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Thread: First autocross! Fail!

  1. #1
    Senior Member Caddy Dad's Avatar
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    First autocross! Fail!

    I've decided to start a build thread so that other newbies can learn from my adventures and also to serve as a kind of peer review from all the talented and helpful builders out there. I called FFR today and Dave B said they were pulling my parts as we spoke so I'm guessing Stewart transportation will be calling soon with a delivery date and asking for me to spend more money :-).

    I've been itching to do this project for a long time. Initially, I wanted to restore a 66 Mustang or a 240Z like I had in college but most of the cars I could find were rust buckets needing a lot more metal work than I could handle. Instead, I decided that the FFR Roadster is going to scratch that itch just fine. I know there is going to be a huge learning curve to get over but like most journeys of a 1000 miles, it starts with a first step. I joined this forum a while back and read through several build threads to get a feel of the scope of work involved and talent required. Then I started hanging out at my local cars and coffee. Met several Mk IV owners (a few Superformance and Backdraft owners too!) and started asking questions. I then took advantage of some cheap summer airfare and visited the FFR factory. I tried on all of the cars in the showroom to see what fit me best (I'm 6'2" 200 lbs). The FIA MK IV Roadster they had fit me like a glove. Jim Schenck wandered into the showroom and I pestered him with more newbie questions. Dan G then came out and gave us the factory tour. Geez they were busy! I didn't even try to get in the coupe they had in the showroom. I was worried I might not be able to get back out without asking for help and making a scene. Turns out my fears were over cautious. After my factory tour, I reached out to a couple of local builders in my area, VAHokie and Boss 427. They were at opposite ends of the build sequence so that gave me a lot of insight into where to start and how to finish. Thanks guys! I then went to the build school where I got a few more assembly tips and more hands on experience. It was money well spent and I think I graduated Cum Laude ;-)

    Up to this point I had only sat in a Mk IV. But what really sealed the deal for me was that on the way home from the build school I stopped off at EdwardB house to check out his gorgeous 20th anniversary Roadster. After about 1.5 hours of Paul being very patient and me asking more newbie questions, Paul asked if I wanted to go for a ride. Heck Yeah! It was a fabulous riding car and the product of a true craftsman. The power, sound and handling were unlike any car I've ever ridden in. I was hooked after that. All of the builders I've met to date really set a high bar. I just hope I can come close to the level of what they've created and pay it forward when I can.

    Enough rambling. Here is what my build is going to look like:
    Complete Kit
    Powder coating
    Power Steering
    Hydraulic clutch
    Dual roll bars
    IRS
    Wilwood brakes
    Leather steering wheel
    17" Halibrand wheels
    Competition dash
    Usual breeze upgrades

    For the go pedal:
    Blue Print Engines 347
    Tremec TKO600
    Hydraulic release bearing

    Boss 427 has been a big help. He dropped off the chassis dolly for me. Looks like I'll be builder #3 on it

    I'll also started to tool up my garage and work shop. At the build school, one of the other students highly recommended the cordless Milwaukee Rivet gun. I picked one up and so far it seems to work great.
    Pictures to follow.

    Thanks to all who care to follow along on my adventures (and misadventures!)

    Frank Smith

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  3. #2
    Senior Member Traveller's Avatar
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    Welcome to the adventure, Frank. I'm only a few months ahead of you but it wouldn't surprise me if you pass me as life seems to keep getting in the way of shop time...

    I look forward to watching your build progress.

