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Thread: 80 Day Build--In time for the London Cobra Show

  1. #1

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    80 Day Build--In time for the London Cobra Show

    Last week we were contracted to build a Mark IV and our client would like to have it completed by the London Cobra Show (London Ohio--not the UK). The show for those of you who have not attended, typically bring out Cobra enthusiasts from all over the country. In prior years we have seen folks from as far away as Vancouver and WA state. Anyway our build specs are as follows:

    Chassis
    Black Powder coated Chassis
    Silver Artery Powder coated sheet metal
    Power steering
    S550 Mustang based IRS
    Electrically actuated parking brake
    FFR 17 Halibrand style wheels, 9 fronts, 10.5 rear
    Performance summer tires 245/45R17 & 315/35R17
    SN95 Mustang GT 11 twin piston front brakes
    S550 Mustang GT 13 single piston rear brakes
    Black powder coated chassis components
    ECUMaster PMU chassis control
    FC wiring harness
    Drivetrain
    2015-2017 low mileage (<18K) 435 HP Mustang 5.0 Coyote engine
    ECUMaster EMU Black ECU
    FC Coil driver module
    Moroso oil pan & pickup
    Energy urethane motor mounts
    FC mount kit
    Ford MT82 G2 6 speed manual transmission
    FC MT82 shifter mechanism
    FC transmission mount
    Stainless full headers & stainless-steel side pipes
    Ceramic Coated Side Pipes
    Header wrap
    FC Driveshaft
    Drive modes
    Mode switching
    Adjustable traction control
    Launch control
    Flat foot shifting
    Custom painted engine cover to match body paint
    Interior
    FC Floor heat, defrost & AC
    Seat heaters
    FFR Roadster seats
    Seat adjusters
    leather steering wheel
    Russ Thompson hub & turn signals
    FC full interior in red and black vinyl and silver painted trim
    FC door panels, handles, Speakers & poppers
    FC dash
    FC center console
    FC rear trim
    Silver trim
    FC carpet set in Dark Read/black
    Waterproof Audio system including Clarion Marine Radio and Kenwood amplifier
    4 door mounted speakers
    Keyless entry and starting
    Thermal/sound insulation
    FC logo gauge package
    FC silver billet bezel for turn & highbeam indicators
    Wilwood pedal box
    Lokar or equivalent accelerator pedal
    4-point seat belts
    Billet, windshield mounted center mirror
    Billet shifter surround
    LED footwell lighting
    Billet cup holders
    FC CaNbuss controls
    Pushbutton starting
    Pushbutton Head light controls
    Pushbutton High beam controls
    Pushbutton Hazard light controls
    Pushbutton parking brake console
    Turn signals on steering column stalk
    Wipers
    Adjustable Drive modes
    Traction Control
    Body
    Silver primary paint color with Black stripes and red accent
    Dodge Viper billet silver
    Venom black
    Adrenalin Red
    Blackout paint package with red accents
    Custom Wheel paint with contrasting spinners
    LED lighting package
    LED headlights
    LED running lights
    LED turn signals
    FC billet fender badges
    Engine compartment and trunk lighting
    Wind wings
    Sun visors
    Aluminum side louvers
    Driver side roll bar
    Roll bar grommets
    Stainless steel quick jacks

    We have the FFR complete kit on order +/- and it will be picked up on 5/2/18---52 days prior to delivery. This would probably be and impossible task if we didn't have a little bit of a head start. Last year we purchased a basic Mk IV to use as a development platform for some enhancement products that we have been developing. We are using the body and chassis out of this kit to get a jump on bodywork and paint as well as sheet metal.

    Our goal is to post progress reports daily...forcing us to make progress every day.

    Hope you enjoy the madness as much as we expect to.

