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Thread: Steve's MK IV Coyote Build

  1. #201
    wareaglescott's Avatar
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    Getting close now Steve. The color really looks great. Cant wait to see you finish it up.
    MK4 #8900 - complete kit - Coyote, TKO600, IRS - Delivered 6/28/16 First Start 10/6/16 Go cart - 10/16/16 Build completed - 4/26/17 - 302 days to build my 302 CI Coyote Cobra - Registered and street legal 5/17/17
    Build Thread http://thefactoryfiveforum.com/showt...e-build-thread
    PHIL 4:13 INSTAGRAM - @scottscobra

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  3. #202
    Senior Member shark92651's Avatar
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    I love these threads when people are nearing the finish line. Looking awesome!

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  5. #203
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    I might have missed it but did you get your seats upholstered. I did the same mod to the Kirkey seats but the quote from the upholsterer made me put them on the shelf.

  6. #204
    Straversi's Avatar
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    Quote Originally Posted by DavidW View Post
    I might have missed it but did you get your seats upholstered. I did the same mod to the Kirkey seats but the quote from the upholsterer made me put them on the shelf.
    I'm getting them done now. The first upholstery shop had them for six weeks and never even gave me an estimate. Kept telling me "his guy" needed to look them over and he'd let me know. After a month of ducking my calls, he admitted "his guy" quit and I should just come pick them up. Second shop said he'd work on these in between his bigger jobs and he'd treat me right. Honestly don't know what they are going to cost. I visited more than a dozen shops. It's difficult to get good shops to do small jobs. The two things I didn't do myself are the seats and paint. Fortunately, the paint was a great experience.
    -Steve
    MK IV #8901 - Complete kit, Coyote, TKO-600, IRS. Ordered 5/23/16, Delivered 7/14/16, First Start 8/13/17, First Go-Kart 10/22/17. Build Thread: http://thefactoryfiveforum.com/showt...V-Coyote-Build

  7. #205
    Senior Member Yama-Bro's Avatar
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    Looking great. The paint is excellent!
    Started dreaming of a Cobra around 1987
    Purchased Complete Kit 6/9/2017, Delivered 9/4/2017, Rolling Chassis 3/30/2018
    Click here for my build thread
    Serial #9158
    Design Engineer at BluePrint Engines

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  9. #206
    Straversi's Avatar
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    Custom Roll Bar Harness Cross Bar and Aluminum Door Sill Trim

    Work continues: I added the edged carpet pieces to the door sills. Loved how this turned out. Thanks to Paul (EdwardB) for the instructions on which edges to have trimmed. I have photos in a previous post.



    With the carpet down, I started to trim and fit the aluminum sill pieces I ordered from Dark Water Customs. The piece on the right has been shaped to fit. The piece on the left has not been touched, yet. The passenger side eventually got similar but not exact trimming.

    I put a 50 grit belt on my table top belt sander. Makes a lot of noise and heat but its allows you to shape pieces like this quickly without trying to use a jig saw. More trimming and fitting than I had imagined but I like the end product.



    Finished product here. Not difficult, but high pucker factor manipulating this piece around and then drilling a painted body. Those are reflections in the door, not scratches. Glad it's done.



    While I was at it, I replaced the stacked washers in the door latch with a thick wall aluminum spacer from McMaster 3/4" OD, 5/16" ID, 5/8" long #92510A801. 5/8" long was perfect for the driver's side. I had to sand down the passenger side about 3/32". That part number is a reference only since I doubt any two cars will have the same latch spacing. Just didn't like the look of all those washers.

    Roll bar bracket/High seat belt mount

    Finally got to mount one of my favorite projects. I was planning to use the Breeze Roll bar so I could weld in the cross tube to mount my shoulder belts higher (extra large torso). Unfortunately, I'm too tall for the lower profile Breeze roll bar.

    Plan B was to use the taller FFR roll bar and add a bolt-on cross bar. Apparently a vendor who used to make them stopped. I found a couple options but didn't like them so I thought about making one.

    I had reconnected with a friend from college and on a Scuba Diving trip and I mentioned the MK-IV. He said, well, you know I have a CNC milling machine in my garage so if need any parts made, let me know. The wheels started turning! I downloaded a 10 day free trial of Turbo-Cad for MAC and drew up an assembly that I thought would work. Sent it to my friend and he manipulated it into machine code and started cutting.



    Everyone has a CNC milling machine right? I seriously want one now.



    End caps machined, edges tumbled, bead blasted, clear anodized and mounted.





    Managed to get the Mike Everson Replicarparts roll bar grommets and trim pieces mounted as well. I powder coated the passenger seat belt grommets satin black. They looked odd shinny and polished with only the one set.