    -Jason
    Last edited by Traveller; 12-11-2019 at 06:24 PM.
    MK4 Complete Kit #9673 | Ordered: 08/07/2019 | Pickup: 08/24/2019
    Gen 2 Coyote, TKO600, IRS, Power Steering, 18" Halibrands, Kirkey Vintage Race Seats, Gas-N Headers and Pipes
    Build Thread: https://thefactoryfiveforum.com/show...IRS-Build-9673

  4. #3
    Straversi's Avatar
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    Welcome. Look forward to following along.
    -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

  5. #4
    Senior Member VAHokie's Avatar
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    Congrats, Frank. Look forward to following along!
    MKIV Complete Kit #9494 l Delivered 1/5/19 l First Start 11/28/20 l First Go-kart 4/11/21 l Carb'd 347 l Mid-shift TKO600 l 3.55 IRS l P/S l Forte Mechanical Throttle Linkage l RT Turn Signal, Drop Trunk l Breeze Upper/Lower Radiator Support, Fan Shroud l Boig Upper/Lower Cool Tubes & Quiet Pipes l 18" FFR Gasser Wheels l Build Thread

  6. #5
    Senior Member edwardb's Avatar
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    Way to go. Congratulations on your order and upcoming delivery. Doesn't look like I completely sold you on the Coyote power () but I tried. Enjoy the build and will be interested to watch your progress.
    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.

  7. #6
    Senior Member Caddy Dad's Avatar
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    LOL! Yes, that was a hard decision for me to make. The Coyote is a fantastic engine and if I ever build another car, it'll definitely be Coyote powered. But, lets get through this build first.

  8. #7
    Senior Member Yama-Bro's Avatar
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    Congrats and welcome to the club! Glad to see another Frank out there (I'm one too).
    Started dreaming of a Cobra around 1987
    Purchased Complete Kit 6/9/2017, Delivered 9/4/2017, Rolling Chassis 3/30/2018, Engine Dyno'ed 3/4/2022, Engine installed 8/27/2022
    Click here for my build thread
    Serial #9158
    Design Engineer at BluePrint Engines

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  10. #8
    Senior Member Caddy Dad's Avatar
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    The first big box showed up today from BPE. 347 stroker, TKO 600 and hydraulic release bearing, 423 HP, 429 Ft lbs.
    https://thefactoryfiveforum.com/atta...7&d=1577736458
    https://thefactoryfiveforum.com/atta...8&d=1577736476

    BPE even removed the mounting boss on the transmission for me. Thanks Johnny! I was really impressed with the shipping crate and packaging that Blueprint did. Lots of wiring, hoses and miscellaneous parts in the fuel accessories box. Not exactly sure where all those go yet, but I've got some time to figure it out.

    The next big delivery should be this week.
    Attached Images Attached Images
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

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  12. #9

    Steve >> aka: GoDadGo
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    Sweeeeeeet Delivery Caddddy Dad!

    Welcome Aboard Brother!

  13. #10
    Senior Member KDubU's Avatar
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    Nice engine! Can’t go wrong with the 347.
    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.

  14. #11
    Senior Member Caddy Dad's Avatar
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    Today was the big day! Kelly from Stewart trucking showed up right on time this AM with a truck load of parts. My neighborhood is a little tricky getting into and he had to back all the way in and around a corner. Good thing he was AZ trucker of the year! I told him I once drove a U-Haul and could help him if he needed it. ;-)

    A super nice guy and his next stops were NC, SC, FL, and OK.

    I completed the inventory today and most parts were in the boxes they were supposed to be in. The POL list is mainly most of the IRS except for center section, the fuel tank cover and a few miscellaneous small parts. I did notice I only got one brake fluid reservoir. I thought I was going to get two. Also the pedals didn't come with the pads. Is that something extra? I was thinking that should have been included. I'll have to double check box 19 and 21 again as they seem to be the catch all boxes that the last few parts got thrown into.

    Some assembly required!

    https://thefactoryfiveforum.com/atta...1&d=1578003579
    https://thefactoryfiveforum.com/atta...1&d=1578003592
    https://thefactoryfiveforum.com/atta...1&d=1578003604
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  15. #12
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    Congrats! I just spoke with Kelly about an hour ago, he'll be at my house at 8:00 in the am. He ran out of hours and had to park it.