    Chris

  2. #2
    Boydster's Avatar
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    Wow... good luck and I'll be watching this one.
    ---Boyd---
    MkIV #9042 build thread
    www.boss427.us
    Plan: 427W-X, TKO600, Moser 3.55 rear.
    Delivered Feb 2017, first start Oct 22, 2017, first go-cart Mar 26, 2018

  3. #3
    Straversi's Avatar
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    Never understood putting ridiculous deadlines on custom projects but, hey, it's his money and project. I'm sure you guys will do great. Sounds like a great build. Look forward to seeing the updates.
    -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

  4. #4

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    Steve,
    I don't in any way fault the client for the tight deadline. This deadline is self imposed as much as anything else. I've been in manufacturing for nearly 50 years and I don't see a big difference in building a custom car and manufacturing a washing machine. Efficiency is all about establishing and implementing a manufacturing process. We spent about 5 man weeks late last year creating and documenting a build process. This build is our first test to see if we can pull it off. It is understood that nothing will ever go as originally planned, that doesn't mean it is not possible. We intend to make daily posts of our progress and challenges--my way of holding myself accountable to the process.

    Go ahead....tell me I am nuts. Pretty much everyone I know thinks so. Please chime in with your critiques, criticisms, and suggestions. I have a thick skin and will benefit greatly from the collective wisdom of those who proceeded me.

    Chris

  5. #5

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    Sounds like fun for all of us here who get to watch! Chris, since you aren't picking up the kit until May 2nd, you'll have plenty of time to join us at Huntington Beach on April 28th.
    818S/C : Chassis #25 with 06 WRX 2.5 turbo, ABS, cruise, PS, A/C, Apple CarPlay, rear camera, power windows & locks, leather & other complexities.
    Mk3 Roadster #6228 4.6L, T45, IRS, PS, PB, ABS, Cruise, Koni's, 17" Halibrands, red w/ silver - 9K miles then sold @ Barrett-Jackson Jan 2011 (got back cash spent).

  6. #6
    Mark Eaton's Avatar
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    This sounds really cool. I will watch with interest. I hope you post photos. I'm not sure what "flat foot shifting" is...

    And I'm curious, how many people will work on the project?

    Mark
    MK4 #9130 , complete kit, arrived 8/10/2017.
    DART SHP 347, EFI, TKO600, IRS
    http://thefactoryfiveforum.com/showt...n-Build-Thread

  7. #7

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    Mark,

    There are a total of 4 people contributing on the project. No one is working on it full time, as our parent company, whom employs us, has other assignments for each of us. Our build plan adds up to about 220 direct labor hours to complete though I believe we will probably run over budget by about 60 hrs. This does not including paint and body which we currently outsource as we don't have the facilities to paint anything larger than a door panel. Two of us aren't doing to much of the direct labor but are working in the background refining design details, sourcing parts and materials, coordinating inventory, etc.

    The plan is to post pictures nearly every day.

    Chris

  8. #8
    Senior Member cgundermann's Avatar
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    Looking forward to the pics...
    MK4 Basic Kit #7404, 347 EFI - Pro M Racing ECM, 30# injectors, 70 mm throttle body, 80 mm MAF, Edelbrock Performer aluminum heads & RPM II intake, all new G-Force T5, 3:55 gears, Pro 5.0 shifter, 3-link, carbon fiber dash/custom Speedhut gauges and paint by Da Bat.

  9. #9


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    Jeff Kleiner's Avatar
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    80 days? Don't let Ron Everett know about this; he'll down a couple of Red Bulls and take it as a personal challenge

    Jeff

  10. #10
    Senior Member Yama-Bro's Avatar
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    Cool, this will be a fun one to watch.
    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

  11. #11

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    Quote Originally Posted by Jeff Kleiner View Post
    80 days? Don't let Ron Everett know about this; he'll down a couple of Red Bulls and take it as a personal challenge

    Jeff


    I not a red bull guy, But yeah, 80 days.... ? I could do that.


    80 days?

