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Thread: 40 Watt Garage & #9365

  1. #81
    Senior Member Clover's Avatar
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    Quote Originally Posted by Fixit View Post
    It is on the truck! It was the 1st kit on the truck, which means it's the last off the truck, but it's on the truck!!
    Wow, I had the same thing happen to me. Jolene had me thinking my kit would be delivered in a week and then I ended up as the first kit on the truck and will be the last off the truck. I did not find out I was last on the truck until after the truck had already driven by me. Last on the truck sucks, feels like it should come with a discount due to how long it takes. I hope you still have some hair left by the time your kit gets to you.

  2. #82
    Senior Member cv2065's Avatar
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    Nice! Mine ‘should’ get picked up this week and delivered next week. Hopefully that schedule keeps!
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  3. #83
    Senior Member Fixit's Avatar
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    Kit Delivery

    Spoke to the Stewart driver yesterday afternoon. He's on track for delivery Monday 7/2, mid-morning! dancenana.gif
    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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  4. #84
    Senior Member cv2065's Avatar
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    Quote Originally Posted by Fixit View Post
    Spoke to the Stewart driver yesterday afternoon. He's on track for delivery Monday 7/2, mid-morning! dancenana.gif
    Nice!! Perfect timing for the holiday! Did the driver call you right when he picked up your kit or after he was on the road?
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  5. #85
    Senior Member Fixit's Avatar
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    After getting all the kits loaded for a run and planning his route, this particular driver (Jim) calls each owner the evening after leaving FFR. Depending on your slot in the truck, he gives a rough estimate on arrival. Once he get got closer he called and gave me the day and an expected ETA time window.

    (I have called him directly twice this past week, just checking that things are going to schedule... not being a "noodge or expectant mother", but I've got a LOT of irons in the fire right now and Monday has to be MkIV day. He has been very cordial and understanding.)
    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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  6. #86
    Senior Member Fixit's Avatar
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    One of the "irons in the Fire" going on is moving my Mom from an Independent Living senior apartment to a Hospice Care facility (Her Pulmonary Fibrosis ramped waaaayyyy up, and she's not able to care for herself anymore).

    What to do with a 3" memory-foam mattress topper?? Those things are impossible. Bought a "Space Bag" and folded the thing up and in, but how to suck all the air out??
    Found a new use for a Ford IRS center-section!
    A hundred pounds of steady-pressure weight and an occasional suck-out of the air and this thing'll be flat in no time!

    IMG_20180630_174622395[1].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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  7. #87
    Senior Member Fixit's Avatar
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    40 Watt Garage - Mk4 Build - It's Here!!

    Foremost I'd like to thank "Stillwater35" and "John E" for giving up a few hours of their Holiday weekend to stop by and help with the unload! Their help with the boxes and photography really made the job go quickly!

    My long wait is over!

    Advise to others for delivery day:
    - Drive the route into your place with a big-rig in mind. (If there's low branches or too-tight corners you'll be unloading somewhere other than your driveway! I met the driver out on the "main" road, he parked, and I drove him into my neighborhood to check and be satisfied he could manouver/get out.)
    - Have some helpers on hand (It will go much quicker, and the driver will thank you)
    - Designate a photographer (you'll be too busy & grinning like an idiot to take decent photos)
    - Have your chassis dolly/jackstands ready! (Steward has a big tire'd cart to get the car up the driveway, but after that it's on you)
    - Have at least 10' x 10' of clear floor space for your boxes, and a place to open them and do inventory later.

    Enough gabbing... onto the fun stuff - #9365 is in the house!
    001.png 003.png 004.png 007.png 011.png 014.png 021.png
    022.png 023.png MrsFixit01.png
    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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  8. #88
    Senior Member KDubU's Avatar
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    Now the fun begins!
    Kyle

    Complete Kit pickup 09/05/2015, 351w, QF680, 3.55, 3-Link, 15" Halibrands with MT's, Painted Viking blue with Wimbledon white stripes on 03/15/2017. Sold in 08/2018 and totally regret it.

  9. #89
    Senior Member Fixit's Avatar
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    Finished my inventory yesterday afternoon.
    Only 1 item "AWOL" - the entire hood hinge package... it isn't here. (at least I won't be needing that for a year!)

