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Thread: Yama-Bro's MK4 Build Thread - #9158

  1. #201
    Senior Member Yama-Bro's Avatar
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    I've questioned whether I should even be worrying about this at this point in the game. Really, the only reason I am is because the manual said to adjust it to 2 up and it seems like others have done it during this part of the build.
    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

  2. #202
    Senior Member broku518's Avatar
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    The dreaded angle, oh boy. You can go so many different directions, up, down, but you need to keep in relation with your tranny shaft. Some people add more spacers, some adjust the bar to rotate the pumpkin. Look at some youtube videos to see this in reality.
    It was really confusing to me at first, but Jeff K. picture and watching videos made it clear. One end goes down, other goes up. I have some notes in my build.
    You can make it really complicated, or really easy

    Tremec app:
    ..However, angles that are 'equal and opposite' are most desirable...


    https://www.youtube.com/watch?v=Idk3BVDVHq4
    Last edited by broku518; 04-30-2018 at 11:18 AM.
    Life is short, so start living it.
    Build thread: http://thefactoryfiveforum.com/showt...-in-the-garage!
    delivery date: 10/31/2017, first start 2/24/2018

  3. #203
    Senior Member Yama-Bro's Avatar
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    Quote Originally Posted by broku518 View Post
    You can make it really complicated, or really easy
    Thanks for the post. I'll check the vid out when I get home. I think I am making this to complicated. I'm going to adjust the pinion angle until the diff is pointing two degrees down. I'm sure that will make my axle have full travel again. Then I will revisit this once I have the engine and tranny installed.
    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

  4. #204
    Senior Member Yama-Bro's Avatar
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    Last night, I got back to making adjustments. I'm almost ready to move onto the next step...

    First off, all these adjustments were done with the rear shocks off, wheels and tires on the axle, and the car on blocks to simulate ride height. I spaced the 4" tubes 4.5" from the ground. This was the first stumbling block I ran into, because I found out my floor jack isn't of the low profile variety. It doesn't go low enough to get under the frame when it's set at ride height. I got by without for this step, but I'm gonna need a new jack eventually. If you are making a list of tools for your build, make sure you have a low profile floor jack.


    I centered the axle in the frame by adjusting the pan hard bar. I put a straight edge across the back edge of the tire and measured to the 4" frame tube on each side. I adjusted until the measurements were equal...
    Passenger side...

    Driver side...


    Next, I readjusted the pinion angle by shortening the upper control arm length. This time I have it set with the front of the diff going 2 down. This took care of the banana bracket hitting the panhard bar bracket. It went from about .25" interference when cycling the suspension to roughly 1.00" clearance. Much better.


    I do have to apologize to ILPBFoot. As I was reading back thru my posts yesterday, I realized he pointed this out to me a while back. Sorry, ILPBFoot. I think the note in the manual about having the pinion 2 up really got me confused. A picture in the manual would do wonders to clear up confusion...
    Quote Originally Posted by ILPBFoot View Post
    Sorry for any confusion....We had the car up on jack stands and set it at 2 degrees down. Then we set it down on the tires with 3 - 2 x 4s under the frame to get the 4.5" ride height. Then once down on the tires I think the pinion angle was close to the 2 degrees up the manual recommends. If you are on the tires and ride height close to the 4 or 4.5" recommended and you are at 2 degrees you are good.

    Steve
    Finally, I remounted the shocks. This time flipped so the coils are up. While doing this I took the opportunity to replace the shock mounting bolts with shorter versions, as the factory five bolts were about 3/8" too long and looked a bit excessive. Unfortunately, after all this, I went to put the wheels on and discovered the tires contact the coil springs. It looks like my options are wheel spacers or shocks with the coil down. For now, against everyone's advice, I am going to flip the shocks so the coils are down and see what I can do with the brake line routing. If it looks to be an issue with brake lines, I'll see what my spacer options are.
    Last edited by Yama-Bro; 05-01-2018 at 09:23 AM.
    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

  5. #205
    Senior Member Yama-Bro's Avatar
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    I tried using some washers as spacers behind the wheels to see what a thick .20" spacer would gain me for clearance. Once the wheel was installed with the makeshift spacers, I discovered I had about .75" clearance between the shock and the tire....What? That can't be right? If they hit before and I add .20" spacers how do I have .75" clearance? Well, it turns out, I must've been stupid or tired the other night and didn't have the wheel seated properly. I put the wheel on without spacers and found I have about .5" clearance. So all is good.



    Now I'm ready to move onto another part of the build...
    Last edited by Yama-Bro; 05-03-2018 at 07:50 AM.
    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

  6. #206
    Senior Member Fixit's Avatar
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    Well, it turns out, I must've been stupid or tired the other night and didn't have the wheel seated properly.
    Don't beat up on yourself too much... we've all been there. (I'm juggling three 25+ camera & intercom installs across two states AND a nationwide/60+ location Card Access conversion - getting a little stupid or tired is easy!)

