2001 Mustang GT Roush Body Kit Install - Mustang Metamorphosis Part 2
We Finish Project Ice Box's Makeover With A Stellar New Look.
From the September, 2008 issue of Muscle Mustangs & Fast Fords
By Frank H. Cicerale
Photography by Frank H. Cicerale, Motor City Auto Body
With a Roush body kit and...
With a Roush body kit and some new color, Project Ice Box's metamorphosis is complete.
Last month, we reintroduced Project Ice Box, our '01 Mustang GT. Currently serving duty as former MM&FF Editor-turned-Editorial-Director Jim Campisano's 600-plus-horsepower daily driver, the decision was made to update the looks of the beloved Pony. After a short hiatus from the pages of this magazine, we brought the white beauty back for a makeover to replace the beat-up Cervini's Stalker body kit with a Roush kit.
In our first installment, we got as far as tearing off all of the mangled and broken aftermarket body pieces, as well as prepping the Roush-supplied Stage 3 bodywork. The one hangup came with the rear bumper, as we had to source a bumper from a wrecked silver GT to attach the new rear valances.
We began by mounting the replacement...
We began by mounting the replacement rear bumper to Ice Box. Previously, the blemishes on the bumper were sanded down, as they would have to be removed when the bumper was shot with paint. The replacement bumper was necessary because the Cervini's Stalker bumper is specific to the body kit. Furthermore, the rear bumper valances included with the Roush kit mate to a stock bumper, which had long ago disappeared.
Careful measurements were...
Careful measurements were taken to ensure that the rear valances were in the same position on either side of the bumper.
The Valances were deemed to...
The Valances were deemed to be in the proper spot, and were installed on the bumper. The bumper was then removed and readied for paint with the rest of the bodywork.
In this issue, we finish off our Mustang's metamorphosis into a New Edge with a Roush flavor. There were some interesting hiccups along the way, but for the most part, the work went fairly smooth. The result is absolutely stunning, as Ice Box's new attitude emanates from the Roush kit's side-exit exhaust.
The crew at Motor City Auto Body (Newark, New Jersey) tackled the task of finishing the job. Since we wanted a uniform look to the car, Manny Costeira and the boys not only shot the new body components in Bright Arctic White, but they also dismantled as much of Ice Box as they could to give it a respray of the same hue. The parts were painted separately from the car so that they were completely bathed in paint, meaning there were no crevices or sides that were left in bare urethane. Once the car and all of the body components were painted, each item was reinstalled.
The same procedure was performed...
The same procedure was performed on both the passenger- and driver-side skirts. The install was more critical with the side skirts, as holes have to be drilled into the fender and quarter-panel lips to mount the skirts. If you're off by just the slightest bit, the car will look different from side to side, and we didn't want that.
Once the side skirt was in...
Once the side skirt was in position, we marked the spot where the holes needed to be drilled. Once the holes were drilled, the procedure was repeated on the other side.
Here you can see the side...
Here you can see the side skirt mocked up and the two points at which the front of the skirt mates to the fender lip. The two body screws mark the points where we had to drill for the side skirt.
Last but not least was the hood, as we planned on adding graphics to it in the form of stripes. We kept the Cervini's Stalker hood, though we wanted to close up the vents to keep water and other stuff out of the engine bay. Enter hiccup number one, as the fiberglass that Motor City used to fill in the vents reacted with the hood's fiberglass, causing the new 'glass to bubble up a bit. The only way to fix this was to remove the added fiberglass, prep, and redo it in a different manner. Once the hood vents were closed off, the hood stripes (`a la the '70 Oldsmobile 4-4-2) were measured, taped off, and shot on the scoops with Graphite Grey Pearl, which can be found on the new Mitsubishi Lancer Evolution. The color is dark enough to be a close match to Ice Box's charcoal interior, and it shows off the lines of the hood.
With everything mocked up...