    I'm pleased with how this assembly turned out but I enjoyed the process even more. I wasn't planning to learn Turbo Cad, I wasn't planning to have any parts machined, I didn't know that a friend of over 30 years happened to have a CNC mill. Interesting things happen when you mention that you are building a car in your garage!

    -Steve
    MK IV #8901 - Complete kit, Coyote, TKO-600, IRS. Ordered 5/23/16, Delivered 7/14/16, First Start 8/13/17, First Go-Kart 10/22/17. Build Thread: http://thefactoryfiveforum.com/showt...V-Coyote-Build

  10. #207
    DavidW's Avatar
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    Quote Originally Posted by Straversi View Post
    I'm getting them done now. The first upholstery shop had them for six weeks and never even gave me an estimate. Kept telling me "his guy" needed to look them over and he'd let me know. After a month of ducking my calls, he admitted "his guy" quit and I should just come pick them up. Second shop said he'd work on these in between his bigger jobs and he'd treat me right. Honestly don't know what they are going to cost. I visited more than a dozen shops. It's difficult to get good shops to do small jobs. The two things I didn't do myself are the seats and paint. Fortunately, the paint was a great experience.
    -Steve
    My estimates were between $3100 and $3400, be careful and good luck with your seats.
    Nice work on the Dark Water Customs door sill aluminum, it looks awesome! Its a lot of massaging to get those to fit right, I only got finished the DS door and just decided to use the FFR supplied weatherstripping. Your paint sure does shine!

  11. #208
    wareaglescott's Avatar
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    IF this guy has a milling machine in his garage I sure would like to see what else he has in that garage! haha
    Spectacular looking piece.
    MK4 #8900 - complete kit - Coyote, TKO600, IRS - Delivered 6/28/16 First Start 10/6/16 Go cart - 10/16/16 Build completed - 4/26/17 - 302 days to build my 302 CI Coyote Cobra - Registered and street legal 5/17/17
    Build Thread http://thefactoryfiveforum.com/showt...e-build-thread
    PHIL 4:13 INSTAGRAM - @scottscobra

  12. #209
    Straversi's Avatar
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    Quote Originally Posted by wareaglescott View Post
    IF this guy has a milling machine in his garage I sure would like to see what else he has in that garage! haha
    Spectacular looking piece.
    Thanks David and Scott.
    Scott, my buddy built cars in his youth but they are no longer his thing. He’s into sound and electronics. He built the most over the top back yard bar/entertainment area you have ever seen. After he finished my project, he took apart the mill and is setting up a new, larger machine.
    -Steve
    MK IV #8901 - Complete kit, Coyote, TKO-600, IRS. Ordered 5/23/16, Delivered 7/14/16, First Start 8/13/17, First Go-Kart 10/22/17. Build Thread: http://thefactoryfiveforum.com/showt...V-Coyote-Build

  13. #210
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    License plate modification and 3-D printed frame

    A while back I mentioned that I planned to trim the license plate rather than cutting into the license plate light/lens. If I was going to trim the plate I wanted to make a custom license plate frame to cover the trimmed edges.

    First I found a car in my office parking lot with one of the new CA black and gold nostalgia plates (not my plate). I trimmed up a manila folder until I got the size and shape I needed.



    After I drew the roll bar shoulder harness bracket in CAD (previous posts), I drew up this license plate frame and made a 3-D surfaced file. My friend with the CNC mill suggested I print the frame, rather that try to machine it.

    I know nothing about 3-D printing but forum member JDAV steered me to a 3-D print company. I uploaded my CAD file, they reviewed it and said it was suitable for 3-D printing, helped me pick out the appropriate material and gave me an immediate quote, $50. 4 days later I had a finished part in my hand. Mind boggling stuff.



    I made a bracket that would place the plate mounting holes higher. Made it out of 1/8" aluminum so I could tap in threads, 10-32 to mount the bracket to the FFR assembly and 1/4-20 to mount the license plate. Drilled a few 1/2" holes to make it lighter, just because.



    Finished assembly.







    The Kleiner mod is easier and cheaper and time proven. I just enjoyed the process of learning something new. I do like how the smaller plate sits in the stripes.