    Got the jack covered... "Blackie" is already lower than the Roadster will be!

    Low.jpg
    John D. - Minneapolis 'Burbs

    1965 El Camino - LT-1, 4L60e, 4wh discs, SC&C susp.
    2013 F-150 Platinum - Twin Turbo 3.5
    2018 Mk4 Roadster - On the way! Build Thread

  7. #207
    Senior Member Yama-Bro's Avatar
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    Quote Originally Posted by Fixit View Post
    Don't beat up on yourself too much... we've all been there. (I'm juggling three 25+ camera & intercom installs across two states AND a nationwide/60+ location Card Access conversion - getting a little stupid or tired is easy!)

    Got the jack covered... "Blackie" is already lower than the Roadster will be!

    Low.jpg
    Thanks man, we'll mark it up to being tired then. Most of my other "toy" vehicles have been ATVs, motorcycles, or Jeeps, so I never had a need for a low profile. I guess it's time.
    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

  8. #208
    Senior Member Yama-Bro's Avatar
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    I took Friday off last week. My plan was to spend the whole day working on the car. I didn't get as much done as I wanted, but I had a lot of fun and everything that I did do went really smooth. I also ended up selling my Harley the that day. It was sad to see it go, but the money is going to go towards the engine and tranny for the car, so that's a good thing. It also opens up a lot of space up in my garage, which is also welcome.

    Anyways, the task for Friday was gas tank install...
    All the parts...


    Fuel level sender parts...


    Fuel level sender parts installed...


    Fuel pickup and vent/rollover valve parts...


    Fuel pickup and vent/rollover valve parts installed...
    I didn't completely lock down the pickup flange, since I haven't determined my fuel pump strategy yet


    Filler neck installed...
    Last edited by Yama-Bro; 05-14-2018 at 02:33 PM.
    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

  9. #209
    Senior Member Yama-Bro's Avatar
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    In the manual it said to flatten out the tank flange so it would sit flat against the standoffs on the frame. It said to use pliers. I tried using a large crescent wrench instead. I thought it worked great. It has a wider contact patch than a pair of pliers, and I had plenty leverage...
    Before...


    After...


    Next, I used the always handy ATV jack to lift it up in place. I thought about selling this jack when I got out of ATV riding. I'm glad I didn't because I keep finding new ways to use it.


    Top-down view of it lifted into place...


    I swung the straps under the tank and attached them to the frame. The driver's side looks perfect...


    The passenger side reached with plenty of threads, but the bolt wasn't perpendicular like the drivers side. I assume this is the way they are sometimes?
    Last edited by Yama-Bro; 05-14-2018 at 02:00 PM.
    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

  10. #210
    Frank,

    I used some aluminum tube as a spacer on the tank strap bolts to help straighten them up. Mine looked the same as yours without the tubing.

    Dave
    There are 10 types of people in this world;
    those who understand binary and those who don't.

    My Build Thread: http://thefactoryfiveforum.com/showt...ter-Build-9754

  11. #211
    Senior Member Yama-Bro's Avatar
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    Next I did Jeff Kleiner's quick jack attachment mod. For anyone who doesn't know what this does; it basically allows you to remove the quick jacks (and body) without dropping the tank. Seems pretty handy to me. Note: I did this right before bolting the tank in all the way. You can't access the lower passenger side with the tank fully installed.

    I looked all over town for 7/16" coupler nuts. I finally found them in a tractor store. After starting this project, I'm beginning to think I need to open a fastener/hardware store in this town . No where ever seems to have what I need. I ended up buying 7/16-14 UNC x 3/4" long bolts. I threw on some metric washers, I believe 14mm, because they have a smaller OD than 7/16 washers. The coupler nuts are 7/16 thread x 1.75" long.


    Bolts installed, viewing from the inside of the frame looking back...
    I did put a drop of blue loc-tite on these to make sure they stay in place.


    Quick jack mounting points as viewed from the back.
    Last edited by Yama-Bro; 05-15-2018 at 10:04 PM.
    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

  12. #212
    Senior Member Yama-Bro's Avatar
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    Quote Originally Posted by Papa View Post
    Frank,

    I used some aluminum tube as a spacer on the tank strap bolts to help straighten them up. Mine looked the same as yours without the tubing.

    Dave
    Good idea Dave! I'll get some tube and give it a try. Thanks again!
    Last edited by Yama-Bro; 05-14-2018 at 02:37 PM.
    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

  13. #213
    Nice headway, Frank, and the rear axle looks fantastic.