  16. #13
    Senior Member bobm488's Avatar
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    Quote Originally Posted by Caddy Dad View Post
    Today was the big day! Kelly from Stewart trucking showed up right on time this AM with a truck load of parts. My neighborhood is a little tricky getting into and he had to back all the way in and around a corner. Good thing he was AZ trucker of the year! I told him I once drove a U-Haul and could help him if he needed it. ;-)

    A super nice guy and his next stops were NC, SC, FL, and OK.

    I completed the inventory today and most parts were in the boxes they were supposed to be in. The POL list is mainly most of the IRS except for center section, the fuel tank cover and a few miscellaneous small parts. I did notice I only got one brake fluid reservoir. I thought I was going to get two. Also the pedals didn't come with the pads. Is that something extra? I was thinking that should have been included. I'll have to double check box 19 and 21 again as they seem to be the catch all boxes that the last few parts got thrown into.

    Some assembly required!

    https://thefactoryfiveforum.com/atta...1&d=1578003579
    https://thefactoryfiveforum.com/atta...1&d=1578003592
    https://thefactoryfiveforum.com/atta...1&d=1578003604
    My Fuel tank liner was in the same box as the fuel tank.
    Yes you should have pedals pads.
    The kits only come with one reservoir.

  17. #14
    Boydster's Avatar
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    We need to work on your picture posting before you get too far into your build thread.

    Excited for you, Frank. Gimee a holler if ya need a hand.
    ---Boyd---
    MkIV #9042 build thread
    www.boss427.us
    427W, TKO600, Moser 3.55 rear.
    Delivered Feb 2017, Graduated Nov 4, 2019

  18. #15
    Senior Member Caddy Dad's Avatar
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    Oh, don't worry. I will definitely need a hand! Especially when it comes to engine/tranny install. I'm already scratching my head on where all the connections go.
    BTW, I want to replace my firewall with a thicker panel from FF Metals. Did you go with the Firewall Forward mod or just a thicker panel?

    Thanks!
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  19. #16
    TMartinLVNV's Avatar
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    Quote Originally Posted by Caddy Dad View Post
    The first big box showed up today from BPE. 347 stroker, TKO 600 and hydraulic release bearing, 423 HP, 429 Ft lbs.
    https://thefactoryfiveforum.com/atta...7&d=1577736458
    https://thefactoryfiveforum.com/atta...8&d=1577736476

    BPE even removed the mounting boss on the transmission for me. Thanks Johnny! I was really impressed with the shipping crate and packaging that Blueprint did. Lots of wiring, hoses and miscellaneous parts in the fuel accessories box. Not exactly sure where all those go yet, but I've got some time to figure it out.

    The next big delivery should be this week.
    That engine looks really sweet! Nice garage floor too.
    MK IV Build #9659, 3 link, 17's, Forte 347, Sniper EFI, power steering, built for a freak sized person with 17" Kirkey Vintage seats, RT drop trunk, RT turn signal, lots of stuff from Breeze Automotive, Wilwood brakes, paint by Jeff Miller

  20. #17
    Senior Member Caddy Dad's Avatar
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    I dove into the build this weekend. I discovered a few more parts that I'm missing that are checked off as being on the shipping list but aren't. I'm also discovering that as I start to assemble some components I'm missing a few critical pieces that bring progress to a halt (i.e. power steering mounting bolts) Sigh. I'll make a call to FFR on Monday and let them know the parts I'm missing.

    Regardless I was able to drill and cleco the engine bay panels. I then removed them, de-burred the holes, broke sharp edges with scotch brite and prepped them for the powder coater this week.
    https://thefactoryfiveforum.com/atta...1&d=1578275204
    https://thefactoryfiveforum.com/atta...1&d=1578275221
    https://thefactoryfiveforum.com/atta...1&d=1578275237

    I then prepped the LCA by lightly scoring the bushings per a tip from the build school. The DS was a PIA to install even after tweaking the mounting mount bracket width. The PS went in with no complaints!
    https://thefactoryfiveforum.com/atta...1&d=1578275278

    The LCA also have a dust cap for the zerk fitting. First time I've ever seen that. A nice touch.
    https://thefactoryfiveforum.com/atta...1&d=1578275295

    I then tried to assemble the front and rear shocks but found I was missing the Delrin washers. I also had one coil over threaded sleeve that would just not allow the spring seat to thread on. Jammed after a few threads. I tried cleaning the threads but No Joy. Also, what tool do people use to adjust the spring seat? Those are both on my list to discuss with FFR.

