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Thread: G3 (Greek Guys' Garage) Roadster Build #9509 (Body off and wheels ready)

  1. #1

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    G3 (Greek Guys' Garage) Roadster Build #9509 (Body off and wheels ready)

    Hey everyone. I've been posting a little and lurking a lot on the forum for many months now. After much deliberation, I ordered a complete roadster kit back in late October and it is finally scheduled to arrive tomorrow so I figured it was about time that I properly introduce myself and kick off a build thread. My name is John (perhaps you gathered that already from my username). My wife and I have a son and a daughter. Building something like this has been a dream of mine for a long time, but now that my kids are both in high school I figured this was the perfect time for a father-daughter-son project, so here we go! We're located in Los Gatos, CA (~1hr. south of San Francisco). I see that there are quite a few active forum members in the Bay Area. It would be fantastic to meet some of you. I've already met a few folks here around town with roadsters.

    My order consists of the following:

    MkIV complete kit:
    - Drivetrain will be Coyote, IRS and TKO600
    - Gen 2 vs. 3 Coyote still up for debate
    - IRS already ordered and received from Forte's (3.55)
    - TKO600 likely to be the modded Liberty's Gears version.

    Other items of note in the FFR order:
    - Chassis is uncoated. Will be powdercoated locally.
    - leather seats and leather steering wheel
    - 18" wheels
    - Wilwood brakes with red calipers front and rear
    - double-adjustable Koni shocks front and rear
    - wind wings, sun visors, wipers
    - sway bars front and rear
    - dual black rollbars
    - deleted side exhaust and PS rack

    I ordered the factory dash with glovebox, but I see that as a sort of backup plan. My first choice is to go with a custom competition layout dash with glovebox (I've also ordered Alex's glovebox kit). Complicating matters a little is that I also plan to install a heater, so I may also go with the FFMetal 'firewall forward' piece to get everything to fit (or fab a box to space the heater forward into the engine bay). Lots of options here, and I'm excited to get to that portion of the build and sort through all that stuff.

    I've already ordered and received a PS rack from Unisteer, and plan to go with GP headers with catalytic converters and Gas-N side pipes for this build.

    My kids and I have already built the frame dolly and body buck, and there has been TONS of garage and shop prep in preparation for the build, including installation of a 4 post lift, compressor and air distribution system. Here are a couple of quick pictures of the "baby in the nursery" before it was picked up, as well as the baby's new nursery when it arrives tomorrow.

    Let me finish this introduction by saying thank you to everyone on the forum for the incredible wealth of knowledge here. I would never have had the courage to undertake something like this if this resource wasn't available. Also, thanks in advance for patiently taking the time to answer all the stupid questions Iíll be asking ;-)

    -John



    Attached Images Attached Images
    Last edited by JohnK; 02-14-2019 at 08:17 PM.

  2. #2
    Straversi's Avatar
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    Congratulations. You have a great space to work in and a solid build plan. Look forward to following along with you and your kid’s on this adventure.
    -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

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    Thanks Steve!

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    Here are a few quick notes on some of the prep work I’ve done in advance of the kit arriving. As I mentioned, I ordered the IRS center section, hubs and knuckles from Forte’s when I ordered the kit back in late October. I did this mostly to have something to work on in advance of the kit arriving, so I wouldn’t go crazy with anticipation. I’ve done the usual prep of the knuckles (drilling out holes as required and cutting off the one leg). In addition, I cleaned up casting lines and surfaces with a die grinder and some Scotchbrite roloc pads, before painting the hubs and knuckles with POR15. This was a bit of a learning experience. I messed up the timing of the 2nd coat, and the first coat had cured too hard, resulting in the 2nd coat not laying out as smoothly as it should have. If you look closely at the knuckles, you can see the surface imperfections, but I’ll chalk it up to a learning experience. I’m glad I did the knuckles before tackling the center section.