    -Steve
    MK IV #8901 - Complete kit, Coyote, TKO-600, IRS. Ordered 5/23/16, Delivered 7/14/16, First Start 8/13/17, First Go-Kart 10/22/17. Build Thread: http://thefactoryfiveforum.com/showt...V-Coyote-Build

  14. #211
    Paul2STL's Avatar
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    Great idea Steve. By the way your car is looking awesome love the color and Jeff's work is just beautiful. You put some really nice touches into your car. Keep up the good work.
    MKIV #9122 Ordered kit 5/24/17 received kit 8/11/17 MK4 Base kit +,First Start 4/7/18, First Go-Cart 4/22/18, Coyote gen2, T-56, 2015 IRS 3.31, 17" Halibrand replicas w/Nitto NT555 G2, Withby Motorcars power brake kit W/Wilwood pedals, 04 Cobra front brakes, 15 Mustang rear brakes with mods, power steering. Build thread: http://thefactoryfiveforum.com/showt...Paul2STL-Build

  15. #212
    Straversi's Avatar
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    Getting close

    Inching closer...

    I added more bed liner inside the wheel wells and nose. Jeff Miller put bed liner where it matters. I added it to the areas where if someone is anal enough to lay on the ground and look up into my wheel wells they will see black and not red with blue overspray. I'm probably the only one who will lay on the ground and look up, so I guess this was just for my own satisfaction.

    Rear wheel wells complete with splash guards mounted.



    Installed the rear bumper and over riders. Nothing to add here except that the front and rear over riders are different. No, it doesn't look good to use one of each. Yep, got it right the second time.



    Added the Breeze trunk prop rod. I used this one for its simplicity. It doesn't hold the trunk open as far as the other style but it does the trick. Funny how simple decisions you make months before (like where to mount a rear wiring harness clamp) can make a simple installation of a trunk prop into a serious chore. No big deal, done.



    Lots of work done in this photo. Dash mounted rear view mirror, sun visors, wind wings, Breeze side mirrors, 1/4" OD vacuum tubing filling the top slot in the windshield.



    In Paul's (EdwardB) thread, page 13, he describes cutting and threading a 10-24 bolt with 10-32 threads to make special bolts with a crown nut head so your bolts will match on the upper hinge with the Breeze mirror and the lower hinge without. I wasn't planning on doing that, but it's one of those things you can't un-see. Long story short, the bolts now match. Thanks Paul, I think. This goes back to laying on the ground looking up into wheel wells I suppose.



    Louvers installed. I had these powder coated bright silver. I waited on this because I was undecided on polished vs mill. Decided I didn't want polished but they would be difficult to keep clean if left raw. I like how the powder coating turned out.



    I finally reassembled my transmission tunnel cover. I had the aluminum side channels and the switch panel I fabricated powder coated satin black. I left the switch guards aluminum. Done. Now I just need the seats!



    When I mounted my dash for the final time, I managed to pinch one of the RT turn signal wires. I was able to fix this without pulling the dash but it did require getting my 6' 6" frame under the dash. Start on the passenger side, legs up and over the rear of the car. Hook the right leg on the roll bar and slide into the driver's side foot box. Make sure you have all of your tools and never do this when no one else is home. Also note that this can not be done if the seats are installed. Should have made a video. The exit was worse but the turn signal is fixed.

    The list is getting short. Side pipe mounts, front splash panels, foot box vent hoses and scoop, reassemble the radiator aluminum.....


    -Steve
    MK IV #8901 - Complete kit, Coyote, TKO-600, IRS. Ordered 5/23/16, Delivered 7/14/16, First Start 8/13/17, First Go-Kart 10/22/17. Build Thread: http://thefactoryfiveforum.com/showt...V-Coyote-Build

  16. #213
    edwardb's Avatar
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    Quote Originally Posted by Straversi View Post
    In Paul's (EdwardB) thread, page 13, he describes cutting and threading a 10-24 bolt with 10-32 threads to make special bolts with a crown nut head so your bolts will match on the upper hinge with the Breeze mirror and the lower hinge without. I wasn't planning on doing that, but it's one of those things you can't un-see. Long story short, the bolts now match. Thanks Paul, I think. This goes back to laying on the ground looking up into wheel wells I suppose...
    You caught my disease. Sorry about that. Everything is looking really great. One suggestion would be to put some layers of undercoat or bedliner on the tire facing side of your splash guards. You'll hear stuff pinging off of them if you don't.
    Build 1: Mk3 Roadster #5125. Sold 11/08/2014.
    Build 2: Mk4 Roadster #7750. Sold 04/10/2017. #7750 Build Thread
    Build 3: Mk4 Roadster 20th Anniversary #8674. 03 of 20. 2015 crate Coyote, 2015 IRS. Legal 04/18/2017. #8674 Build Thread
    Build 4: Gen 3 Type 65 Coupe #59. Delivered 12/2/2017. #59 Coupe Build Thread

