BA's MK4 build thread by Wallace18

[wallace18]

Today BA and son dropped off his MK4. They have been working on it for 4 years but as it does, life sometimes gets in the way. They contacted me thru Henry and I now have the pleasure of making their dream come true. I will be finishing it to go out to paint by a paint shop of his choice. Nice Kit. Coyote, IRS, Wilwood's, etc. I have to deliver a 818C I sold for the next few days. Also have a daughter getting married next week. So I most likely won't get too much done till the week of the 20th. Then I will start with an inventory. I am looking forward to this build. The MK4 is my favorite to build.

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[wallace18]

Got to work on the MK4 today. I pulled the engine and transmission as some work needs to be done on both. Also we will redo all the aluminum and brake lines. Going to add some cool stuff down the road. I also replaced the rusted bolts on the foot box for the drivers side that mount the Wilwood pedal assembly with S/S ones. Good days work.

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[wallace18]

Mocked up the rest of the foot box/firewall aluminum. I coated the back of the cockpit aluminum with Truck bed-liner. Much more durable, IMO. The foot boxes and firewall first get a couple of coats of Lizard Skin Sound deadener. Then they will get 2 coats of Ceramic heat coating. This has worked well in my 15 previous builds. The sound deadener is grey but the ceramic coating is black. I just use a small roller to apply. It dries up in no time in the Florida sun. LOL. I will coat the underside of the floor on the lift sometime next week.

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[Robodent]

Tom your living the dream and staying busy doing what you like to do. Great work. Rob

[nucjd19]

Going to be fun to see what you end up doing. Look forward to following this one.

[wallace18]

Painted the rusty rear end and installed the breather nipple and hose. Cleaned up the brake lines some. Put the last coat of Lizard Skin Ceramic heat coating on stuff. Painted rusty e-brake handle. Taking rest of the week off for my step-daughter's wedding.

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[wallace18]

Finished up brake lines and most of the foot-boxes. Installed painted E-Brake handle. Sealed up passenger foot-box with patch panels for large openings left over.

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[wallace18]

Filled the rear end with proper fluid. Come in nice package that has LSD additive already in it. Allows easy install vs old style bottles. Mocked up and drilled all rear chassis aluminum.

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[wallace18]

Today I coated panels, installed fuel tank, fuel filter/pressure regulator, fuel lines, rear wiring harness then installed coated panels.
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[wallace18]

It has been very hot here last 2 days. 98-99 temps with 110-115 heat index. I had to mow my lawn yesterday so no work on the MK4. Today I installed the hydraulic master cylinder to the pedal after getting rid of the cable stuff. I finished up trunk area and mounted battery, electric disconnect and working on main cables some. Storm coming in has halted work today at 3PM. I will get back at it Monday. Most likely start on getting powertrain ready to go in chassis.

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[wallace18]

Got back at it today. First I finished up main battery cables. Then made and installed a charcoal canister for fuel tank vent hose. Next I installed missing oil pan bolts and checked over the install. Then removed P/S idler bracket and painted it. Installed Oil pressure sender and temperature sender in Coyote. Mated trans back to engine after checking clutch out. Installed Forte's clutch slave cylinder setup, very nice, IMO.

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[wallace18]

Good day today. Reinstalled engine/trans. Hooked up starter, O2 sensors, headers, Slave cylinder line, fluid reservoir, serpentine belt, drive shaft, alternator, P/S high pressure line and some misc. wires. Will work mostly on wiring the rest of the week. Drivers side header is a PITA. Coyote is a big engine, LOL.

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[Railroad]

I was looking at the pic of your battery. I hope it is a sealed model. You do not need the battery off gassing hydrogen in the trunk.

[wallace18]

I was looking at the pic of your battery. I hope it is a seal model. You do not need the battery off gassing hydrogen in the trunk.

It is a mustang battery as described in the manual. I have built 16 FFR's and never had an issue. The trunk is not sealed air tight and this has the caps that gather the fumes and allow it to drip back into the cells.

[wallace18]

Had to remove the alt. to install the oil cooler stuff. I need to order some #10 hose for everything. Mike Forte sent some nice stuff. I finished up P/S hoses, resv. and hooked back steering shaft. Started back on Coyote harness some as well as mounted computer, fuse box and hooked up throttle pedal. Installed some of the hose plugs as well as joined the heater lines.

