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Thread: RonJon24’s Build Thread #9460: Inventory Complete

  1. #1
    Junior Member RonJon24's Avatar
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    RonJon24’s Build Thread #9460: Inventory Complete

    Hello everyone!

    I would like to start my build thread, it is a little early since I just put my order in a couple weeks ago, but I am excited to get started. My build is planned to be picked up from FFR on 10/26.

    I decided to do the donor car with the Base Kit. I owned an ‘88 (upgraded EFI to ‘89) Mustang GT Hatch, it was a complete POS aside from the powertrain that I rebuilt in college.

    ‘88 Mustang GT Upgrades (for which I remember):
    - Trickflow Twisted Wedge Heads, Cam (Stage 1), and Intake
    - 100 shot Plate system from TrickFlow (w/mini controller)
    - 24# Injectors
    - Summit Ignition Box
    - Cold Air Intake (from RH Quarter Panel box)
    - Removed A/C, Removed EGR
    - 5-way KONI adjustable shocks
    - Tubular Upper/Lower Rear Control Arms
    - 3.55 gears
    - Rebuilt (upgraded 2nd/3rd) Tremec T5
    - ...Many other small items

    My plan is to take the good things that I have upgraded on the Mustang from the above and use that as a base for my Roadster. At least get something out of that old project car! Here are some pictures of the care gutted!

    18C62030-CB5D-439C-BB68-56C1C04B98C3.jpg83661637-3078-4AB6-B861-5CA74E66CA41.jpgAC978498-8AA2-45D7-BD91-539D29DC1A0F.jpg5FC96F70-EBCF-4B5A-981E-507C6475C1CA.jpeg2A66F5A5-FC0D-4333-B615-CDCDB7E2A3C7.jpg

    I think the build will probably take me more than a year so my target to to have a go-kart by the end of next summer and hopefully the car done by the summer of 2020, worst case it leaks into 2021.

    Where I am at right now
    I am currently tearing down my old 302 that I rebuilt in college and cleaning everything up for painting the engine. Boy-oh-boy did I make a ton of mistakes back then. I barely cleaned the parts before painting them, causing almost all of the paint to come off the aluminum timing chain cover, and look absolutely terrible. Same thing for the T5 bell housing (why I painted that I have no idea).

    So my plan for the engine is to keep everything internally the same, just clean it up and paint it properly. Maybe slightly controversial, but I really hate the look of aluminum mixed with painted components on the engine, so through my research I am planning to paint all of the aluminum with a solid etching and a base conversion coating (Alodine). Then I will prime the engine with Eastwood High Temp 2K Primer and paint with Eastwood High Temp 2K Gloss Black. Because of difficulty getting to spots, I am going to paint with the lower intake off, paint that and the upper separately as well as some other small components. Everything I think paint will not be good for, I am going to have blasted and powder coated gloss black.

    Everything on the Engine will be gloss black! Trying to give it a mean look!

    Really working to get the engine painted before I go pick-up the kit! Want to have this thing be a showpiece in the corner of the garage to motivate me to get to that point in the build!
    Last edited by RonJon24; 08-22-2018 at 12:49 PM. Reason: Typo
    MkIV Roadster Base Kit ordered on 8/8/2018, Scheduled for pick-up on 10/26/2018

    Toyota Engineer looking to turn my college project car, 1988 Ford Mustang GT...flat black...not a nice vehicle, into a awesome machine to tear up the streets, strip, and track!!

  2. #2
    Senior Member HiggyMK4#????'s Avatar
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    Nice start! Keep up with the updates!!
    'Collecting knowledge and parts for a future build'

  3. #3
    Straversi's Avatar
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    Welcome to the party. Great to have a good donor that you know! Always a crap shoot when you start with someone else's head ache.
    Look forward to following your progress. And don't worry, all of those boxes full of shiny new parts that are about to arrive will keep you motivated.
    -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, Registered and Completed 10/18/18. Build Thread: http://thefactoryfiveforum.com/showt...V-Coyote-Build Graduation Thread: https://thefactoryfiveforum.com/show...-Roadster-8901

  4. #4
    Senior Member bil1024's Avatar
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    Awesome, congrats,
    MK III w/3 link

  5. #5
    Junior Member RonJon24's Avatar
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    Planning the trip out to Wareham, MA

    So I am currently planning out the trip to pick-up the kit at the end of Oct. FFR completion date is 10/20, but I have a commitment at home on 10/23. THe wife and I are not so fond of drive 12hrs from MI to Wareham, MA and back just for this purpose so we are planning to take a few days off and enjoy the excursion.

    Our current plan is to Drive from MI to the Finger Lakes region of NY, stay for 2 days and then, drive to Boston to stay the weekend. Then we can pick-up the car on Monday 10/27 in the morning and head on home.