  17. #214
    wareaglescott's Avatar
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    Eagerly anticipating some graduation pictures! I think the powder coated side louvers are great looking. You have quite a few unique touches that are really making this a great looking build!
    MK4 #8900 - complete kit - Coyote, TKO600, IRS - Delivered 6/28/16 First Start 10/6/16 Go cart - 10/16/16 Build completed - 4/26/17 - 302 days to build my 302 CI Coyote Cobra - Registered and street legal 5/17/17
    Build Thread http://thefactoryfiveforum.com/showt...e-build-thread
    PHIL 4:13 INSTAGRAM - @scottscobra

  18. #215
    Straversi's Avatar
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    Thanks Paul & Scott,
    Ha, you two represent my inner conflict pretty well. I have Scott on one shoulder saying “Finish it, go smoke the tires!” and I have Paul whispering in my other ear “You know it might look better IMHO if you hand made some custom bolts...”

    All kidding aside, thank you both for the compliments. Always encouraging coming from either of you.
    -Steve
    MK IV #8901 - Complete kit, Coyote, TKO-600, IRS. Ordered 5/23/16, Delivered 7/14/16, First Start 8/13/17, First Go-Kart 10/22/17. Build Thread: http://thefactoryfiveforum.com/showt...V-Coyote-Build

  19. #216
    Straversi's Avatar
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    Ventilated Kirkey Seats

    Ventilated seats are in. This should be the last of my one-off projects.

    My original plans called for Kirkey vintage low backs for added head and leg room. I did not care for the Kirkey covers so I started to sketch out some ideas. My first sketches (before I even ordered the Mk IV) were based on the GT-40 seats. The racing GT-40 seats covers were stretched over webbing and a frame so the grommets were functional and provided some ventilation.



    The best feature I ever had on a daily driver was the ventilated seat in an Infinity M-45. That got me thinking...

    Quick research discovered that all of the OEM and aftermarket seat ventilating systems required 4"-6" of foam in the base and were way too complex. I looked into dirt-track and off-road and found air blowers for helmets and cool-suits but nothing to attach to a seat. I did find a composite racing seat that had air plenums integrated into the seat. That was the idea but I couldn't use or afford that seat. I came up with a small, low amp, 120 cfm fan and after many iterations with cardboard, came up with a plenum that I could fabricate and attach to the back of the Kirkey seat. It all had to fit in the small void low behind the seat since I was unwilling to give up any head or leg room.



    I mocked up the assembly (experimented with number and size of holes) and got pretty good airflow so I thought it was worth a shot.



    The grommets were not compatible with the seat heating pads and I wanted to keep the air plenum simple, so I decided to concentrate the airflow to the lumbar area. Since the you really sink into the Kirkeys I figured if I could get any airflow directed to the small of my back I'd be golden.



    First thought was to weld the plenum to the back of the seat, but welding the .040 plenum to the much thicker seat was challenging, so I riveted the plenum to the seat with flush rivets and then sealed it up with several layers of lizard skin.





    I drilled 12 holes in the back of the seat. The trick would be to get an upholstery shop to make seat covers with grommets that would line up with my holes and actually direct and not block the airflow.

    To be continued...
    MK IV #8901 - Complete kit, Coyote, TKO-600, IRS. Ordered 5/23/16, Delivered 7/14/16, First Start 8/13/17, First Go-Kart 10/22/17. Build Thread: http://thefactoryfiveforum.com/showt...V-Coyote-Build

  20. #217
    Straversi's Avatar
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    Ventilated Seats Continued...

    I found a great upholsterer and he had some great ideas on how to pull it off. The difficult part for him was not the holes or grommets, but the fact that I needed to be able to bolt my seats directly to the floor and to the back of the cockpit. His cushions needed to have the grommets, seat heat pads and be at least partially removable. Simple, right?

    Mounting holes and ventilating holes in the seat.



    I also made a small bracket for the seat heater switches. I wanted to hide the more modern looking switches and they fit under the seat perfectly.



    Fan and wiring attached.



    Finished product.



    Installed.



    The grommets in the lumbar are functional. The grommets in the base of the seat are just cosmetic but add symmetry.



    So, was it worth it? I'll let you know after the first long trip up I-5. I like the look if nothing else.

    -Steve
    MK IV #8901 - Complete kit, Coyote, TKO-600, IRS. Ordered 5/23/16, Delivered 7/14/16, First Start 8/13/17, First Go-Kart 10/22/17. Build Thread: http://thefactoryfiveforum.com/showt...V-Coyote-Build

  21. #218
    Senior Member Jdav's Avatar
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    That’s pretty cool. I love the ingenuity
    MK4 #9028 - Coyote - TKO600
    Delivery: 1/30/17 First Start: 7/23/17 Legal: 10/5/17
    Build thread: http://thefactoryfiveforum.com/showt...8-Build-Thread

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