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[wallace18]

Worked on some different stuff today. First since we are using a hydraulic clutch I decided to use the FFR clutch switch for the Ford Coyote harness. Unfortunately the switch in the car was bad. Lucky for me I had some new ones from automatic builds I have done in the past. I then adjusted the brake and clutch switches for proper working. I also fixed a poor ground for the interior harness. I had filled the brake/clutch reservoir a day ago and found puddles under the rear brake calipers. There was no aluminum washer between the banjo fitting and the caliper. I had some left over from previous builds so that was an easy fix. Next I painted the front of the radiator and the fan shroud as per customer request. Then installed all of that using Breeze mounts. That allowed me to finish up all the cooling hoses. I used a black cooling system over flow tank instead of the long polished FFR unit. Looks pretty good, IMO.

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[wallace18]

I started the day thinking I would get a lot done. Not the way it turned out. However I did finish up the intake. I had to get a 4" sleeve and some grommets and nipples. But finally got everything as it should be.

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[wallace18]

Did not have much time today to spend on MK4. I was able to feed Coyote Fuse panel, alt., and 250 amp fuse as well as RF harness battery + cables. Also hooked up Coyote harness starter wire. I have some obligations in the AM this week so mostly afternoons on the MK4 this week. Waiting on #10AN hoses to complete oil circuit then maybe get ready for a start up next week.

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[wallace18]

Nothing too exciting today. Just wiring up rest of Coyote harness, horns, radiator fan and trying to tidy up as I go. I found 2 wires not attached to the ignition switch. Glad I peeled the tape back. All OK now.

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[wallace18]

Today I worked mostly on 2 things. 1 thing that bothered me was the Coyote fuse panel had no diagram inside the lid. I took a reduced copy of the fuse panel layout and glued it to the inside of the fuse panel lid. Next I cleaned up the dash wiring and installed a self-canceling turn-signal module with custom buttons. IMO, this is so much better than the RF setup. It not only does the T/S but 4-way as well. No need for flasher relays and you can eliminate a bunch of wires. I also install a programing switch for the clock as well as the speedo. Speedhut should include 2 switches IMO. I also installed the glove box. There was no aluminum plate for inside the glove box door anywhere in any of the owners boxes. I decided to install with 2 black 3/16 rivets. Much stronger than the epoxy route the instructions say to do, IMO. I will start on oil lines tomorrow.

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[wallace18]

Started on the oil cooler/remote filter lines. I am waiting on some more #10 AN 90 degree fittings for the cooler. I finished up the gas tank access holes for the sender and fuel pump. I also wired up the tach wire. The speedhut oil pressure sender was bad. Waiting on a replacement from them.

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[wallace18]

Had to mow grass this morning. I did find time to install both roll bars. Marsha and I did a final bleed of the brakes and clutch. I am super happy with both pedals. Waiting on a oil pressure transducer then I will try a start up of the engine.

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[wallace18]

Had visitors and honey do's last couple days. Did finally get parts for start up and modified steering hole trim to fit dash. I took off customer's steering wheel to keep it nice till I am done with car. I have an old wood one I use during builds. here is start up video. Engine runs fine. I have to see why tach is not working and fuel gauge is not accurate. I will run it more tomorrow.

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[wallace18]

Good day today. I was able to fix the fuel gauge and tach with just reprogramming them. I ran the engine for an hour or so. Fan ran fine and no leaks and good gauge readings all the way. Installed a set of quiet pipes I had so the neighbors don't try to kill me, LOL. Installed the lower dash panel from Replicaparts. I installed 2 LED cabin lights and a power port in it as well. Installed the OBD2 and check engine light as well. Installed the transmission top cover and shifter. Fixed a slight P/S leak at the rack. Topped off all fluids.

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[wallace18]

Spent the morning rewiring and adjusting the brake light switch for proper function. Then install rest of driver's foot box and removable cover. Installed rest of MAT 66 in the interior of the cockpit. Also installed a by-pass switch for clutch switch if you want to start car without depressing clutch. Ran the car thru all gears on the lift. Everything so far checks out good. Next week I will try to do a basic alignment as I really do not have the stuff to do 18" wheels. I will get it close then owner can have a shop with modern equipment do it later. Hope to go-cart next week.

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[wallace18]

Today I was able to put together the headlight assemblies, hood hinge assemblies and mount the seats. We got a seat slider from Speedway as FFR is currently O/S. Now have 6" front to back travel on drivers seat. Hope to do front and rear basic alignment this week.