    I then moved on to assemble the UCA. As most people have discovered the upper ball joints that come with the kit, just go in a few threads and then jam up tight. The Howe ball joints went in like butter (added blue locktite as per directions). I tightened them the best I could in the bench vise as depicted in the book. However when I tried to adjust the trailing sleeve to the spec called out in the book (7.375") the best I could get was 7.5" I've read where others have trimmed the sleeve while others have not. Will 7.5" be enough? Will I need to trim? Any insight here would be appreciated.

    https://thefactoryfiveforum.com/atta...1&d=1578275261

    I then got motivated and tried to see how the power steering rack would fit with the Breeze bushings and Moog tie rods. I opened the bag with the power steering parts and.... No bolts or nuts. Sigh.
    https://thefactoryfiveforum.com/atta...1&d=1578275313

    Not willing to give up so easily, I then decided to take a look at the front hubs. What's the best way to remove the ring gear around the inside of the hub? Or do I just leave it alone?
    https://thefactoryfiveforum.com/atta...1&d=1578275328

    So I just called it a day from there and figured it was time to grab a beer, think about the last two days and what I need to work on this week.

    Thanks!
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  21. #18
    Senior Member Caddy Dad's Avatar
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    Quote Originally Posted by TMartinLVNV View Post
    That engine looks really sweet! Nice garage floor too.
    Oh man I know! I'm really looking forward to firing it up and hearing the lumpy idle. I had the floors done professionally a few years back by Granite Garage floors. It's held up really well. The only problem is when I drop a small nut or washer it disappears!
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  22. #19
    Senior Member edwardb's Avatar
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    - Your steering rack mounting bolts should be with the other suspension hardware. The box-by-box listing is your friend to find specific parts. I'll bet you find them listed there and in that box. Not necessarily with power steering components.

    - Hard to say whether that UCA adjuster should be trimmed. Like you said, some get away with not trimming, others don't. Many preemptively go ahead and trim it now to save disassembly down the road. Doesn't hurt to be trimmed even if not actually needed. Or you could wait and see when doing your alignment. Whatever is your preference.

    - If you want to remove that toothed ring on the front hubs (it's a tone ring for an ABS wheel speed sensor), cut it most of the way through with a cut off wheel or even a Dremel (that's what I've used) then hit the cut with a screwdriver and it will break and pop right off. It's hard and brittle. I suspect it's installed by heating/expanding. So nearly impossible to get off without breaking it off. At least that's my experience.

    BTW, your pictures are really tiny. Just thumbnails I think.
    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.

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  24. #20
    Senior Member Caddy Dad's Avatar
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    I'll keep looking for the mounting bolts. Yes, I think I need to spend more time with my box by box listing. I may go ahead and trim them this week while waiting for the panels to come back. I didn't even think about cutting the tone ring, but that's a great idea. I'll take a look at it this week after I buy a new dremel tool. My old one of 25+ years finally died on me today.

    Yes, I'm picture challenged on this forum and still learning
    LCA FR.jpg
    Attached Images Attached Images
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  25. #21
    Joynt Venture's Avatar
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    Just wandered into the house after an 8am delivery from Stewart with Kelly at the wheel. Great guy and a gentleman to work with. Headed to build school in a week or so. Plan on fine tooth inventory before that. Enjoy your build! I know I will!

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  27. #22
    Senior Member Caddy Dad's Avatar
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    Cool! Enjoy the build school. Jim and Scott were my instructors. It was fun and gave me more insight into all the pieces that go together to make a fun project.

