Don's 35 Extended Build

[DonImbimbo]

Our build has begun on our 35 Extended Cab. We took delivery very early on Feb 8. meeting Stewart Transport 1/4 mile from our house (as we live at the end of a dead end gravel road with a couple of tight turns).

We placed our order on August 16, 2022.

I will eventually start an official build thread over in the proper place with details on our objectives for the build and the options we chose. But for now, here is where we are at.

• All the front suspension is installed
• Front brakes are installed
• pedal box is in
• steering rack with tie rod ends installed
• fuel tank may go in today

The cab is still on the chassis. I'm working somewhat out of sequence due to back ordered (POL) and missing parts.

Now here is my first question regarding Front Upper Ball Joints.

There have been quite a few differences between the build manual and the kit. For instance the front upper ball joints screw into the control arm from the spindle side of the arm, where the joints on the lower arm are pre-welded in.

I'm looking for some advice on these ball joints.

• What torque spec to use
• should they have a thread locker applied
• they are 1-7/8 inch across the flats of a square drive. What tool would you use for this

I followed Erik's build on the SEMA truck but I assume he blasted through his build in order to get to the show. And I don't recall seeing details like this in his videos.

Helpful or encouraging comments appreciated.

Don

[VIRGIN MIKE]

I would not use loc-tite on anything until I was sure it wasn't coming back apart; as a first time builder and tinkerer, I have taken almost everything apart at least once and a few times on some assemblies. the CA / spindle ball joints and tie rod ball joint connections use castle nuts and cotter pins - seat them snug and back the nut off til you can get the cotter pin thru the hole in the ball joint stud; too tight and they will bind

[DonImbimbo]

I got a response from F5. They said that no loc-tite required, no need to buy a special socket, just place the ball joint flats in a vise and use the rest of the upper control to tighten it up.

P1030580 (Large).JPG

Don

[DonImbimbo]

I have not posted very often about my build. Things are going kind of slow because of missing (MIK) parts and backordered (POL) parts. But I have managed to get to the grill area.

My question involves the Condenser brackets.

What I think I have is the following:

• Regular truck grill
• Regular truck radiator
• "New Style" condenser with hardlines attached #35049
• "New Style" upper condenser brackets #35172 & 35173
• "New Style" lower condenser brackets #35175 & 35176

Here is a mock up picture

NewCondenser&Brackets.jpg

If you notice, the lower brackets have a predrilled hole and the upper brackets have a pre-made 'T' slot.

Does anyone know how these should be positioned? I think I might have them close to being correct, as to left vs. right, but not sure.

Of course the Build Manual for the A/C Option really does not address the "newer" parts (condenser and brackets). I'm just wondering if anyone has used these yet?

Don

[DonImbimbo]

Mocking up the radiator on the grill they seem to be incompatible.

Here is what I see.

IMG_0935.jpg

I have positioned the radiator centered on the lower grill tab. And the upper part of the radiator looks like it will clear the Cowl Support bracket.

But the grill upper tab mounting hole is off the edge of the radiator mount tab.

IMG_0936.jpg

Measuring the distance between the outside holes on the grill I have 13-15/16, center to center. Measuring the total distance across the outside edges of the radiator tabs I have 14-3/8.

And they expect 1/4 holes to be drilled in the radiator tabs? That leaves almost nothing between the edge of the hole and the edge of the tab.

In addition, the upper radiator tab is only 2 inches wide, the lower one is 2-3/8 wide.

This looks like a BIG design problem to me.

To add to this I don't seem to have the radiator mounting hardware, such as the spacers that mount it off the grill tabs.

[DonImbimbo]

I think I may have discovered the problem. I may have the wrong radiator.

GrillAssembly.JPG

Looking at the attached document I received from F5:

The Grill is #33006. That's the same part number as in my Pack List.
The Radiator is #33243. The Radiator part number in my Pack List is#34289.

In addition, looking back at the picture I posted of the rad I have, the fan mounts onto those four studs, where in the assembly drawing above it mounts to "Fan Brackets".

I don't have the fan yet, mine is a MIK part. But it's supposed to be #34389 where the assembly diagram shows #10668.

At every step of my build so far (and it's only been less than 60 days) it seems my kit is the "red headed step child" of Factory Five.

I'll see if I can get Tech Support to review this message thread.

[edwardb]

It was a couple years ago so might have changed. But my truck came with Griffin Radiator 9D-11278-00, Factory Five part number 34289.

[DonImbimbo]

It was a couple years ago so might have changed. But my truck came with Griffin Radiator 9D-11278-00, Factory Five part number 34289.

I contacted Griffin and got a response. They have not made that 9D-11278-00 radiator for F5 since 2020. It was a "special" for F5 not a standard unit. They told me if I wanted one I would have to go through their "custom" shop. That means I would have to submit a detailed drawing to them for the part I want them to make and the cost would be about $1200.00.

That's not going to happen because I don't have the confidence that I could specify what would work accurately enough.