    Hold my beer.
    FFinisher/AKA RE63

  12. #12

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    Day 80--

    A little progress yesterday...not much picture worthy...mostly spent ordering components, etc. That being said, here is a bit of eye candy.
    First, the [icture that inspired our color selection.
    2016_ACR.jpg

    We shot some color plaques to share with the client to get final sign off. The intention is that the car will be silver with traditional width black stripes and the space in between the black stripes will be red.

    180405 Color Plaques.jpg

  13. #13
    Kyle @ Forma's Avatar
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    Quote Originally Posted by Mark Eaton View Post
    I'm not sure what "flat foot shifting" is...
    Under heavy throttle, it allows you to shift without letting off the gas pedal. If you try this in a normal vehicle, you'll bounce off the rev-limiter. FFS acts as a temporary lower rev limiter to keep the RPM at the ideal place for the next gear. Multiple parameters ensure that this only happens under heavy throttle and while you're moving, so you don't notice it's there until you use it.

    Picture this:
    You're sitting in the driver's seat. Turn traction control "off" and drive mode to "sport". When the light turns green, peg the gas pedal to the floor and drop the clutch. Tire smoke ensues. Make lots of noise at 7000 RPM until you finally gain traction, then jab the clutch and quickly engage second gear, all while your right foot stays glued to the floor. Repeat until you are going too fast, then you can finally let your right foot up.

    And that, sir, is how you drive a rental.

    Oops, I mean a car with Flat Foot Shifting.

  14. #14

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    Day 79

    Made a bit of progress...once again not a lot that is picture worthy. Fitting sheet metal....
    All of the sheet metal should be ready to go to powder coat on Monday.
    Along with the sheet metal and in conjunction with that work stream we started packaging the air box for the HVAC unit.
    We fabricated a laser cut/3D printed panel for the upper trunk area to hold the air box. The triangle in the air box is where we will create all of our ducting/air valves to control Heat (discharges from under the seats), A/C (comes out of the dash), and the defrost (ducted to the windshield).

    180406 HVAC 1.jpg
    180406 HVAC 2.jpg

    More later today
    Chris

  15. #15

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    Day 63

    Day 63--Progress is painfully slow. We are still two weeks away from picking up our Kit from Factory Five. Though we are still making progress. I've unfortunately had to travel the past two weeks to out of state client meetings and it has impacted my ability to make the progress that we were hoping to make. None the less here is where we stand:
    Doug completed the CAD work on the interior design details.
    180421 interior CAD 1.jpg180421 interior CAD 2.jpg
    This enabled us to start 3D printing some of the components even before it was completed
    2018-04-21 3d door panels.jpg
    I know that this doesn't look like much, however, by Tuesday these should be finished door panels.
    This week we met with our client and got a sign off on the interior finishes.
    2018-04-21 Interior Vinyl.jpg
    The Red will be the primary color of the dash and the top of the door panels
    The Silver gray will be used on the center console extending up the center of the dash under the gauges. We may use this on the door recesses with red stitching .
    The Black will be used on the sides of the console and the bottom of the doors.
    The silver paint (same as the body) will be used for the painted accents. This is shown yellow/green on the cad screen capture.
    Outside of the interior, parts are showing up every day.
    Moroso Oil pan so we can start building up our engine. Need to get the engine/tranny in the frame so that we can finalize our ducting to the defrost vents. We don't have good CAD data on this so we will have to wait till we can get this dropped in place.
    Also received our A/C unit from RestoMod Air. as well as small but important stuff like Breeze battery box, ECU, PMU (power management unit), CAN input card, security system, etc.
    Kyle wrapped up the new wiring harness design and we should start fabricating this on Monday. Goal is to have the wiring harness installed by the end of next week. Nearly 300 wires in our harness, pretty much has everything. It will even wipe your nose.
    Finally, Tim has been working diligently on the painted parts. All of the sheet metal is out to the powder coater and should be back by the time the wiring harness is installed.
    Tim has also been working on getting the body completed. Thursday and Friday we shot paint. Monday we will shoot the clear.
    2018-04-21 Paint 1.jpg2018-04-21 Paint 2.jpg2018-04-21 Paint 3.jpg2018-04-21 Paint 4.jpg2018-04-21 Paint 5.jpg

    I'll try to post more as the week progresses,

    Chris
    Chris

  16. #16
    Senior Member cgundermann's Avatar
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    Looking good! Thanks for the posts, I’m liking the paint scheme...