    Frank
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  28. #23
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    Quote Originally Posted by Caddy Dad View Post
    I dove into the build this weekend. I discovered a few more parts that I'm missing that are checked off as being on the shipping list but aren't. I'm also discovering that as I start to assemble some components I'm missing a few critical pieces that bring progress to a halt (i.e. power steering mounting bolts) Sigh. I'll make a call to FFR on Monday and let them know the parts I'm missing.

    Regardless I was able to drill and cleco the engine bay panels. I then removed them, de-burred the holes, broke sharp edges with scotch brite and prepped them for the powder coater this week.
    https://thefactoryfiveforum.com/atta...1&d=1578275204
    https://thefactoryfiveforum.com/atta...1&d=1578275221
    https://thefactoryfiveforum.com/atta...1&d=1578275237

    I then prepped the LCA by lightly scoring the bushings per a tip from the build school. The DS was a PIA to install even after tweaking the mounting mount bracket width. The PS went in with no complaints!
    https://thefactoryfiveforum.com/atta...1&d=1578275278

    The LCA also have a dust cap for the zerk fitting. First time I've ever seen that. A nice touch.
    https://thefactoryfiveforum.com/atta...1&d=1578275295

    I then tried to assemble the front and rear shocks but found I was missing the Delrin washers. I also had one coil over threaded sleeve that would just not allow the spring seat to thread on. Jammed after a few threads. I tried cleaning the threads but No Joy. Also, what tool do people use to adjust the spring seat? Those are both on my list to discuss with FFR.

    I then moved on to assemble the UCA. As most people have discovered the upper ball joints that come with the kit, just go in a few threads and then jam up tight. The Howe ball joints went in like butter (added blue locktite as per directions). I tightened them the best I could in the bench vise as depicted in the book. However when I tried to adjust the trailing sleeve to the spec called out in the book (7.375") the best I could get was 7.5" I've read where others have trimmed the sleeve while others have not. Will 7.5" be enough? Will I need to trim? Any insight here would be appreciated.

    https://thefactoryfiveforum.com/atta...1&d=1578275261

    I then got motivated and tried to see how the power steering rack would fit with the Breeze bushings and Moog tie rods. I opened the bag with the power steering parts and.... No bolts or nuts. Sigh.
    https://thefactoryfiveforum.com/atta...1&d=1578275313

    Not willing to give up so easily, I then decided to take a look at the front hubs. What's the best way to remove the ring gear around the inside of the hub? Or do I just leave it alone?
    https://thefactoryfiveforum.com/atta...1&d=1578275328

    So I just called it a day from there and figured it was time to grab a beer, think about the last two days and what I need to work on this week.

    Thanks!
    On the ball joints, the problem is with the powder coating on the threads on the UCA's. Knock that off the threads with a small wire wheel and they will thread right in. Note also that the steering rack hardware was in another box for me.

  29. #24
    Senior Member Caddy Dad's Avatar
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    I worked on a few more small tasks today. I dropped off 21 panels at the powder coater today. Their matt black sample chip seemed to match the FFR powder coating closely. It's the first time I've used this company but they promised a 7-10 day turnaround and at $19 a panel it seemed like a good price. We'll see how they turn out.

    I also followed EdwardB advice and took my dremel tool to the tone ring on the front hubs. 15 seconds with the dremel and then a nice tap with a hammer and screw driver, they were off! No muss no fuss. Thanks Paul!

    I also fitted the drive shaft adapter to the IRS to ensure the bolt holes would line up. I was a little worried because the parts list calls it out as an automatic transmission adapter. It fit perfect. While the IRS was out of the box, I hit it with some clear to protect it from dirt and corrosion. I think it looks pretty cool with the manufacturing and inspections marks on it.