    Post #127 gave me a chuckle. I spent over 30 hrs chasing my tail with my IRS rear gear pattern, then I bought the same book. I kinda wish I'd switched the order.
    MK4 #7838: IRS 3.55 TrueTrac T5 331

  14. #214
    Frank,

    First no need to apologize in post #204. Glad it all worked out.

    How long are the 7/16" coupler nuts you bought? You said a 3/4" long bolt but nothing on the nuts. Looks like about 2 inches?

    Thanks

    Steve
    Mk4 Roadster #3919, complete kit Received 4-10-18. Moser 8.8. Wilwood front and back brakes. Blue Print 427 w TKO 600

  15. #215
    Senior Member Yama-Bro's Avatar
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    Quote Originally Posted by John Ibele View Post
    Nice headway, Frank, and the rear axle looks fantastic.

    Post #127 gave me a chuckle. I spent over 30 hrs chasing my tail with my IRS rear gear pattern, then I bought the same book. I kinda wish I'd switched the order.
    Ha ha, I'm starting to think we all have those moments.
    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

  16. #216
    Senior Member Yama-Bro's Avatar
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    Quote Originally Posted by ILPBFoot View Post
    Frank,

    First no need to apologize in post #204. Glad it all worked out.

    How long are the 7/16" coupler nuts you bought? You said a 3/4" long bolt but nothing on the nuts. Looks like about 2 inches?

    Thanks

    Steve
    You are close. They are 1.75" long. They were the only option, so I went with it. I've read of other's using 1/2" long bolt, but I could find any of those in 7/16". That's also one of the reasons I decided to use a washer under the bolt, (to reduce the thread engagement).
    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

  17. #217
    Senior Member Yama-Bro's Avatar
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    Ok, so through out this build I've wondered where some of you guys are finding your information in the manual. I just wasn't seeing some of it. In fact, I've heard other people say the manual is pretty good...I was really starting to disagree with that. Well tonight, I was trying to figure out what do do with all these pedal box parts. There is nothing in the manual about the Wilwood pedal box. That's when I noticed....I have the base kit manual. LOL no wonder there's a lot of stuff left out of it. Hopefully FFR will send me the right one. I think it'll make the build a little easier.

    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

  18. #218
    Hey Brother that only goes to show how good you are.....the instructions are cheating...lol

  19. #219
    Senior Member Yama-Bro's Avatar
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    Quote Originally Posted by Scubasommer View Post
    Hey Brother that only goes to show how good you are.....the instructions are cheating...lol
    haha, thanks! I've been doing a lot of looking at pictures on this forum. That helps a lot.
    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

  20. #220
    Quote Originally Posted by Yama-Bro View Post
    Ok, so through out this build I've wondered where some of you guys are finding your information in the manual. I just wasn't seeing some of it. In fact, I've heard other people say the manual is pretty good...I was really starting to disagree with that. Well tonight, I was trying to figure out what do do with all these pedal box parts. There is nothing in the manual about the Wilwood pedal box. That's when I noticed....I have the base kit manual. LOL no wonder there's a lot of stuff left out of it. Hopefully FFR will send me the right one. I think it'll make the build a little easier.

    Okay, that makes sense. I was thinking, "how did he get that far ahead of me, tracking down two kids and still getting to the fuel tank before I did?" Then I saw photos without anything done with the pedal box. Now I know why
    MK4 #7838: IRS 3.55 TrueTrac T5 331

  21. #221
    Senior Member Yama-Bro's Avatar
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    Quote Originally Posted by John Ibele View Post
    Okay, that makes sense. I was thinking, "how did he get that far ahead of me, tracking down two kids and still getting to the fuel tank before I did?" Then I saw photos without anything done with the pedal box. Now I know why
    Yep, I've been jumping around a bit and doing some things out of order. Or at least what I thought was out of order.
    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

  22. #222
    Senior Member Yama-Bro's Avatar
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    I didn't have a lot of time to devote to the Cobra this weekend, but I still managed to make a little progress. We cut out the opening in the firewall for the heater and temporarily installed the firewall on the frame. I am considering Mike Forte's mechanical throttle linkage. Would this be a good time to install it? Or is it better to do once I have the engine between the frame rails? Also...is this the time to rivet the firewall? Or can we still do it later? Thanks!

    I printed the pattern in the back of the instructions at 100% scale and cut it out with scissors and my precision surgery scalpel.


    The instructions suggested checking the pattern to the heater. Good thing I did, the holes were off far enough that the grommets wouldn't have fit right.


    I relocated the holes...


    And taped the pattern to the firewall...


    I used a combination of metal cutting shears, drill bits, and hole saws to cut out the holes.


    Then using a die grinder, I smoothed out the sharp edges...


    The boys came out and helped drill holes and cleco...
    Last edited by Yama-Bro; Yesterday at 06:26 PM.
    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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