    The challenge is Boston. It is seeming hard to find (at least online) parking in Boston for a Truck and 14í flatbed trailer. Also, had no idea how expensive Boston is to stay, jeez. My current idea is to park at one of the T parking lots while we are in Boston, they physically look like they can take a truck and trailer, no information on policy on their website. I put in an e-mail to the MBTA and they replied that all of the parking spots in their lots are standard size, so they can not accommodate. I am wondering if this is true since I can see on Google Street view that the lots have the space to pull through two spots like a normal parking lot. Anyone know the area well enough?

    Other than that, it should be a fun week!
    MkIV Roadster Base Kit ordered on 8/8/2018, Scheduled for pick-up on 10/26/2018

    Toyota Engineer looking to turn my college project car, 1988 Ford Mustang GT...flat black...not a nice vehicle, into a awesome machine to tear up the streets, strip, and track!!

  6. #6
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    I would suggest finding a place to park the truck and trailer outside of Boston and then either Uber or take the train into town. I don't want any part of driving in Boston (if you haven't been there before, it's nuts) and the hotels are much cheaper outside downtown. My daughter is at BU and this is what we do every time we visit. Maybe Dave Smith would let you park them at the factory while you're touring Boston over the weekend.

    You wouldn't know a Michael Peterson within Toyota Racing, would you? Used to live in Seattle?
    Mk4 #8861 Complete kit. Delivered: 27 Apr 2016, Roller: 12 Jan 2018

    Forte: 2016 Coyote & cover, alternator, engine controls, clutch kit, bellhousing, Moroso pan, TKO600, midshift, 3.55 axle, 190lph fuel pump, Spectre air inlet and filter. Breeze: battery forward and switch, fuel pressure regulator and braided hose, radiator shroud and mounts. Replicaparts: radiator panel, under dash panel, weathertight connectors.

  7. #7
    Senior Member Yama-Bro's Avatar
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    Cool, Congrats, and welcome to the club!
    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. #8
    Junior Member RonJon24's Avatar
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    Initiator, thanks for the tips! Thought about contacting the factory, it’s just not ideal for commuting into town based on the stations. I think the closest station might be Plymouth?

    I don’t know a Micheal Peterson. I work at the Toyota Motor North America technical center in MI, working on designing your mom’s Camry. Haha. No racing folks here unfortunately. I do know some folks that transferred from TRD, but I’m not familiar with anyone currently in the organization.
    MkIV Roadster Base Kit ordered on 8/8/2018, Scheduled for pick-up on 10/26/2018

    Toyota Engineer looking to turn my college project car, 1988 Ford Mustang GT...flat black...not a nice vehicle, into a awesome machine to tear up the streets, strip, and track!!

  9. #9
    Junior Member RonJon24's Avatar
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    Talking Quick Update - Got the Engine Painted

    Just a real quick update for you guys, I was able to get my Engine painted last night. Turned out awesome! I have some nice Ford Racing valve covers on their way to top of this 302 in a tux.
    DAA5D07A-D479-4D68-A1DF-B9C6E089671E.jpegB0D8A647-5694-4DFE-A57F-D067AD208929.jpeg

    Next step is cleaning my garage bay for the build. I am thinking to put some shelving along one wall to hold all of my donor and new parts.

    In addition, I am planning to put the body on a body buck and lift it in my garage to get it up and out of the way. Normally I could use 2 of the 3 garage bays in my garage, but my friends are staying with us now using one of the bays for their storage. Anyone have experience building a lift and or mechanism to lift the body up to the ceiling for storage?
    MkIV Roadster Base Kit ordered on 8/8/2018, Scheduled for pick-up on 10/26/2018

    Toyota Engineer looking to turn my college project car, 1988 Ford Mustang GT...flat black...not a nice vehicle, into a awesome machine to tear up the streets, strip, and track!!

  10. #10
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    Quote Originally Posted by RonJon24 View Post
    I am thinking to put some shelving along one wall to hold all of my donor and new parts.

    In addition, I am planning to put the body on a body buck and lift it in my garage to get it up and out of the way. Normally I could use 2 of the 3 garage bays in my garage, but my friends are staying with us now using one of the bays for their storage. Anyone have experience building a lift and or mechanism to lift the body up to the ceiling for storage?
    Several people have bought or designed/built lifts for ceiling storage. Search the forum and you'll find lots of good info and pictures.

    You'll never have enough shelves. I found this approach to work really well, using space that I couldn't use for any other purpose. We now have the Xmas tree, camping supplies, and several F5 boxes that I won't need for a while stashed away on Mightyshelves.
    http://contractorkurt.com/2012/02/18...mightyshelves/
    Mk4 #8861 Complete kit. Delivered: 27 Apr 2016, Roller: 12 Jan 2018

    Forte: 2016 Coyote & cover, alternator, engine controls, clutch kit, bellhousing, Moroso pan, TKO600, midshift, 3.55 axle, 190lph fuel pump, Spectre air inlet and filter. Breeze: battery forward and switch, fuel pressure regulator and braided hose, radiator shroud and mounts. Replicaparts: radiator panel, under dash panel, weathertight connectors.

