Fluge's Build Thread

[Fluge]

Inspired by a few other fun build threads, I thought I would try to start my own. I also decided to post it on this forum. FFR is where the car originated and so it seems right to post here and help build the archive.

I took delivery in 2009 and have been picking away at it since...despite almost selling it at one point.

Edit: I REALLY NEED TO GIVE CREDIT TO ALL THE COUPE BUILDERS. 90% of the things I did were first done by other builders. I likely never would have thought to do most of those things. Thank you.

I would like to see others start similar build threads...it can be helpful not only to other builders but also to them...

My plan is to post a timewarp of pictures showing some of the more meaningful shots leading to it's current state of re-assembly. My way of reliving the journey to date.

I'll try to post a few pictures every few days and we'll see how it goes. if the past gets too old, I'll speed it up...

Marc

[Gbeck]

I think I'll enjoy the time warp. Keep 'em coming!
Q: was it delivered with the aluminum panels installed as in the last pic, or it that your handiwork?

[QSL]

Good stuff!

[Fluge]

Gbeck

No that's the way it was delivered and what it looked like at the end of Day 1.
The larger aluminum panels come screwed to the frame with a few self tapping screws. There are a few things you should do before you remove them...like label them and note how the panels overlap. The manual suggests outlining the frame on the panels so that you can drill the rivet holes. That worked for me but you may want to consider waiting until all the aluminum pieces have been positioned. The position of the panels on delivery may need to be tweaked a bit in order to get optimal positioning of all the panels.

I'll try to keep all the pictures in chronological order.


Marc

[Rodster]

Marc -
Very good idea, it will be good to see the "before" and "afters" . ..

-wayne

[Fluge]

One of the first things I did was figure out where I wanted to rear wheels to sit in the wheel well. Because I am using pin drive, I had to get the rear solid axle housing cut. While I was at it, I had 9 inch housing ends welded onto the housing and custom axles made by Bears Performance.

The other Mod I wanted to make was for the power brakes. This turned out to be a much bigger deal than I thought it would be. I needed to change the frame around the booster, lower the steering flange and later I found out I needed to modify the steering column cushion bearing on the dash 2x2 in order to lower to the steering column. In the end I also added a booster spacer to help clear the steering column.

[Fluge]

I had a tough time installing the banana bracket. I had to grind the finish of the housing and smooth things out a bit. Once I got it on I welded the bracket to the housing and also installed the vintage performance brace...maybe overkill...

While in the overkill mode (and because I have a welder) I added the Breeze upper control arm brace. It is intended as a bolt on but I welded it on and used the bolt holes for rosette welds.

[vnmsss]

Marc.....Great thread! Thanks so much for posting!! That crate sure brings back memories, and it wasn't all that long ago that this was the way all of the kits were shipped. Just the photos of the mods you made for the brake booster, the 3-link supports, and the info on the pin drive are already very helpful. I am also grateful that we're building an archive of information on this forum as well. Thank you!!

I very much appreciate your kind words on my build as well, and am reminded every day of just how lucky I am to be part of this amazingly talented and kind community.

Keep the photos and info coming!! Lovin' it!

Karen

[Fluge]

Thanks Karen

I was just looking through your Blog...makes me want to do another one and I haven't even finished this one...

Marc

[Fluge]

I know this may seem like a step back but I liked how the original FFR had shoulder belt anchors...so I modified the rear frame to allow anchors to be bolted below the trunk floor. The angle is such that with the low back seats the belts would fit the way they were intended...within 10 degrees below the shoulders.

I also wanted head rests so I made brackets and welded them to the crossbar. The head rests are adjustable up and down.

I added a dead pedal and a lip to the driver's side 4" tube for the aluminum dropped floor to sit on.

[Fluge]

To add support to the back of the body I added an arched brace across the back that is tucked in under the back upper lip of the body...otherwise my body was resting just on the two back upper corners.

I did the usual firewall A/C mod.

Another challenge with the black body was the driver's side door. The skins hadn't been glued together properly and the only way to get a proper fit without a 3 or 4 inch striker was to cut the back of the door and reglass it. An easier solution would have been to just use a red door but they only came out after I was done.

[Fluge]

Warp speed ahead ....

I then fitted the hood but it was too high along the sides so I had to slice the lower edge off,
Trim the side wall and splice the lower piece back on.

Once the hood was fitted I installed the rad shroud and reinforced the bottom of it with aluminum.

I relocated the e-brake handle to the top of the tunnel. I had to rework the brackets and use some of the many ideas members have posted here and elsewhere.

[Fluge]

I added access doors to the trunk. The gas tank is a Spectra tank.

The rear glass was released just in time...easy to fit and only minor body work needed on an unfinished body to make it look great.

I used Forte's drive shaft loop. I decided I wanted it to be removable but welded to the 4" tubes...so I came up with this. The ends were later welded in place completely.

I bought quite a few pieces from Russ Thompson...door sills, front rad cover, gas pedal, A pillar slats, turn signal and these pontoon covers. Thanks Russ!

[Fluge]

I bought this modular dash from a forum vendor and made dash side pieces with left over material.

I decided to make the cowel vents functional and connected both sides to the footboxes with blast gates.

[Fluge]

I made heat shields for the footboxes using 16 gauge polished SS panels. In addition to the 1/4 inch airgap, there will be a layer of insulation material in between.

I used the Breeze roadster fan shroud and adapted it to the coupe by cutting and riveting it back together.

Knowing I would have the body at the body shop for a while, I made a body buck.