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[toadster]

Today I was able to put together the headlight assemblies, hood hinge assemblies and mount the seats. We got a seat slider from Speedway as FFR is currently O/S. Now have 6" front to back travel on drivers seat. Hope to do front and rear basic alignment this week.

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I'm on the fence about the seat sliders, I like your speedway slider setup- looks 'thin' in height as compared to others
some have stated that adding sliders raised the seat up a bit higher than expected

How do they feel from sturdiness setup?
are you using the breeze seat mounts as well?

[wallace18]

I'm on the fence about the sliders, I like your speedway slider setup- looks 'thin' in height as compared to others - how do they feel from sturdiness setup?
are you using the breeze seat mounts as well?

No Breeze mounts, just sliders.

Today I drove 600 miles round trip to leave off the side pipes for Performance Coatings to ceramic heat coat black. Should be ready in 2-3 weeks .

https://www.headercoatings.com/pages/Motor_Sports

[wallace18]

Did a basic front and rear alignment. I use a combination of equipment. I added tie-rod lock nuts. Should be fine for go-carting. Owner will have to have it finalized with a good alignment shop when he takes possession of car.

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[wallace18]

Mocked up headlights, tail lights and gas filler. As per FFR body videos you have to enlarge all holes.

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[wallace18]

Good day today. First I got the body out in some shade. Then marked the body as per FFR body video. I do it a little differently. I use 1/4" tape then mark the cut with a black sharpie. Once Marsha came home after lunch I go-carted the car. Car ran fine. Very Fast!!! Slight P/S leak at pump I will deal with once it is cooled down. I drove about 2 miles. Everything worked fine. Temps all good as well as all gauges read good. Speedo worked well also. Here is my usual driveway short video. LOL.

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[wallace18]

Had to take a day off to help my wife Marsha and mow the lawn. Today though I first addressed 3 items that needed attention after the go-cart run.
1. Adjusted the clutch. It was engaging too close to the floor.
2. Fix leaking P/S pump. I had to replace the nylon o-ring for the pressure hose at the pump.
3. brakes needed bedding and rebleed.

The clutch was easy as it was just a few turns on the slave rod. Great feel now and shifts much better.
After Marsha helped me bleed the front brakes again I still had air in the line. I had to relocate to reservoir higher and the air problem was fixed. I then bedded the brakes as per Wilwood instructions. Stops great now for manual brakes. I road tested the go-cart agin. Everything is good now.

Next I did the body trimming as per the FFR body video. The side pipes are ready at Performance coatings in GA. I will go get them on Friday.

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[wallace18]

Went to GA. today to get side pipes back from Performance coatings.

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[wallace18]

Today I finished trimming the side-pipe openings. Then I power washed the body, Then applied truck bed liner coating to the underside of the body. Put some MAT 66 insulation on the inside of the firewall. I was going to install bulb seal on chassis but it separated from the grip part. New stuff on order from MCMaster-Carr.

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[wallace18]

Bulb seal showed up after lunch. I was able to install all of it. McMaster-Carr stuff is 1000% better than FFR stuff, IMO. I started install of carpet. Hope to finish up carpet and put body on Tomorrow or Thursday.

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[wallace18]

`Finished up carpet. Had 2 buddies come by and help me install body. Body bolted down in back first, then front. Seems to fit real well so far.

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[wallace18]

Installed fuel cap, hose and ground strap. Wired up all 4 tail lights with weather pac connectors. Mocked up rear splash guards and made my own forward ones for rear wheel wells. Then coated with black truck bed liner.

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[JB in NOVA]

`Finished up carpet. Had 2 buddies come by and help me install body. Body bolted down in back first, then front. Seems to fit real well so far.

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Looks sharp! Nice job.

[wallace18]

On Friday I had some family stuff to take care of. I did find the time to put a second coat on rear wheel well splash units. Then installed with tec-screws in case removal is needed in future.

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[wallace18]

To clearance the body for the roll bars. I use the following tools. I also have an old roll bar back piece I use to mark how much I need to trim from the body. Then I drill all the roll bar grommet parts/ body out for 1/8" rivets down the road after paint. I like them much better than the screws and nuts. I then installed the seat belts and seats. I installed the trunk seal but it is coming apart like the other bulb seal.

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