  11. #11
    Junior Member RonJon24's Avatar
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    Update: Pickup and Prep

    Hey everyone, I am happy to report that my wife and I successfully made the trip out to Factory Five and back with the Roadster!
    AF8D9743-59F3-4D52-A205-F04A2AD52708.jpeg6058B074-9CC1-439E-AA39-ED64B2C9ADF8.jpeg57BACCF3-4E61-4D2D-801F-D792D916ACED.jpeg5FD1F196-43CD-4A87-BEFB-571079E32033.jpeg40C132E8-79D1-49D4-99E0-C4F959F4D294.jpeg

    Was really nervous about making the trip through Canada on the way back to MI, but we had zero problems. Once we got back we unloaded and positioned the car in Garage stall #3. Looks like Iíve got FFR #9460!
    029316D1-BBA0-4BF7-8265-2008A3312E25.jpg86C0A72C-5886-4EEB-8D0C-10FB41EA490E.jpeg

    Iím currently storing a house worth of stuff in my garage and basement, so space is at a min right now at my place, so I built the body buck to be able to be hoisted up and down from the rafters as shown here. I also put a slotted shelf under the body for the Hood, Doors and Trunk.
    886C151F-8DDA-43F2-95CD-D79DAF7D304F.jpgB5E76FB6-08D5-4CD5-A5A0-674ECCEFEA3D.jpgAE01801C-C237-4763-9F29-D025E985A5BC.jpg

    Also was able to get inventory done and only found a couple mounted parts (fasteners) on the body missing! Which I assume is pretty good based on what I have read from others! After that I gathered everything that was from my donor Mustang and all raw steel parts from the kit and dropped them off at Powdercoat on Monday. Really excited to get started on the build once my parts come back!

    Not sure what the best course of action is on the aluminum. Should I leave it on and process one pc at a time (I just plan on Sharkhide for them)? Or pull them all off, process them and reattach and rivet as I go?
    MkIV Roadster Base Kit ordered on 8/8/2018, Scheduled for pick-up on 10/26/2018

    Toyota Engineer looking to turn my college project car, 1988 Ford Mustang GT...flat black...not a nice vehicle, into a awesome machine to tear up the streets, strip, and track!!

  12. #12
    wareaglescott's Avatar
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    Congrats on getting it home. Enjoy the 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 - @scottsrides

  13. #13
    edwardb's Avatar
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    Quote Originally Posted by RonJon24 View Post
    Not sure what the best course of action is on the aluminum. Should I leave it on and process one pc at a time (I just plan on Sharkhide for them)? Or pull them all off, process them and reattach and rivet as I go?
    The generally recommended process, and one that I've also followed, is to fit, drill, and cleco the pieces in the order shown in the build manual. The sequence is pretty important because it helps to assure all the correct overlaps and fits. Then Sharkhide (in your case), then permanently bond and rivet. Don't be in a hurry to rivet panels though. F panels on the front yes, but then after that, look at brake lines, fuel lines, electrical harness (mainly the rear harness) installations before installing permanently. Hope that helps a little.

    Congrats on your pickup. Have made that trip a couple times my self (including the Canada route) and it's pretty exciting. We're practically neighbors, so give me a shout with questions or if you need any help.
    Last edited by edwardb; 11-04-2018 at 08:46 AM.
    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. Gen 3 crate Coyote. Delivered 12/2/2017. #59 Coupe Build Thread

  14. #14
    Junior Member RonJon24's Avatar
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    Thanks Edwardb!

    Any recommendations for a machine shop in the Detroit Metro area? I need to get my driveshaft shortened.
    MkIV Roadster Base Kit ordered on 8/8/2018, Scheduled for pick-up on 10/26/2018

    Toyota Engineer looking to turn my college project car, 1988 Ford Mustang GT...flat black...not a nice vehicle, into a awesome machine to tear up the streets, strip, and track!!

  15. #15
    edwardb's Avatar
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    Quote Originally Posted by RonJon24 View Post
    Thanks Edwardb!

    Any recommendations for a machine shop in the Detroit Metro area? I need to get my driveshaft shortened.
    I'm sure there are many that would do a good job with that. The only machine shop I've had actual personal experience with is http://www.dsengine.com/. Recommended to me by a buddy, and they did a good job on the 306 in my first Roadster build. I don't know if they do driveshafts though.

    This shop helped with a ratio change and were great to work with. Also did one for another buddy. http://www.ringandpinionshop.com/. Doesn't look like they do driveshafts, but I'll bet they could recommend a place.
    Last edited by edwardb; 11-01-2018 at 10:13 AM.
    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. Gen 3 crate Coyote. Delivered 12/2/2017. #59 Coupe Build Thread

  16. #16
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    Sounds exactly like what I want to do, I'm jealous!

    Some local places I've heard suggested for driveshaft work.
    Joint Clutch and Gear
    Shaftmasters
    DTS - http://www.drivetrainspecialists.com/

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