    There's several items on the "POL" sheet, but only two that are mission critical to get started - the 4 threaded sleeves for the shocks/springs, and the CV/axle shafts. Not having these parts puts a stop to hanging the suspension pretty quickly. I'll call FFR after the holiday and try to get an ETA on those, and report the missing hinges.

    That's about it at the 40 Watt. Going to head "up nort to da cabin doncha know".
    Have a safe Independence Day - come home with all the fingers you started with!
    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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  10. #90
    Senior Member Higgybulin's Avatar
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    I am so jealous right now!!!!! I'm sure you'll be enjoying your holiday!!! CONGRATS!
    Higgy

  11. #91

    Steve >> aka: GoDadGo
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    Congratulations Mr. Fixit, Congratulations!

  12. #92
    Senior Member edwardb's Avatar
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    Quote Originally Posted by Fixit View Post
    There's several items on the "POL" sheet, but only two that are mission critical to get started - the 4 threaded sleeves for the shocks/springs, and the CV/axle shafts. Not having these parts puts a stop to hanging the suspension pretty quickly.
    Sounds like a short POL. Nice. You can get a ton of work done on the front and rear suspension without those parts. The assembled coilovers can easily be added to the completed front and rear suspensions. The CV axles can be added into the rear suspension by removing the UCA to knuckle bolt. The knuckles swing down and allow the axle to go in. Just don't tighten that top bolt until you have the axles.
    Build 1: Mk3 Roadster #5125. Sold 11/08/2014. Build 2: Mk4 Roadster #7750. Sold 04/10/2017. Build Thread
    Build 3: Mk4 Roadster 20th Anniversary #8674. Sold 09/07/2020. Build Thread and Video. Build 4: Gen 3 Type 65 Coupe #59. Gen 3 Coyote. Legal 03/04/2020. Build Thread and Video
    Build 5: 35 Hot Rod Truck #138. LS3 and 4L65E auto. Rcvd 01/05/2021. Legal 04/20/2023. Build Thread. Sold 11/9/2023.

  13. #93
    Senior Member Fixit's Avatar
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    Yup... the POL is mostly some of the option parts ordered, the PS hoses, and the roll bar - nigglypiggly stuff that can arrive as it does.
    Seems that Koni parts have been a problem (at least what the threads are reporting).
    I'm tempted to fab up some "dummy" solid shocks/springs out of some tubing to have a rig to bolt in. Not too crazy about having all the suspension stuff hanging at full-droop for a month or better.

    Brings up an interesting question. How much fun would it be for those of you with completed cars (established ride height) to get a center to center measurement (+/- an eighth inch) of the upper & lower shock mounts bolts? Front & Rear would be needed.
    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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  14. #94
    Senior Member Fixit's Avatar
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    40 Watt Garage - Mk4 Build - Post delivery body removal

    Made some progress today...
    Got the body separated from the chassis, and fab'd up a flying rig to hang the body from the ceiling.

    I used the dimensions from the numerous "Body Buck" plans out there, but be warned - they are close but no cigar. You'll have to take the main "humpy" pieces and fine-tune them to contour to your body.

    I'm mainly on my own for all shop sessions, and this was no exception. I built the flying rig, removed the body, set it on the rig, and got it flown with one person. (Not gonna say it was easy, but common sense, my engine crane, and going slow & easy are the key).

    "Blackie" is a bit nervous tonight... not too crazy about #9365 in the upper bunk.

    IMG_20180704_204132346_HDR.jpgIMG_20180704_204202414_HDR.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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  15. #95
    Senior Member edwardb's Avatar
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    Quote Originally Posted by Fixit View Post
    Not too crazy about having all the suspension stuff hanging at full-droop for a month or better...
    Not that much difference between full-droop with or without the coilovers. Especially the rear suspension. IMO not an issue.
    Last edited by edwardb; 07-05-2018 at 06:16 AM.
    Build 1: Mk3 Roadster #5125. Sold 11/08/2014. Build 2: Mk4 Roadster #7750. Sold 04/10/2017. Build Thread
    Build 3: Mk4 Roadster 20th Anniversary #8674. Sold 09/07/2020. Build Thread and Video. Build 4: Gen 3 Type 65 Coupe #59. Gen 3 Coyote. Legal 03/04/2020. Build Thread and Video
    Build 5: 35 Hot Rod Truck #138. LS3 and 4L65E auto. Rcvd 01/05/2021. Legal 04/20/2023. Build Thread. Sold 11/9/2023.