With everything mocked up (front and rear bumpers, rear wing, and side skirts), the car was disassembled and made ready to be rolled into the paint booth. First, the side mirrors, badges, headlights, and taillights were removed. Then the interior portions that needed to be removed were taken out, followed by the windshield and rear glass.
The hood was sprayed with...
The hood was sprayed with Bright Arctic White paint. Each body component was sprayed separately of the car so that every last spot on them was covered.
After the car was sprayed...
After the car was sprayed in the white and clear, it was rolled back into the assembly bay, where it would be put back together complete with the new body components.
Motor City also installed our replacement headlights. The old headlight lenses were scarred and pitted from years of New Jersey highway abuse, and it wouldn't be right to have a car with a new body kit, fresh paint, and dilapidated headlights. Rather than going with a factory-style replacement, however, we decided to play the contrast game by picking up a set of smoked headlights from American Muscle. While the original headlight style was fine, the smoked look matches the dark interior color and the hood stripes. With their clear corners, the new headlights have a sinister look that enhances the fact that Project Ice Box not only has attitude, but can back it up with its supercharged poked and stroked Two-Valve mod motor.
We also installed an HID (High Intensity Discharge) conversion kit for the headlights. Having seen more and more Mustang enthusiasts make this change, and having driven a few BMWs with the same-style headlamp, we decided it was only right to upgrade the illumination the headlights provide. The kit from American Muscle comes with everything needed for installation, and the blue light that now emanates from the front end of Ice Box not only looks cool, but thanks to the improved illumination and visibility, will help Campy see any problems on his way home from the office each night.
We began by reinstalling all...
We began by reinstalling all of the parts on the car.
Also going on were the taillights...
Also going on were the taillights and all of the badges that were removed when the car was rolled into the paint booth.
Motor city's crew reinstalled...
Motor city's crew reinstalled all of the removed interior pieces, along with the rear window and windshield.
The first new body component...
The first new body component to be permanently installed on Ice Box was the Roush wing.
The pedestals were bolted...
The pedestals were bolted to the trunk lid first; then the wing was put on and secured.
Next, the side skirts were...
Next, the side skirts were bolted on. This was a simple procedure of lining up the holes and tightening the fasteners.
With Ice Box's headlights...
With Ice Box's headlights being so chewed up, it was only right we replace them with something stylish, such as these American Muscle smoked headlights with clear corners. The headlights are a direct replacement for the factory ones.
In addition to the new headlights,...
In addition to the new headlights, we also sourced an HID conversion kit from American Muscle. The kit comes in this cool case, and features a pair of 9007 bulbs and all of the wiring and hardware needed for an easy install. A word of caution, however-be careful when transporting and installing the HIDs, as they are extremely susceptible to breaking.
On went the rear bumper with...
On went the rear bumper with accompanying rear valances.
The only other hiccup in this project's metamorphosis involved the exhaust system. Since Ice Box is equipped with subframe connectors, when it came time to link up the side-exit exhaust system, the Roush mufflers wouldn't fit in the desired location underneath the car. To remedy that, we had a local muffler shop create new pipes and relocate the mufflers to get everything to fit. When all was said and done, the car sounded aggressive, but not annoyingly so.
Overall, swapping Ice Box over from the Cervini's kit to the Roush kit was relatively easy. Once we mounted the Nitto tires on the new Roush wheels, the package was complete, though a front license-plate mount, a new running-pony emblem, and maybe a billet grille are in the works to finish everything off. How often can you put a car into paint jail and get it back in a respectable amount of time? We were quite happy with the results, and we can't wait to hit the road and find out what passersby think.
The Final Tally
We Added a few additional parts and pieces to our list since Part 1. Keep in mind this is the cost of the parts only. Labor on a job such as this and the appropriate amount of paint needed depends on the shop chosen and the brand of paint used. Included with the following list is everything we needed to transform Project Ice Box to Roush status.
Following the rear-bumper...
Following the rear-bumper install, the front bumper and the Roush foglight kit were installed up front. Once the bumper was on, the HIDs were installed into the headlights.