[DonImbimbo]

Continuing with my mockup of the radiator area. I added the cowl brace to the grill to see how much room I had to move the radiator toward the top of the grill.

If I get that upper radiator tab centered over the two mounting holes of the grill, the radiator touches the cowl support.

CowlBrace.jpg

Doesn't look right to me.

I am assuming that the rounded tank of the radiator goes UP as the bung of the temp sensor would be in the bottom tank. I think I have seen pictures of this orientation, otherwise the temp bung would be at the top.

[Lew]

I have the same radiator as you and when I complained about it I was basically told everything is fine ,make it work. Tabs are just too small.

[DonImbimbo]

I have the same radiator as you and when I complained about it I was basically told everything is fine ,make it work. Tabs are just too small.

I think the only way to "make it work" would be to fasten the radiator with only 6 bolts, not using the top most bolt on the radiator. The hood hinge bracket mounts on that upper grill mount with two bolts. And I would have to figure out how to capture/sandwich the condenser mounting bracket in there.

The other alternative is to use a flat head bolt just for the radiator top hole, making a new hole in the grill. The hood hinge would still use the original two holes.

[Lew]

I ended up with some ½ holes bridged with washers. Halfa**ed set up IHO.

[DonImbimbo]

I got the "official" answer. Drill extra holes and make it work.

[edwardb]

Unless something's changed, that's not like the radiator that came with my truck kit two plus years ago. Reference the Griffin part number from my previous post. Don't have a direct on picture of it, but you can see from this pic it's very different than yours and clears that cowl brace by quite a bit. It was a tight fit with the A/C condenser, grille, and getting the angle right.

[DonImbimbo]

Could you measure the width of the upper radiator mounting tabs? Looking at the two bolts that mount your radiator to the grill, there is no way I could get them positioned to be so far from the edge of the tab. As mentioned above, my upper tabs are only 2 inches wide, barely enough to cover the grill mount holes.

Yea, looks like a very different radiator, even though the part number supposedly matches.

[edwardb]

Could you measure the width of the upper radiator mounting tabs? Looking at the two bolts that mount your radiator to the grill, there is no way I could get them positioned to be so far from the edge of the tab. As mentioned above, my upper tabs are only 2 inches wide, barely enough to cover the grill mount holes.

Yea, looks like a very different radiator, even though the part number supposedly matches.

A little hard to measure precisely since mine is all together. But as best I can tell, in the range of 18 inches bolt centerline to centerline.

[Erik W. Treves]

That radiator is for the 35 deluxe nose not the regular nose. You can see it on Day 34 video

[DonImbimbo]

That radiator is for the 35 deluxe nose not the regular nose. You can see it on Day 34 video

Yea, I looked at that video again and the radiator I have looks like yours.

I tried to mock up the grill area on the truck with the radiator behind the grill. With the grill pulled as far away from the frame as possible and the radiator lifted right up against the cowl brace, this radiator hits the frame under the bottom edge.

It just doesn't fit.

I would have to lift the grill / grill mounts on the suspension bolts up to try to get the radiator to clear the frame.

Thanks for your reply.

[DonImbimbo]

Here's what I know.

I ordered the full fender kit (#35244) and the Engine Cover kit (#34617) .

I think I have the correct grill, see the pictures earlier in this thread. As confirmation, here is the box the grill came in.

Grill_PN (Medium).JPG

The part number is #33006.

It might be the incorrect radiator (#34289). I have no way to prove that's what was in the box. But I'm not the only one that has seen this issue and the F5 response is just drill extra holes to mount the radiator.

I'll mount the grill on the truck today and hold the front fender up to it to see how things match up (w/o the cowl).

[Erik W. Treves]

I double confirmed with engineering.. there are specific radiators for each nose... you cannot mix and match.

[DonImbimbo]

I double confirmed with engineering.. there are specific radiators for each nose... you cannot mix and match.

And I just got an email from F5 that says for the 35 Truck, the radiator is the SAME whether you have the standard grill or deluxe grill. They also said that on the 33 Hot Rod the radiator is different between the two grills.

So I really don't know what to believe. But I know I'm going to have a hard time making this one work, especially with the condenser in front of the radiator. If I take the top of the grill and push it toward the windshield, I'll get more space at the bottom to clear the frame. But I don't know at this point how that will affect the engine side cover alignment, interface with fenders or the engine hood.

[Just 1 More]

And I just got an email from F5 that says for the 35 Truck, the radiator is the SAME whether you have the standard grill or deluxe grill. They also said that on the 33 Hot Rod the radiator is different between the two grills.

So I really don't know what to believe. But I know I'm going to have a hard time making this one work, especially with the condenser in front of the radiator. If I take the top of the grill and push it toward the windshield, I'll get more space at the bottom to clear the frame. But I don't know at this point how that will affect the engine side cover alignment, interface with fenders or the engine hood.

I have both radiators for the 33 Hot Rod, Mine came with the 32 grill and radiator and I changed to the 33. This is the 32
20221227_154809.jpg

[Erik W. Treves]

all I can tell is that having built both and speaking with engineering (not email) there are 2 radiators available - the deluxe radiator is smaller

[Erik W. Treves]

Any reason not to contact FFR and get the correct Radiator?