    IRS Diff.jpg
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  30. #25
    Boydster's Avatar
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    Quote Originally Posted by Caddy Dad View Post
    Oh, don't worry. I will definitely need a hand! Especially when it comes to engine/tranny install. I'm already scratching my head on where all the connections go.
    BTW, I want to replace my firewall with a thicker panel from FF Metals. Did you go with the Firewall Forward mod or just a thicker panel?

    Thanks!
    I got the thicker FF panel, stock location.
    ---Boyd---
    MkIV #9042 build thread
    www.boss427.us
    427W, TKO600, Moser 3.55 rear.
    Delivered Feb 2017, Graduated Nov 4, 2019

  31. #26
    Senior Member Caddy Dad's Avatar
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    I worked on a few more tasks today. The powder coater called and said my parts were finished. A 3 day turn around. Not bad! The matt black matches perfectly to the chassis. All of the cockpit panels came back in one box but it was easy to fit all the pieces back together.
    Attachment 120382

    I then installed the F panels and inserted 10-24 Rivnuts in the elephant ears as suggested. (following EdwardB playbook). I then temporarily installed the ears with #10 SS screws and washers. I'm really liking the silver and black look of the rivets and screws.
    Attachment 120383

    Attachment 120384

    The Milwaukee cordless rivet gun made quick work pulling the rivets
    Attachment 120385

    I also came up with a simple method for labeling and identifying the panels before I send them to the powder coater. Maybe somebody has already done this but here is what I did. I use a thick Sharpie and write on the panel the part name, number and placement/fitment of tabs as I take them apart. I then take a picture and store it on my PC. I then prep the panels by deburring, breaking sharp edges, etc and wiping down with Acetone. The markings come right off and the panels are ready to be powder coated.
    Attachment 120386

    I now have to decide if I want to get the rest of the panels powder coated or just hit them with some kind of bedliner since most of them will never be seen unless the car is on a lift. What do most people do?

    I'm still waiting on POL list and the missing delrin washers. Once I get those, I can finish up the front suspension and check off my first milestone.

    Cheers!
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  32. #27
    Not a waxer Jeff Kleiner's Avatar
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    Just an FYI: all of your photos come back as "Invalid attachment"

    Jeff

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  34. #28
    Senior Member Caddy Dad's Avatar
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    That's strange. Seemed to be working yesterday.
    Picture test:
    Cordless Rivet gun.jpg
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  35. #29
    Straversi's Avatar
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    I couldn’t open your photos in posts 17 and 26. The photo in the last post worked.
    -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

  36. #30
    Senior Member Caddy Dad's Avatar
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    Here is a re-post of the pictures from #26

    Engine bay
    Powder Coat engine bay.jpg

    F Panel
    PS F Panel.jpg

    Elephant ear
    PS Elephant Ear.jpg

    Rivet gun
    Cordless Rivet gun.jpg
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  37. #31
    Not a waxer Jeff Kleiner's Avatar
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    Pictures show up now; looks good!

    I'd caution you about leaving that painter's tape on for very long---I got one in for paint that had had it left on past it's recommended time and the owner was having a Bi*** of a time getting it off. Personally I don't use it and fail to see the need but that's just me...

    Jeff

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  39. #32
    Papa's Avatar
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    Quote Originally Posted by Jeff Kleiner View Post
    Pictures show up now; looks good!

    I'd caution you about leaving that painter's tape on for very long---I got one in for paint that had had it left on past it's recommended time and the owner was having a Bi*** of a time getting it off. Personally I don't use it and fail to see the need but that's just me...

    Jeff
    I'll second Jeff's caution! I taped up my chassis in the engine compartment for a couple of months and it took me a couple of hours to get all that stuff off.
    Last edited by Papa; 01-11-2020 at 07:04 PM.
    My Build Thread: http://thefactoryfiveforum.com/showt...ter-Build-9754
    (Most viewed Roadster build thread on this forum!)

    Delivered: 6/17/2017
    First Start: 12/30/2017
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    Legal: 1/30/2020

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  41. #33
    Senior Member Caddy Dad's Avatar
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    Quote Originally Posted by Jeff Kleiner View Post
    Pictures show up now; looks good!