Once the HID bulbs were in...
Once the HID bulbs were in the headlights, the new lamps were put in their respective position and adjusted for proper illumination.
Here's the front end minus...
Here's the front end minus the upper grille and running-pony emblem. Those two items were installed after the rest of the car was reassembled.
|Roush body kit|| |
|(front fascia kit, left/right side skirts,||$865.75|
|skirts, left/right rear valance,|| |
|wing with pedestals, and|
|all mounting hardware)|
|Roush chrome 18-inch rims||$595.70|
|18x9 PN SM03-22232-SAC|| |
|18x10 PN SM03-22243-SAC|
|Roush side-exit exhaust||$936.00|
|PN SM01-4K000-V8|| |
|American Muscle Smoked Headlights|
|w/Clear Corners (PN 42000)||$199.99|
|American Muscle HID Dual-Beam|| |
|Headlight Conversion Kit|
|w/9007 Bulb (PN 22002)||$279.99|
Words From Above
We sat down with Project Ice Box's caretaker, Editorial Director Jim Campisano, for his take on the Pony's makeover.
"The Roush exhaust is definitely quieter at an idle, but a bit more rambunctious at speed," Campy says. "On the highway up to 65-70 mph, it's a little bit loud, though it cleans up the faster you go. Stand on the throttle, and it sounds just like Greg Biffle's Cup car. I like that, but who wouldn't?
"As far as looks go, we've always loved the Stalker kit from Cervini's, and I think its design held up well over the years. It fits the New Edge Mustang body great. But magazine project cars are always evolving, and it was time for Ice Box to change. The Roush body kit is equally exciting, and you almost never see a real Stage 2 or 3 Roush Mustang on the street, so you won't see yourself coming and going. The front air dam is bold, as is the rear wing, but the sidepipes not only tie everything together, they make the car stand out.
"Overall, the new paint from Motor City Auto Body is brilliant, and the chrome Roush wheels and smoked headlights complete the package."
The last part to go on the...
The last part to go on the car was the Cervini's hood, as we had something special in store for it.
After the hood was shot in...
After the hood was shot in the white and clear, the areas on top of the scoops where we wanted to install the stripes were roughed up with sand-paper and readied for application. We left the underside alone.
We moved the hood into the...
We moved the hood into the paint booth, where the stripes were measured and outlined. For uniformity, we had to make sure the stripes were in the same spot on both scoops.
We used 1/4-inch masking tape...
We used 1/4-inch masking tape to outline the stripe on the hoodscoops.
Here you can see that the...
Here you can see that the opening on the hood scoop vents were fiberglassed closed so water and other junk would not make their way into the engine compartment. After the fiberglass reacted with the hood the first time, a second go-around was made before primer and paint were applied.
Once the hood was completed,...
Once the hood was completed, it was bolted to Ice Box and shut. Following that, the remaining trim pieces were put on, the Nitto tires were transferred over to the new Roush rims, and-after a minor snafu with the subframe connectors-the Roush exhaust was installed.
The finished product shows...
The finished product shows Ice Box wearing her new threads, along with the new hood and the rear wing.
For paint, we chose Bright...
For paint, we chose Bright Arctic White, with stripes of Graphite Grey Pearl, which is a Mitsubishi Lancer Evolution color. In the right angle with the sun shining, the pearl in the stripes is clearly evident. The hoodscoop stripes came out great, and when combined with the smoked headlights, really make the car stand out in a crowd.
The Roush wheel package completes...
The Roush wheel package completes the overall look of the car, as the 18-inch chrome five-spoke rims complement the whole kit perfectly.
According to Editorial Director...
According to Editorial Director Jim Campisano, the Roush side-exit exhaust makes Ice Box "sound like Greg Biffle's Cup car." That's some compliment!
With the headlight switch...
With the headlight switch pulled, the HID lights flicker on and gradually illuminate to full power. The blue hue goes well with the conventional glow coming from the Roush foglights.