[Rodster]

Fluge -
Thanks for posting your build pictures and notes - I like the dash mods and the structure / body support add-ons you did. The engine-side dash mod - the vertical sheet at the passenger side - should be perfect for my A/C install. (I started to sketch out a more complicated modification, your solution will look better than my original plan.)

Keep it up, I am looking forward to more!

-wayne

[Jacob McCrea]

I also appreciate seeing these build photos; please keep 'em coming!

[Fluge]

When things go missing, this is the number one cause.

Body work has been slow but I am pleased with the workmanship.

I decided to add hood louvers like the Superformance coupe. I made these mesh inserts.

[Fluge]

Yes I borrowed another idea...this time from Russ Thompson...I made brackets to support the A/C condensor...this one almost cost me a finger but 95% healed now.

I made access panels for the rear trunk sides and the driver footbox.

The side pieces of the firewall didn't fit well so I made new ones. I made good use of the body on...body off...body on...body off.... routine...

[Fluge]

I wanted the option of installing a spare wheel in the trunk so I added a plate to the frame and came up with this way of holding the wheel down. I may still add leather straps but just for show.

You can see the shoulder belt anchors and the tie down anchors (x5) I added in the trunk.

[snakebit31]

I think I'll enjoy the time warp. Keep 'em coming!
Q: was it delivered with the aluminum panels installed as in the last pic, or it that your handiwork?

Just to clarify Marc's answer. The panels are shipped from F5 attached, however, they are just positioned and held with a few sheet metal screws. You still need to fit, trim and rivet into place for final assembly.

Rob

[Fluge]

When I had the car loaded onto a flatbed for the first time (on the way to the bodyshop) I realized that I could use a tow hook high enough to spare damage to the body....so I came up with this...a detachable tow hook bolts to this bracket and the hole in the aluminum is covered with a plate when not needed.

[Fluge]

Nothing original on the body work so far...

The vent holes in the quarter windows have been rounded out a bit more since this picture was taken.

[CaptainCalf]

Nice work!

[Fluge]

While the frame was going back and forth to the bodyshop for body fitting, I kept busy by cleaning the aluminum pieces in preparation for sandblasting and powdercoating....

Not having decided on the exact plans for the transmission tunnel, I made a few pieces...one of them still blank.

[Fluge]

Always something to do....

I used POR-15 to clean up the rear end.

[Fluge]

Progress on the body. Slicksand went on and then we refitted the body on the frame for a final test fit. Put on a few of the peripherals also. The A pillar slats were test fitted with the window frames installed to make sure there was no interference.

Sent the bare frame and all aluminum pieces for sandblasting and powdercoating.

[Fluge]

Started bolting things back on...will need to make time to download the latest pictures. I have the front and rear suspension back on at this point

Marc

[Rodster]

This is going to be great to watch. The chassis finish came out really nice.

[Fluge]

Engine has been ready for a few months...can't wait to get it in the car!

This is my engine builder. A GREAT guy.

"In front of 90,000 fans at the Pomona, California Raceway in February, 1970, sport history was made as he became the first Canadian ever to win a major racing championship in a national United States drag racing meet. "

[John Dol]

Marc,

Exciting times in your garage!!

John

[Gbeck]

Engine has been ready for a few months...can't wait to get it in the car!

http://s561.photobucket.com/user/DDO..._2056.mp4.html

Off topic, but couldn't help but notice the nicely modded Limer in the garage, too. Nice!

[CJBergquist]

Looking good Marc. I wish I had pre-assembled my car but my wife would have shot me when I started to disassemble the car.....

[Fluge]

The Limer belongs to my engine builder...that was in his garage. Great looking car.

As for the re-assembly...I know what you mean. I have car parts all over the house but the exercise room took the biggest hit. Good incentive to put it back together though. I thought putting it back together would go faster but there is still a process to follow and lots if details to work out that weren't part on the mock up...such as the insulation.

Marc

[Fluge]

I used bedliner on the fuel tank shield and POR-15 on the tank.

The straps are powdercoated silver

Marc

[Fluge]

My suspension is almost done now. I have the rear 3-link with the Vintage banana brace upgrade. I also welded the banana bracket to the housing. The axle housing was shortened to accommodate the pin drive set up. I also converted the axle housing ends to 9" ends which does away with the center C clip. I noticed that the rear LCA grease fittings were only held in by a single thread so I re-drilled and tapped for a larger thread fitting on each side. The rear lower shock mount bolts were replaced with longer ones that allowed me to add the limiting straps. I know these may not be needed but they hold the rear up about 1/2 inch higher than at full drop...so it should limit anything. The new upper and lower shock bolts have a shank that is just the right length for the application. I just finished making up some brackets to help direct the e-brake cable around the 3-link suspension. I hope to get those painted and installed this weekend.

The front suspension has the SAI mod. I changed the LCA bolts to longer bolts to insure that thread was showing after full Torque. I replaced the original LCA sleeves with the slightly longer ones offered by Breeze. The original UCA sleeves were replaced with slightly longer steel sleeves to insure that I would have enough thread inside to the sleeves.

Marc

[Fluge]

For the manual steering rack I used the breeze Offset rack kit. I'm still looking for nice brake line clips at a reasonable cost...any ideas?

[Fluge]

I installed the rear rotors, calipers and pin drive adaptors.

In order to stabilize the e-brake cable around the suspension, I made brackets with grommets. I still have to mount the one on the banana bracket that you can see just hanging there.

[Fluge]

I welded brackets to the front and back of the main 4" tubes for tie-down purposes. I put these rings on although I could just strap directly in the bracket holes. I know some prefer to tie-down the suspension rather than the frame....I have some ideas for that also.

[Fluge]

Updated Post #30. I really need to get better pictures of the engine but it is out of town at the moment.

Marc