    I also went ahead and replaced the lugs on the rear hubs so I could get them prepped and painted. Pounding out the old lugs in the vice with padded jaws and driving in the new ones with the impact gun was a pretty painless process. I took the new lugs to the bench sander and put a little flat on each head to give them a bit more space from the bearing seal.



    In Paul’s (Edwardb) roadster build thread, he mentions making a cover for the ABS sensor mount on the knuckles. I thought this was a great idea, as water getting in there doesn’t sound like it would be good. When I inspected the hubs, I realized that the mounting holes (smaller of the two holes) weren’t tapped for a fastener. I figured if I was going to tap one hole, I might as well tap both and skip having to fabricate a cover. So I measured the two holes with the digital calipers and determined that the smaller holes are the perfect size for a ľ-20 tap and the larger holes are the perfect size for a 7/16-20 tap. I ordered some ĺ” long set screws in both sizes from McMaster and liberally coated them with red Loctite, and both holes are now plugged up nicely.



    Lastly, the kids and I built a frame dolly and body buck. I found some excellent templates on the forum for the body buck but was stumped for a bit on how to scale up the drawing to actual size. I know it doesn’t have to be exact, but the OCD part of me wanted it to be as close as possible, given that someone had gone to the trouble to make accurate templates. We have a projector for watching outdoor movies on our deck in the summer, and it occurred to me to hook up the laptop to the projector and project the template onto the OSB panel and trace out the shape with a Sharpie. Voila! Perfect scaling of the template.

    Last edited by JohnK; 01-29-2019 at 11:47 AM.

  5. #5
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    looks like a interesting build so I got something to follow, too cold to leave house in minnethota

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    Quote Originally Posted by Houdini View Post
    looks like a interesting build so I got something to follow, too cold to leave house in minnethota
    Yeah, from the looks of it on the news you all are getting hammered with some bad weather right now. It's been pretty cold here too. Only got up to 67 today.
    MkIV Roadster build: Coyote, IRS, TKO600. Ordered 10/24/18. Delivered 1/29/19. Build thread here.

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    Hello John and welcome to the forum,
    Building your car will be a great experience, especially if you can get your kids involved.
    I am on the finishing stages with mine which I received May of 2018. My build plans are identical to yours except for the side exhaust delete. I am currently working through the DMV registration process and have learned a lot about said process. I am in Half Moon Bay so it's only a short drive to Los Gatos and I actually grew up in Campbell. Let me know if you want to get together sometime.
    Thanks
    Greg

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    Hey Greg! Wow - you really moved fast on your build! Thanks so much for the note. I'd love to get together sometime and see your roadster and hear about your build and the registration process.

    -John
    MkIV Roadster build: Coyote, IRS, TKO600. Ordered 10/24/18. Delivered 1/29/19. Build thread here.

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    Today was D-Day (Delivery Day)! It's important to note that Los Gatos is a pretty small town that's tucked into the foothills of the Santa Cruz mountains. Why is this important? Well, because in practical terms this means that there are many hilly neighborhoods with narrow, windy streets. Our house sits atop a small hill, and the last half-mile consists of tight tree-lined hairpin turns. In short, there's zero chance that Stewart Transport could get their massive truck up the street to my house. I had already forewarned them of this and had made arrangements with a local towing company with a flatbed tow truck to meet the driver somewhere more convenient. The tow truck driver came by my house to pick up the frame dolly, and we then went together to meet Scott from Stewart Transport. He had found a nice spot right off the freeway, and we were able to offload the chassis directly from the Stewart truck onto the frame dolly on the tow truck. We managed to squeeze in all the boxes alongside the chassis, and we were on our way pretty quickly. This was all happening on the main road through town in the middle of the afternoon rush, so it was quite the spectacle, but it all went off without a hitch. We were soon back at the house and had all the boxes unloaded and the chassis onto the four post lift.


