cowls welded over.....
I'll seal these with epoxy. It will give the rain water and dirt a nice channel to follow out of the car and to the ground.