  16. #96
    Boydster's Avatar
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    Quote Originally Posted by Fixit View Post
    Brings up an interesting question. How much fun would it be for those of you with completed cars (established ride height) to get a center to center measurement (+/- an eighth inch) of the upper & lower shock mounts bolts? Front & Rear would be needed.
    As I found out when setting ride height and my car was quite different from some other, very popular builds... so much so that I thought something was wrong. A small weight change on the front can make a significant difference in the shock ride height settings. They will NOT all be same, some may not even be close.
    ---Boyd---
    MkIV #9042 build thread
    www.boss427.us
    427W, TKO600, Moser 3.55 rear.
    Delivered Feb 2017, Graduated Nov 4, 2019

  17. #97
    Not a waxer Jeff Kleiner's Avatar
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    Congrats on the arrival!

    I agree that letting the suspension hang is a non-issue however if you do wish to make up some tubes to serve as place holders for mock up with the typical 4.5 to 5" ride height the front is ~14" center to center, rear with 3 link is ~16" and T-Bird IRS is ~14". I do not have a car with the '15 IRS here right now so can't help with that dimension if that's what you are using. Perhaps Paul or someone else with that configuration will get that for you.

    Cheers,
    Jeff

  18. #98
    David aka Ducky2009 Ducky2009's Avatar
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    Quote Originally Posted by Fixit View Post
    Made some progress today...
    Got the body separated from the chassis, and fab'd up a flying rig to hang the body from the ceiling.

    "Blackie" is a bit nervous tonight... not too crazy about #9365 in the upper bunk.......
    Well John, if your garage is too full, I'll volunteer to safe keep your El Camino for a year while you're building the roadster. LOL

    Congrats and welcome!
    MK4 Build #9035 Delivered 2/17/17, First Start & Go-Kart 6/2/17, Licensed 9/1/17
    Paint - Lightning Blue Metallic, No Hood Scoop, No Stripes
    Gen 2 Coyote Engine & TKO-600. Solid Axle, 8.8-3.55, Power Steering, Power Brakes, Dual Roll Bars
    Heater and Glove Box, Drop Trunk, Wipers, Radio, FFR Vintage Gauges, Custom Dash
    Build Thread: http://thefactoryfiveforum.com/showt...MK4-Build-9035

  19. #99
    Senior Member Fixit's Avatar
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    Well John, if your garage is too full, I'll volunteer to safe keep your El Camino for a year while you're building the roadster. LOL
    I've already got a Chevelle Club buddy offering space in his shop...
    The last of my "direct from Ford" backorder (via Forte's) arrived yesterday - the Controls Pack for the Coyote.

    Now that I've got the dang car here, I don't have any time to wrench! I'm doing "Road Warrior" nearly every week for the next 90 days!
    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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  20. #100
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    CONGRATULATIONS! I'll be following your build closely 'cause I am just about ready to order. Gotta finish my new house first. However I'll be doing an old school SBF BOSS 302 with IRS, Love your dolly.

  21. #101
    Senior Member cv2065's Avatar
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    Hey John. Thanks for the delivery day advice. Started thinking about a few things. When I had my 67 Camaro picked up once sold, a guy came into our neighborhood with a pretty long car carrier connected to a Dualie, that I would say held 5 cars in a row. He didn't seem to have any issues coming in, but we do have a lot of morons that park on the side of the road when they shouldn't be. My roads look about as wide as yours. That FFR truck looks pretty long. I take it the driver tries everything he can to get into the neighborhood.

    I guess if it doesn't fit, then its time for a U-Haul trailer of some kind? I'll have ask the driver what would need to be done as a 'Plan B'.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  22. #102
    Senior Member Fixit's Avatar
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    Yeah... a 5th-Wheel car hauler on a dualie is nothing compared to a Kenworth w/ dbl sleeper pulling a 53' trailer.
    The driver's concerns are:
    Tight radius corners (90-deg w/ parked cars)
    Width (again parked cars)
    Low hanging branches or service lines (Leaved limbs that would brush out of the way seemed to be OK, but nothing that'd scratch/gouge/hole the trailer)

    Plan B could be as simple as a couple buddies with pickups for the boxes, and if it's not too far, your chassis/body can make it to the driveway on Stewart's big-tire cart. (2nd pic on delivery set above)
    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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  23. #103
    Senior Member Fixit's Avatar
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    40 Watt Garage - Mk4 Build - Tins/Panel work