    I glanced through the POL list and had to laugh. The very first item noted on the POL list is the assembly manual. Not likely to get too far without that! OK, in reality, I have a PDF copy of the manual already, so it's not going to hold anything up, but it's pretty funny nonetheless. The only other items of note on the POL list are the front lower control arms. Hopefully, those show up soon. Everything else on the list is minor, and not anything I'll need any time soon. All in all, far better than I expected given that I ordered during the winter sale.


    Next up - inventory!

    MkIV Roadster build: Coyote, IRS, TKO600. Ordered 10/24/18. Delivered 1/29/19. Build thread here.

  10. #10
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    John,
    Congratulations on your new delivery. Like Chrismas in January!
    Anytime you want to get together just let me know and we can work something out.
    Greg

  11. #11
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    Looking Good John!
    Funny story, I was the delivery after yours that day, and I'm also Greek, and my wife's family calls me Greek Guy or GG for short...
    Wife says I need to finish some house projects before I start, so I'll be following your thread closely since you'll be a few steps ahead of me.
    Preston

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    Hey Preston. How funny! Thanks for the note, and welcome to the forum. My wife saw your post and said, "Oh, was that an option... having you do more stuff around the house before starting the build?" I said, "No, not really." ;-). Good luck with your build. I don't know how far ahead of you I'll be. I managed to throw my back out the day after the kit was delivered so not a whole lot of progress. I'm 3/4 of the way through the inventory and I'm hoping to wrap that up tomorrow.

    -John
    MkIV Roadster build: Coyote, IRS, TKO600. Ordered 10/24/18. Delivered 1/29/19. Build thread here.

  13. #13
    Senior Member Yama-Bro's Avatar
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    Congrats! And welcome!
    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

  14. #14
    Senior Member Fixit's Avatar
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    Welcome to the asylum!
    It is ironic that the kit shows up, and there's no book... Looking good on your work in preparation.

    My first choice is to go with a custom competition layout dash with glovebox (I've also ordered Alex's glovebox kit). Complicating matters a little is that I also plan to install a heater, so I may also go with the FFMetal 'firewall forward' piece to get everything to fit (or fab a box to space the heater forward into the engine bay)
    #9365 is also running a Coyote, with a heater, and a glovebox. I didn't do the "firewall forward" or an extender box... I made my own glovebox from fiberglass. Here's where that saga starts. The other thing to consider with the heater is clearance to the Coyote - that thing is all cylinder head. Take a look here for pics on my install of the heater control valve. Things are tight without the extension or firewall forward option.
    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 - #9365 Build Thread

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    Thanks John! Your build thread will be a great reference when I get to that point in my build. I appreciate it.
    MkIV Roadster build: Coyote, IRS, TKO600. Ordered 10/24/18. Delivered 1/29/19. Build thread here.

  16. #16

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    I finally finished the inventory of all the boxes yesterday. I found a handful of missing items, but nothing major. Mostly various small fasteners and other assorted things that I won't be needing for a bit. That list has been e-mailed off to Dave and I'm sure it'll be handled quickly. I want to thank VAHokie for asking the "Hey I found this thing and don't know what it is" questions in his build thread. I came across some of those same items and was scratching my head for a moment before remembering that I had seen them in his thread.

    There were a couple of options that I ordered after I finalized my kit order, but before it had shipped, hoping that they could be thrown into the same shipment and save on separate shipping costs. There must have been a mixup somewhere because they didn't make it into the shipment. One is the heater kit, which I won't need for a bit, but the other is the spherical bearing upgrade kits for the front and rear control arms. Those I'll need as soon as I get the chassis back from powder coat. It hasn't yet been sent off for PC, so it'll be a few weeks before I need them. Hopefully, I'll have those, plus my POL front lower control arms, by then. Many of the items on my POL list, including the assembly manual, must have shown up at the 11th hour, as they were thrown into a 'catchall' box #23. It was good to see that ~75% of the items on my POL list were actually in that box. So now the only thing on the POL list that will hold me up any time soon is those front lower control arms. I spoke with the folks at FFR today, and those should hopefully be headed my way in the next couple of weeks so all should be well.