    Chris
    MK4 Basic Kit #7404, 347 EFI - Pro M Racing ECM, 30# injectors, 70 mm throttle body, 80 mm MAF, Edelbrock Performer aluminum heads & RPM II intake, all new G-Force T5, 3:55 gears, Pro 5.0 shifter, 3-link, carbon fiber dash/custom Speedhut gauges and paint by Da Bat.

  17. #17

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    Day 61--Till Cobra Show

    Finished the clear and wet sanding. Part way through the buffing and polishing.
    180423 Paint with Clear 1.jpg180423 Paint with Clear 2.jpg
    Color really pops with the addition of the clear.

    Minor set back...the manufacturer of our CAN BUSS boards just announced a new version. We have been designing around the older board and don't want to tie us into a corner for future builds. Need to make sure that the current product will continue to be supported and available. Otherwise, our design needs to accommodate both. It is never easy.

    Chris
    Chris

  18. #18


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    Jeff Kleiner's Avatar
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    Plastic scoop molded to 'glass hood?

    Jeff

  19. #19
    Doug @ Forma's Avatar
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    Quote Originally Posted by Jeff Kleiner View Post
    Plastic scoop molded to 'glass hood?

    Jeff
    Yes, just like we did with our first Mark IV. Some more info in our build thread here.

  20. #20
    Senior Member cgundermann's Avatar
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    Sweeeeeeeet!

    Chris
    MK4 Basic Kit #7404, 347 EFI - Pro M Racing ECM, 30# injectors, 70 mm throttle body, 80 mm MAF, Edelbrock Performer aluminum heads & RPM II intake, all new G-Force T5, 3:55 gears, Pro 5.0 shifter, 3-link, carbon fiber dash/custom Speedhut gauges and paint by Da Bat.

  21. #21

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    That is correct. This is the second one that we have done this way and so far, no issues. I didn't personally do this bonding work, but I can check with my body guy to get the details of the process and the products that he used, if you are interested. I realize that many want to pay homage to the original/authentic Cobras, however, our aesthetic goals are to build to current production car fits and finishes. I'm not claiming that we achieve this objective, but that is still where our aspirations lie,

    Chris
    Chris

  22. #22


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    Jeff Kleiner's Avatar
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    Quote Originally Posted by Chris @ Forma View Post
    That is correct. This is the second one that we have done this way and so far, no issues. I didn't personally do this bonding work, but I can check with my body guy to get the details of the process and the products that he used, if you are interested...

    Chris
    Thanks Chris. I was just curious and will only mold in the 'glass scoops. I've done some trading among customers to wind up with fiberglass ones to bond and plastic ones to bolt on. If your guy is having long term success with his method of bonding the dissimilar materials my hat is off to him!

    Jeff

  23. #23
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    I am building my car for London too! I just don't know what year... is that the same?

  24. #24

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    Ours needs to be done by June 22, 2018. 56 Days from today. FYI, I'm picking up our kit next Wednesday.
    Chris

  25. #25

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    16 Days to complete a pile of work

    We have been making quite a bit of progress, though there is still much to do.
    Our wiring harness is complete and installed in the chassis
    2018-05-21 14.42.42-1.jpg
    2018-06-06 16.51.46-1.jpg
    We completed the door panels. Assembly in the picture is missing a painted part that trims out the door panel after installation that goes directly below the red component.
    2018-05-22 16.50.56-1.jpg
    We have completed the dash assembly except for the glove box and glove box door. These will be completed tomorrow.
    2018-06-06 16.51.21-1.jpg
    The instrument cluster is also assemble and ready for installation.
    2018-06-06 17.01.35-1.jpg
    Finally, we completed the engine wiring harness and installed the engine and tranny.
    2018-06-06 16.51.55-1.jpg
    Hope to be ready to drop the body on by Monday or Tuesday.