    I've been on the road all week, with an itch I couldn't scratch!
    Lucky for me I have a wonderful/beautiful/compassionate woman who told me "I know it's killing you, go out to the shop and work on your car... BUT - You're taking me out to dinner tonight!" DEAL!!
    Garage East_7-14-2018_11-37-35-961 AM.jpg

    Some of the 1st steps in the build manual instruct you to pull all the tins, save the screws, and get started with the "F" panels and suspension.
    However this got me thinking.
    Looking a the panel attachment/alignment from the factory - It's really pretty damn good! Whoever's putting the panels in, and running the TEK screws in is doing a very good job. Why waste all this work?

    I decided to work on the footbox & firewall tins first. I've got all the tins from the firewall forward fitted, trimmed, holes deburred, and in a pile for paint.
    Tools:
    Supplied spacing gauge
    12" & 36" stainless straight-edge/ruler
    Fine-point Sharpie
    Cordless drill
    1/8" HSS bit
    RH, LH, and Straight tin snips
    Fine-tooth Mill File
    Counter-sink bit
    Panel Seamer (HVAC/Ductwork tool - you can get them cheaper than HD, but just for an idea of what to get)
    Cleco's (Got my kit from these guys - Trick Tools)

    The only trimming needed was where a panel layed down/ended on a flat near a weld bead. (I'm guessing the tins were laid out off of the CAD file for the frame, and if there was no weld bead, the edges would line up exactly.) I had to trim off between 1/8 & 3/16 in a few areas to get the panel to sit flat. No big deal.
    Also, when the panels are Cleco'd together, mark any areas or corners that really should have a radius on them.

    After all the holes were drilled and the panels removed, I twirled the countersink (by hand!) in each hole to break the burr off. (Don't reshape the hole, just break the edge.) Take your file & snips and make any radii that you noted.

    Today will probably be deburring the long edges & cleaning, and shooting the panels with some acid-etch primer. (Haven't decided on final color yet).

    You'll also see a few reasons for my "elevated" chassis dolly.
    Dolly_12.jpgDolly_13.jpg

    DS_Footbox01.pngDS_Footbox02.pngDS_Footbox03.pngDS_Footbox04.pngDS_Footbox05.pngDS_Footbox06.pngDS_Footbox07.png
    Last edited by Fixit; 07-15-2018 at 07:57 AM.
    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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

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  25. #104
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    Dang. There is a lot of aluminum on the roadster! It's so fresh and clean looking too.

  26. #105
    Senior Member cv2065's Avatar
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    Plan B could be as simple as a couple buddies with pickups for the boxes, and if it's not too far, your chassis/body can make it to the driveway on Stewart's big-tire cart. (2nd pic on delivery set above)
    I’m thinking this is the way we’ll have to go. How many people did it take to transfer the frame/body to your dolly from the big wheeled cart?
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

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  28. #106
    Senior Member Fixit's Avatar
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    The Chassis/Body was lowered right from the truck onto my dolly - no transfer - no effort.
    The whole rig only weighs a few hundred pounds. 4 guys would be plenty to lift it off of the Stewart cart onto your dolly/jackstands.
    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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  29. #107
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    When mine was delivered the driver lifted one end off the cart at a time so we could fit jack stands under it. I have since done the same easily

  30. #108
    Senior Member cv2065's Avatar
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    Quote Originally Posted by Fixit View Post
    Looking a the panel attachment/alignment from the factory - It's really pretty damn good! Whoever's putting the panels in, and running the TEK screws in is doing a very good job. Why waste all this work?
    I was thinking the very same thing!
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  31. #109
    Senior Member Fixit's Avatar
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    Back from a wonderful week in Wausau WI... job from hell/wrong parts/subs not done/spent more on next-day...

    Anyway - Had a bunch of my POL items waiting for me when I got back home, most importantly my CV/Axle shafts!
    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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  32. #110
    doddmoore's Avatar
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    Do you have plans for that dolly, OR what I really would need are the dimensions you used for the width and the length where the dolly meets the frame.

    Thanks in advance.
    "Doddmoore," Mitchell Moore on facebook, Follow Tonks347Cobra on Instagram
    MK IV Complete kit, SB Ford 347, Holley Sniper EFI, TKO 500, Moser 8.8 Solid axle, Wilwoods, Power Steering
    My Build Thread: Tonks347, The Baker's Build
    Slow and steady wins the race.

