Doug's Mk4 Build Thread - Annapolis, MD

[dmoran]

Hey Everybody,

Welcome to my build thread.

I'm going to try to keep this as up to date as possible mostly for my own documentation but I'm hoping some of you smart guys will check in once in a while to keep me on the right path. I completely welcome any advice (especially the good kind) from you'se guys who have been there and done that. Also, if you see anything I'm doing that you think is a bad idea or maybe there's a better alternative, then please, don't hesitate to comment. I have a build plan but nothing is written in stone and I won't be offended. I may not always take the advice but I will always listen.

My background is in electrical engineering but I have worked my whole life in software including writing Space Shuttle checkout, control and monitoring software at KSC back in the 80's and 90's. I have always been a DIY'er and tinkerer but this is my first full car build. I attended the FFR Build School back in February with my father and son which was awesome.

Here is a quick version of the plan:

GOAL: Build a non-donor Factory Five Mk 4 Roadster for weekend fun.
I'm not trying to make a perfect period correct Cobra replica. I'd actually like it to have a more modern flavor. Where there are options I favor simple, for example: non power brakes and steering, no heater, no A/C etc. About the only exception to the simple rule is EFI which I think will actually be easier to keep in tune in the long run. Plus, being a computer geek, I love the idea of working with the engine telemetry from the computer.

Kit: Mark 4 Roadster base kit #8843 - Picked up 3/19/16

• Powder-coated
• Pre-cut holes
• 3-Link Deluxe Rear Suspension package
• Rear Brake Kit with 11.65″ Rotors...
• FFR LCA's and front spindle kit
• FFR Front Brakes
• FFR Steering rack
• FFR 11.65″ Rear Brake Kit
• Wilwood pedal box
• Russ Thompson Throttle Pedal
• Halibrand Replica Wheels, 17″ x 9″ Front and 17″ x 10.5″ Rear (Yay for the 1/2 price winter sale)

Engine: Roush Racing 331 SRXE Crate Engine: - Delivery by end of March

• Small Block Ford (Reconditioned 302)
• Stroked to 331 cid
• 350 hp
• 350 ft-lbf torque
• Aluminum Heads
• Aluminum Dual Plane Intake Manifold
• T-Body EFI - FAST EZ-EFI Self-Tuning Fuel Injection System
• Canton Racing Front Sump Oil Pan
• Ford Motorsport 90 Degree Oil Filter Adaptor
• Cobra Replica Alternator, Bracket, Pulleys & Belt
• MSD #6425 Ignition Box, #8202 Ignition Coil

Transmission: Tremec #5008 TKO-600 5-Speed Manual Transmission - Delivery by end of March

• .64 Overdrive
• Single Disc Clutch & Pressure Plate w/ Mech Release Bearing
• Mechanical Clutch Release Fork
• Quicktime #RM-6065 SFI Rated Steel Bellhousing

Rear End: Mike Forte's 8.8" Mustang Rear End - Pickup 3/18/16

• 3.55 Ford Racing Gears
• 5 Lug 31 Spline Yukon Axles
• 31 Spline Cobra TracLoc
• Mustang Pinion Flange
• Fully Checked/Reconditioned Axle Housing

Exhaust: Gas-n Polished Stainless Steel Side Pipes and Long Tube SS headers
Not ordered yet. I've heard good things about these - any comments?

• Constructed from T-304 stainless steel. This includes the wool packing, muffler, merge collectors, and 3/8” thick flanges.
• The merge collectors are built with scavenger spikes for better flow and sound.
• Sound has been adjusted to be quieter by using a flow-through muffler design.
• Small amount of fiberglass packing in the muffler to add to the sound quality.

Tires: Nitto NT05

• 315/35-17 on rear
• 275/40-17 on front

Hopefully that's enough to get me started and keep busy for a while - thanks for stopping bye
Doug