    I'd caution you about leaving that painter's tape on for very long---I got one in for paint that had had it left on past it's recommended time and the owner was having a Bi*** of a time getting it off. Personally I don't use it and fail to see the need but that's just me...

    Jeff
    I agree. It was getting in the way today so I just took it off. If I scratch the powder coat, I'll just have to touch it up
    Thanks for the feed back
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  42. #34
    Senior Member Caddy Dad's Avatar
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    I work on a few more items today. As many others before have found out, there is always something to work on. Gotta keep making progress while waiting on POL and MIK (Missing In Kit) parts to show up. The Wilwood brakes were delivered earlier this week so I decided to mount the hubs to the rotors and safety wire them. These rotors are massive! Per the instructions, I added Locktite and torqued each bolt to 155 In Lbs. I then moved on to safety wiring them. How hard can it be? After about an hour and a little help from Google I realized I had wired 4 of them backwards! Ugh. I think Charlie Taylor was rolling over in his grave! (Bonus points to those who know who Charlie was) I removed the wires and started over. The first re-wire took about 15 minutes but I quickly got the hang of it and by the time I got to the fourth rotor, I could do a wire in less than 5 minutes. Actually, it was a lot of fun learning a new skill and putting it to good use.

    Safety wire close up.jpg

    Safety wire.jpg

    I also got an email from FFR on what the power steering mounting hardware looks like and which box it might be in. With that help, I was able to locate it easily. It was in a bag inside another bag for steering components that I set aside for later install. Anyway, I was able to install the power steering unit and the Breeze offset bushings without too much fuss. I needed to add a few shims (washers) on each side but it went in fine.

    Power steering mounted but not torqued down yet.
    Power steering.jpg

    I plan on working on the RT drop trunk mod next and drilling more aluminum panels

    Thanks!
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  43. #35
    Senior Member edwardb's Avatar
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    Quote Originally Posted by Caddy Dad View Post
    I agree. It was getting in the way today so I just took it off. If I scratch the powder coat, I'll just have to touch it up
    Thanks for the feed back
    I've used the painters tape and not had any trouble with it coming right back off after many months. But I defer to others who have had issues. My garage shop never gets terribly cold or hot, so perhaps that makes a difference. Maybe I'm the only one that drops tools, parts, etc. or is just plain clumsy. So I prefer some type of protection and even the best touch-ups are often visible. Another option that I've seen some use, and used quite a bit on my Coupe build, was foam pipe insulation from Home Depot/Lowes. Comes in several sizes, is really cheap, and with a wrap of tape every couple feet (that never touches the chassis) stays in place pretty well. I had it mainly on the top rails of my Coupe build, plus the roll bars, since those are what were in the firing line of my work. Has since graduated to shelf storage since the body is on. But did the job for me.
    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.

  44. #36
    Senior Member Caddy Dad's Avatar
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    I spent the afternoon finishing up a few minor tasks and then got organized for the install of the IRS differential. Following the EdwardB playbook I bought a couple 5/8 x 5" bolts and ground a taper in them to resemble a drift pin. I don't have a bench grinder so I went at it with a 4" angle grinder. They're not pretty but they worked really well. They also came in handy installing the Toe Arms, LCAs and UCAs.

    Attachment 120625

    I then got the differential set up on my motorcycle lift and shop crane. Using techniques from EdwardB and Kool AC, I was able to rig it up with 3 ratchet straps, lift it vertically, tilt it back horizontal and then lower it down with out too much grumbling from my helper (teenage daughter who is home and winter break). I little wiggling, grunting and a few smacks on the drift pins and it was in! It went in easier than I was expecting.