    I haven't yet done the inventory of all the 'mounted' components but I should have the body off in the next few days and I'll be able to wrap up that final part of the inventory. Now I get to sort the boxes into the "need sooner" and "need later" piles and stack the former in the garage cabinets and take the latter down to the basement. I have to tell you, I'm glad that I'm done counting fasteners.



    One other notable item is that my tires showed up the other day. I went with what seems like one of the consensus favorite solutions here - the BF Goodrich G-Force Rival S. 245/40R18 and 315/30R18. It took a bit of hunting and searching and sleuthing before I figured out what was going on, as every time I searched for that model in those sizes I would come up empty. Apparently, in the 245/40 front, the Rival-S has been replaced by the Rival-S 1.5, while the Rival-S is still the current offering for the rear. Once I realized that, Tirerack.com had both in stock and at my house in a couple of days.



    I think I'll need to play with ride height a bit.

    I'm planning to powder coat the wheels gloss black and leave the spinners and spinner adapters aluminum, but before I send the wheels off for PC I'm going to drill and tap them for set screws to lock in the spinner adapters, per Edwardb's excellent guidance. I just need to come up with a good way to figure out which adapters go back to which wheels once I get them back from PC.
    Last edited by JohnK; 02-07-2019 at 08:34 PM.
    MkIV Roadster build: Coyote, IRS, TKO600. Ordered 10/24/18. Delivered 1/29/19. Build thread here.

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    Quick update: We've been busy with other stuff the last few days and hit with back-to-back severe rainstorms and power outages, but we did manage to get the body off the chassis and onto the body buck. I also got the wheels back from powder coat and had the tires mounted and balanced today. Those are some pretty sinister-looking wheels!





    MkIV Roadster build: Coyote, IRS, TKO600. Ordered 10/24/18. Delivered 1/29/19. Build thread here.

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    My son and I made some good progress today. We labeled, photographed and removed all the sheet metal and we got started on cleaning up the frame in preparation for powder coat.



    Here's Nik cleaning up a weld:



    I also made a few last-minute upgrades to the body buck in preparation for moving it to an offsite storage unit. I added a rib running between the front and back scribed pieces, and then made a support for the body using a piece of foam roller. This stops the body from bouncing and flexing as the cart is moved around. Since it'll be traveling on the back of a flatbed tow truck there was some concern about it not bouncing around too much and also keeping it on the body buck, so I shrink-wrapped the entire body onto the buck.



    Also a few logistical updates. I sent my steering hub to Russ Thomspon and had a complete turn signal assembly back in my hands two days later. That's some impressive service! Looks like a very nice piece and a nice upgrade. I also called and placed my deposit for an upgraded/syncronized TKO 600 with Pro 5.0 shifter from Liberty's Gears. They're currently running at 12 weeks lead-time, so I'm glad I got my order in now. Lastly, I received three boxes from Factory Five yesterday. I now have all my missing and POL items except for two, and those I won't need until much later (3 prong flasher and license plate bracket). Most importantly, I now have my lower control arms and spherical bearing upgrade material so I'm good to go on suspension assembly. All in all, I'm thrilled with how quickly they resolved all the backordered items.
    Last edited by JohnK; 02-17-2019 at 10:21 PM.
    MkIV Roadster build: Coyote, IRS, TKO600. Ordered 10/24/18. Delivered 1/29/19. Build thread here.

  20. #19
    Senior Member Fixit's Avatar
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    Looks Good!!

    It appears that you're addressing some of the issues that I wish FFR would pay more attention to pre-powder coat... some of the weld beads where the aluminum panels rest. There are several locations where trimming/notching the panels is required for them to clear a weld bead and lay flat.
    You on the other hand can just grind off the offending material!
    Check your "tins" where they lay against the frame members and mark the frame for interference.

    (PS... get your kid/helper/Nik to wear proper shoes in the shop...)
    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 - #9365 Build Thread

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