[DonImbimbo]

Any reason not to contact FFR and get the correct Radiator?

I have tried three separate times (Tech Support and Customer Service) and again today. They insist I have the correct radiator.

I have the condenser mounted in the grill and I have the fiberglass cowl fitting the grill. Tomorrow I'll drill holes in the radiator tabs, fit the spacers, and mount that. Then see how this hole thing is going to work on the truck including with the hood hinges.

Thanks for asking.

[DonS]

So I’m just starting on the radiator. What did you end up doing and is it working? Thanks, just two weeks into my build. DonS

[DonImbimbo]

So I’m just starting on the radiator. What did you end up doing and is it working? Thanks, just two weeks into my build. DonS

I did get the radiator to fit, barely. There is less than 1/4 inch of clearance between the fan and the shock bolts. And probably the same amount of clearance between the bottom of the radiator and the frame. It's a tight fit.

IMG_1013.jpg

I used the Factory Five condenser and condenser brackets. But I made all my own spacers to mount the radiator to the grill, on top of the condenser brackets. My spacer sizes ranged from 0.625 to 0.750. The grill mounting areas are NOT in the same plane so each spacer turns out to be a unique size.

This would be my advice:

• Make sure your grill support brackets mount to the frame aligning with the UPPER suspension holes, regardless of how you setup your suspension.
• Mount the grill as far forward as you can using the elongated holes on the grill support brackets
• Mount the radiator as high as possible on the grill. I have about 1/4 inch of clearance between the radiator and the grill surround bracket. This allowed me to get all eight radiator mounting bolts to be placed on the radiator mounting tabs.

I checked my grill location by setting the hood in place to make sure I still had some material to trim for proper gaps and to check the angle of the grill with the hood.

IMG_0957 (Medium).JPG

Also, I did not follow the F5 build procedure, did my own thing.

I hope this helps.

[DonS]

Thanks so much. still trying to line everything up, the radiator tabs are very short. Not sure I can get all 8 bolts in, maybe partial on the top holes. DomS

[DonImbimbo]

Mark,

Earlier in this thread I posted a picture of the hood fitting with the grill / cowl. I did this to verify that the hinges would work.

And yes, the last picture shows the spacers under the radiator tab but the hinge bracket is on top of the radiator.

This was the only solution to getting the hinge pivot to not interfere with the fiberglass cowl.

Around page 406 in the build you will notice that they have the hinges done the way I did them. The "part #1" in the drawing shows in the table as "Right Hinge" but clearly it is on the left. Part #6 is in the table as "Left" but is on the right.

So whatever works for you.

BTW - edwardb also has the hinges on his truck as I am doing them.

[mkassab]

Don, et. al.,

I still think how I have it set up matches the manual.

Page 409 is the Hot Rod.... but page 408 is the truck setup with the 90* bend facing outward... see below pic

Screenshot 2023-05-17 144543.jpg

The manual also shows the bracket on top of the radiator tab, however, the radiator tab is on the grill tab directly with no spacers.... which is what my setup is... see pic

IMG_2110.jpg

The way you have yours now, I think, is grill tab, condenser tab, spacer, radiator tab the bracket with 90* bend facing inward.

Hope this helps

Mark

[Lew]

Hey Mark,
I agree that you have it set up as per the manual. But for me it did not work for the reasons Don stated. My hood would only fit and work the way I sent you
photos of.

Lewis

[mkassab]

Thanks Don and Lewis..... I'll get it figured out.

one further question.... My lower radiator hose outlet hits the frame when setting on the chassis. Did you just pull up on the brackets that "slot" into the upper control arm bushing bolts to pick up on the radiator.... and/or remove some metal under the lower radiator hose outlet?

Thanks

Mark

[DonImbimbo]

I saw the "blue truck pic" and noticed that they have the hinge stop bolt in backwards, probably because it collided with the cowl, which is what happened with my first install.

Then I changed my setup to match what others have done. I also completed the entire setup of the hood hinge with the hood, and all went well.

So ... to each his own. Whatever works for you is the correct way for you and your build.

[Erik W. Treves]

Mark the Blue truck has the hinge mounted inward - the pic is a blurry I think ... my prototype on the original truck has it mounted like yours mostly. Basically you need to get the radiator and condenser as close as possible to the grill and then have the bracket installed.. keep in mind the brackets do get updated from time to time - but generally the install is the same

[mkassab]

Mark the Blue truck has the hinge mounted inward - the pic is a blurry I think ... my prototype on the original truck has it mounted like yours mostly. Basically you need to get the radiator and condenser as close as possible to the grill and then have the bracket installed.. keep in mind the brackets do get updated from time to time - but generally the install is the same

Thanks Erik.... Mine is like you have pictured above. I'll also add my setup is just like Walace18's build.... so I do think I have mine correct... but time will tell once I start to install/fit my Hood and it's Hinges.

Mark