  33. #111
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    The width of the dolly between the two shoulder stops should be 19" that leaves room to wrap with carpet for protection if you choose, the overall length is 60". That could be more if you prefer.
    Build#1: MKIV Roadster #9320

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  35. #112
    Senior Member Fixit's Avatar
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    Total overall length is 60"
    Distance between the "saddles" is 24" (to the bottom/center of the 4" radius cut into the 4x4 uprights)

    (Haven't gotten around to making a dimensioned drawing of the rig yet.)
    Casters & Step-Jack Locks are from Northern Tool
    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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  36. #113
    Senior Member Fixit's Avatar
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    40 Watt Garage - Front Suspension

    Time for an update. After a wonderful week in Brookings SD, I was able to spend some quality time in the 40 Watt Garage on the roadster.
    Friday was front suspension day.
    Saturday was rear suspension day.
    Sunday was flying to Greenville SC...

    Friday:
    After gathering all my parts together I got started assembling. I am impressed with the weld & jig quality by FFR. I didn't have any problem getting the lower A-Arms into the sockets, although getting a wrench on the upper A-Arm cross-shaft nuts is a bit tricky.

    I have the exact same style upper A-Arms on my '65 El Camino, and I learned an important lesson installing those - lube the crap out of the adjustment sleeves before bolting them on the car.
    You'll have to dis-assemble the arms to flip the balljoint hole to the correct angle, and this is the perfect time to do it.
    (If you don't lube them up, it will be very difficult to crank the adjuster sleeves when there's weight on the suspension... don't ask me how I know. A liberal slathering with Anti-Seize inside the adjuster will do. Just be warned - this stuff is diabolical and regardless of how careful you are...
    antiseize.png

    Shock & coil assembly is straightforward (why don't they include an adjustment spanner??)
    Spindle & steer-arms is also straightforward (pay attention to the instructions!! You install the steer-arms on the "wrong" side of the car)


    Here's a few pictures:
    002.jpg003.jpg004.jpg005.jpg006.jpg007.jpg008.jpg009.jpg010.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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  37. #114
    Senior Member Fixit's Avatar
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    40 Watt Garage - Rear Suspension

    Saturday:

    Time to get that 85lb. lump of aluminum off my parts washer cabinet!

    Surfed around for a bit, and of all places Menards had the required 5/8" drill bit (about $12) to open up the mounting holes on the differential housing and the suspension knuckles.
    Word of Caution Here:
    For those who haven't done this type of operation before, there's a few things to be aware of...
    - you're opening up an already large hole, by not very much - and the 5/8" bit IS going to grab and pull in hard.
    - have the workpiece securely clamped or have a helper really hang on to it.
    - try and feed the bit in slowly and take small bites at it.

    Cutting off the "ears" on the knuckles:
    If you don't have a metal-cutting bandsaw, a "Porta-Band", or a reciprocating (SawzAll) saw, beg/borrow/buy/rent one. It will make this job a breeze. Measure twice, cut once.
    After the tabs were cut off, I dressed the surface and edges with a mill file. I also filled the ABS sensor holes with clear silicone.

    Mounting the Differential:
    This thing's a beast, and it's HEAVY. There's not much room to work. Have the following tools & supplies ready:
    - A couple of long drift punches
    - Rubber Mallet
    - Old Towels
    - Required mounting bolts from the hardware kits.

    Install the bushings and sleeves per the instructions

    I set the differential on a couple of milkcrates, and slid it under the car. I laid a towel on the frame crossmember (under the U-joint area) and got mentally ready for this.
    - With a hefty grunt, lift the differential up & over the crossmember, and get the forward ears on top of the lower control arm mounting tabs.
    - Have a drift punch ready, and pivot the rear of the diff up. Get a drift through one of the mount tabs, and into the diff housing.
    - Hang on to it, and get the other drift into the other hole.

    There will be some space between the rear mounting ears and the frame tabs. The diff will be resting ON the control arm tab, the drift punches holding the rear - it's really close to being aligned.

    - Get the forward bolts and the rubber mallet ready
    - Lift up on the front of the diff, and slide it rearward on the drift punches (don't let them fall out of the frame tabs)
    - Get a forward mount bolt into the hole, and persuade it into the frame tab with the mallet. Repeat on the other side.