    [email protected]
    Chris

  26. #26
    DavidW's Avatar
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    Lets see some more pictures, two days to go!!!!!!!

  27. #27

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    LCS...build update

    Well we were disappointed not to get the car done before the show, though we did take it to the show. It looks spectacular...but there is still quite of bit of work to do under the skin.

    My team did an absolutely fantastic job pulling off the nearly impossible task of getting it to the show. At 3:00 PM on Friday we moved the body to the Chassis for the first time since they were separated just prior to paint. My guy, got it to the show by 9:30 on Saturday. Including mounting the doors, windshield, hood, trunk lid, installing our proprietary door latches, inner door panels, etc. For a static display...it looks fantastic.

    We were so exhausted and busy at the show nearly everyone forgot to take any pictures. Doug did get a few.
    2018-06-23 10.51.09_Reduced.jpg2018-06-23 10.53.07_Reduced.jpg2018-06-23 10.53.19_Reduced.jpg2018-06-23 10.53.26_Reduced.jpg

    Our customer for this car is the Ohio Cobra Club and this is their 2019 Raffle car to benefit the Cystic Fibrosis Society. This year they sold about 10,000 Raffle tickets and for next year (with our build) we are hoping for 15-20,000. You can win this car by simply buying a raffle ticket on line once we make final delivery.

    We still have a number of tasks to wrap up...
    Photo shoot for the Club...unfortunately delayed till Friday due to rain on Tuesday and Wednesday.
    Remove the body to wrap up the wiring to HVAC which is located in the trunk.
    Install new glove box as the initial one has a clearance issue.
    Correct a wiring issue with the CAN-Buss controls in the center console
    Paint the spinners Red
    Install inner fender sheet metal
    Install spray on liner on inside of fenders
    Fire up the engine and tune
    Road test for setting the traction control parameters
    Road test balance brakes
    Rework the front wiring harness to get rid of our signature green sleeving in the engine bay (clashes with the paint scheme).

    There are other smaller items...but these are the big ones.

    Our biggest challenge right now is that the car needs to be a another show in a little over a week and we don't have much time to get the body off, make the changes, and get the body back on for the Arthritis Foundation show on the 6th. Goal is to deliver the car and get paid on Friday the 13th....Maybe we'll wait till the following Monday.

    I did shoot a couple of pics in the final week...just ran out of time to get things posted.
    20180620_152618_Reduced.jpg
    Under seat duct for heat
    20180620_152637_Reduced.jpg
    Defrost ducting
    20180620_183501_Reduced.jpg
    CAN-Buss board for launch control, traction control, drive mode, control of parking brake, headlights, wipers, etc. Mounted in a temp 3D printed bezel
    20180620_183512_Reduced.jpg
    Top of temp bezel
    20180621_190645_Reduced.jpg
    Test fit of center console.

    I'll post some more shots after our photo shoot tomorrow.

    Chris
    Attached Images Attached Images
    Chris

  28. #28
    wareaglescott's Avatar
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    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

  29. #29

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    Opps....Meant to say my Guys did a great job....it was a team effort
    Chris

  30. #30
    Senior Member cgundermann's Avatar
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    Very, very nice styling!
    MK4 Basic Kit #7404, 347 EFI - Pro M Racing ECM, 30# injectors, 70 mm throttle body, 80 mm MAF, Edelbrock Performer aluminum heads & RPM II intake, all new G-Force T5, 3:55 gears, Pro 5.0 shifter, 3-link, carbon fiber dash/custom Speedhut gauges and paint by Da Bat.