    Attachment 120626
    Attachment 120627

    I then proceeded to tighten down the mounting bolts. After I got all four bolts to torque spec, I found that I have a gap on the rear DS ear and the front PS ear. Am I going to need shims for these?
    Attachment 120629
    Attachment 120630

    I then moved on and mounted the toe arms. The Toe arms were assembled per the drawing, but for some reason there were some extra parts in the bag when I got done; two bolts and 2 RH jam nuts. Does FFR do this on occasion? I checked and double checked the drawing and the parts list. Best I can guess is that they threw in some bonus parts? Seems odd to me.
    Attachment 120631

    I installed the toe arms with a little tweaking to the mounting ears and then moved onto the Lower Control Arms. A little bit more tweaking and a few whacks with my new drift pins and the LCAs went in without a fuss.

    Feeling bold, I then tried to assemble the Upper Control Arms and quickly got stopped in my tracks. I tried to thread in the bushing the UCAs but they only go in about a 1/2 inch before binding up hard. Looking at the threads, I'm guessing it was tapped then welded together, and something happened in the process. Now the sleeves won't thread in. I tried cleaning the threads with scotchbrite but that did nothing to help the situation. So now I'm thinking the threads will need to be chased with a tap. Does anyone know what size tap should be used? I know its at least and inch if not more in diameter. Any insight or different tachnique would be appreciated.
    IRS UCA binding.jpg

    Thanks!
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  45. #37
    Senior Member Caddy Dad's Avatar
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    Seems like the forum disruptions the other day broke the links to my pictures. Reposting here

    Drift pins
    Handy tools.jpg

    IRS install
    IRS in the house.jpg
    IRS in the house2.jpg

    DS IRS gap
    IRS DS Rear ear gap.jpg

    PS IRS gap
    IRS PS front ear gap.jpg

    I've since heard back from FFR tech support and they said the gaps are fine. The 4 bolts bottom out on the sleeves inside the bushings. The IRS is not going anywhere

    Bonus parts
    IRS Toe Arm Spare parts.jpg

    Thanks!
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  46. #38
    Boydster's Avatar
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    Glad ya got it in!~ Sorry I wasnt able to help...
    ---Boyd---
    MkIV #9042 build thread
    www.boss427.us
    427W, TKO600, Moser 3.55 rear.
    Delivered Feb 2017, Graduated Nov 4, 2019

  47. #39
    Senior Member Caddy Dad's Avatar
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    No worries. I've got plenty of other tasks that I'm definitely going to need your help. Maybe even look over what I've done to make sure I didn't overlook something, or install backwards.

    Thanks!
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

  48. #40
    Senior Member Caddy Dad's Avatar
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    I spent a few more hours today working on the front and rear suspension, plus a trip the the local HF for a new torque wrench and my local Ace for a few nuts and bolts.

    I ordered a 1.25-12 tap to chase the threads on the IRS UCAs and it showed up early this AM. It worked perfect and I was able to get the adjusting bung to thread in smoothly now.
    UCA thread chase.jpg

    I then made a trip to my local HF to pick up a torque wrench that went to 225 -250 Ft Lbs. The lady at the checkout asked what in the world I was going to be using it for. I explained it was needed to mount the front hubs and then asked if she wanted to help. Her and the other staff bust out in laughter as they all know she's not very good with tools!

    I torqued the hubs to spec (with a lot of grunting) and then moved on to installing the IRS UCAs No issues there. Torqued all bolts and lubed all fittings on the IRS. The rest of the IRS is next on my list.

    I then installed the front Wilwood brakes. They needed one 0.04 shim to get centered. Installation was straight forward and a non event. Here is a few pics of the front end so far. The pivot nuts on the UCA are just finger tight as I have not yet done a rough adjustment yet. The power steering rack and tie rods are also finger tight awaiting the steering shaft and bearing installation.
    PS Wilwood.jpg
    PS Wilwood2.jpg

    A good days work!
    Mk IV Roadster #9749, Kit received Jan 2, 2020, Blueprint SBF 347 TKO600 Holley Sniper EFI, Dual roll bars, IRS, 17" Halibrand, Nitto 555 G2 245, 315 Road legal Oct 20, 2020

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