    You should now be able to replace the drift punches with the proper rear mounting bolts (one at a time!)
    - NO TOOLS here - Get the bolts started into the threads by hand!
    - Once both bolts are started by several threads, then break out the tools.
    - Torque all fasteners to the recommended amount.

    I installed the differential by myself, in under an hour. If you work carefully, smart, and have the right tools at the ready it is not a bad job. Having the differential 95% of the way up into it's hole (milk crates) was a huge help - I only had to lift it about 6" to get it up and into the frame.
    001.jpg 002.jpg 003.jpg 004.jpg 005.jpg 006.jpg

    Control Arms & Knuckles:
    After the differential, this was a breeze. The instructions aren't as clear as I'd like, but things go together well.
    - I'd advise doing the anti-seize slather on the upper main arm, and toe-arm internal threads (where the reducing bushing and Heim joint go together.)
    - Your friends will be the drift punches and rubber mallet.
    The arms fit very tightly into the frame tabs.
    I did "tweak" the lower ends of the tabs outward a bit to get the arm bushings started into their spots - use a BIG adjustable wrench gently closed on the tab, and give it a little bend.

    007.jpg 008.jpg 009.jpg 010.jpg

    (Attentive readers will note there's something missing... No Axle Shafts! I want to replace the axle shaft seals on the differential housing before installing the half-shafts - so none of the arm bolts are final torqued, or the coil overs installed yet.)
    Last edited by Fixit; 07-25-2018 at 08:29 PM.
    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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

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  39. #115
    Not a waxer Jeff Kleiner's Avatar
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    Great progress with nice photos and good text John!

    Question: I think yours is the newest I have seen photos of; maybe it's just the pics but it appears that your powder coating is a satin finish black. They've always been gloss black. Which is it?

    Carry on!

    Jeff

  40. #116
    Mark Eaton's Avatar
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    I have the exact same style upper A-Arms on my '65 El Camino, and I learned an important lesson installing those - lube the crap out of the adjustment sleeves before bolting them on the car.
    Thanks for the tip. There's something else I will go back and redo...
    MK4 #9130 , complete kit, arrived 8/10/2017, Street Legal 2/14/2020.
    DART SHP 347, EFI, TKO600, IRS
    http://thefactoryfiveforum.com/showt...n-Build-Thread

  41. #117
    Senior Member Fixit's Avatar
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    For whatever reason my chassis and suspension parts are a satin/semi-gloss black... and I actually don't mind. I prefer the lower gloss (hides scuffs/scratches better!)
    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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  42. #118
    Not a waxer Jeff Kleiner's Avatar
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    Quote Originally Posted by Fixit View Post
    For whatever reason my chassis and suspension parts are a satin/semi-gloss black... and I actually don't mind. I prefer the lower gloss (hides scuffs/scratches better!)
    Hmmm, I'll check with FFR to see if that is now the norm. Have to say that I'm not a fan of it. About to place a Coupe order and if satin/semi is what they're doing on everything now I'd rather go uncoated and get it done here.

    Jeff

  43. #119
    Senior Member cv2065's Avatar
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    Quote Originally Posted by Fixit View Post
    For whatever reason my chassis and suspension parts are a satin/semi-gloss black... and I actually don't mind. I prefer the lower gloss (hides scuffs/scratches better!)
    Same with mine. It’s a Satin finish on the frame.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  44. #120
    Senior Member Fixit's Avatar
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    Got back from South Carolina yesterday afternoon... I don't know how you "Southern Boys" handle that humidity - everytime I stepped out of an air con'd building my glasses fogged over for 3 minutes! (I guess you could ask how we handle 15 below zero for a month, but you know if the air HURTS, you're still alive...)

    Being pro-active on the way from the airport, I stopped at my local NAPA and picked up a couple of axle seals. My little alarm bell didn't go off when the putz behind the counter asked me "What gear ratio is the rear end?" (Why do you need to know the ratio?) Whatever... $30 lighter I got home and checked. NOPE, wrong parts. Ran the number and he gave me 2 pinion shaft seals, not axle shaft seals. I've got the correct parts on will-call via online, and will hit the door when they open.

    Today should be "Rear Suspension Day - v2.0" - I'll try and remember to take pictures.
    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 w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

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