  31. #31
    Senior Member Yama-Bro's Avatar
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    I love how you guys use 3D prints to use as final parts. I always think of 3D prints as prototypes, just because that's how I've used them for the years at the places I've worked. I need to dream up something to use them for on my car. Cool stuff! Keep up the good work.
    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

  32. #32
    Senior Member cv2065's Avatar
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    Looks great. I'd like to see some detail and pics on that console and dash!
    MKIV Roadster - Complete Kit - Delivered 7/17/18

  33. #33

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    Update

    This past week was a bit challenging to make progress.
    We need to take the body off to address some wiring issues, however, we needed to get the car photographed as this was built for the Ohio Cobra club for their annual Raffle car. Rained Tuesday and Wednesday, our photographer was not available on Thursday, so we were stuck waiting until Friday evening. We shot a couple of hundred high res pics, and on Saturday selected one of PhotoShop for color correction that the Club will print on the Raffle ticket. Our goal for the coming year is to sell out all of the tickets and we are partnering with the Ohio Cobra club to do just that. I haven't heard from the board as to how many tickets they are planning on printing, but I am pushing for either 15K or 20k. Regardless, I encourage the community to get behind this effort. It is your chance to own a nearly $100K build with the purchase of a $20 ticket. The raffle benefits the Cystic Fibrosis Foundation. Raffle tickets will be available on the Ohio Cobra's web site by the end of the week. I encourage everyone in the community to participate.

    I would also like to acknowledge Aesthetic Finishers, GP Headers, and Factory Five Racing for the discounts that they provided us in achieving this spectacular build.

    Here is the raffle ticket pic that we selected for the raffle ticket.

    Forma 4228 Edit V1-1_Reduced.jpg
    Chris

  34. #34

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    Regarding our center console and dash assemblies, they consist of quite a large number of parts. Here is a CAD screen capture of our interior design.

    170701-80075 -1 Screen capture.pdf

    The material selected for each of the components is based on the job that we are asking the component to do. Although we have a number of custom sheet metal parts in the assembly, these parts are relegated to structural rectilinear components:
    Dash Structure
    top of tunnel (bottom of center console assembly)
    glove box door (inner, outer, hinges)
    attachment clip retainers (hold Volkswagen interior assembly clips to 3D printed parts)
    Dash structure attachment brackets

    Some of these parts, such as the dash structure are moderately complex parts
    170701-80075 -9 Screen capture.pdf

    Other structural parts include custom aluminum extrusions. These are also appearance parts and are green/yellow and straight in the first image image.
    The curved yellow/green parts in the first image are 3D printed and painted.

    The back side of the dash looks like this:
    170701-80075 -2 Screen capture.pdf

    The gauge cluster/climate control assembly snaps into place on the dash and the back side of it is shown here:
    170701-80075 -4 Screen capture.pdf
    This assembly consists of 3D printed parts, laser cut ABS sheet, a hand full of small sheet metal parts etc.

    Here is the dash assembly with the gauge assembly removed.

    170701-80075 -3 Screen capture.pdf

    The rear console assembly is all 3D printed then upholstered or painted. It is worthy of noting that our HVAC system is located in the trunk space between the roll bars and the AC ducts run through our console assembly. Attachments for this duct is located at the back of the rear console assembly.

    170701-80075 -5 Screen capture.pdf170701-80075 -6 Screen capture.pdf

    The center console consists of sheet metal, extrusions, laser cut ABS sheet, and of course 3D printed parts.

    170701-80075 -7 Screen capture.pdf170701-80075 -8 Screen capture.pdf170701-80075 -10 Screen capture.pdf

    Underneath it all there are a few relatively complex 3D printed parts. At the fire wall, we have our Wiring Hub. This houses the fuse box which is accessible from the engine compartment, interior lighting controls, system busses (power, ground, and ignition power) and the security system. Below this part is a duct transition that takes defrost air from the tunnel to behind the dash. Finally, we have another duct for getting the defrost air from below the trunk and into the tunnel shaped to package around the IRS/drive shaft attachment flange (We are using the 205-2018 Mustang rear end).

    I could write all day and not capture everything, but these hare the major elements.
    Chris

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    Chris

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