CM's MK4 build by Wallace18

[wallace18]

I have a MK4 kit coming tomorrow by Stewart Transport. I am building it for a customer CM. It will be the 1st automatic MK4 I have built, but I have built a 33 and 35 with auto's. I am looking forward to this one as it will be a little different from the previous 6 MK4's I built. This will be my 18th kit overall. Here is a few details.

MK4 Complete Kit with a Blueprint 302 Carb with a 4R70W automatic transmission. Also S/S side pipes, headers, chrome drivers roll bar, wind wings, visors, floor-mats, P/S, P/B, Moser 3-link rear end, 4-wheel disc brakes, Vintage gauges, 17" wheel/tire combo, carpeted trunk, door panels, self canceling turn signals and some other goodies. It should be a really fun driver to cruz around in. I will post photos of the delivery tomorrow.

[Railroad]

Sounds just right!

[wallace18]

Stewart showed up right on time at 9:30. Kelly and I unloaded everything real quick. I was able to get it up on the lift and will start taking off the body and inventory this afternoon. Still waiting on Moser rear end and Blueprint engine/transmission package.

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[wallace18]

After lunch Fed-Ex delivered the Moser rear end. We took off the body and set it on the body buck. I was able to inventory 21 boxes. I am not a fan of the new inventory sheets or packaging. Old style lists were much more detailed and seldom was stuff missing from boxes that FFR checked off as being in the box. So far 5 boxes missing 1 or more items. Hope to finish up inventory tomorrow and get missing parts list to FFR on Monday.

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[wallace18]

Finished up inventory. About 20 missing parts. Emailed FFR. Mocked up and coated front aluminum panels. Assembled fuel tank as inventory sheet left a lot to be desired in detail. This way I knew I had all the parts. I feel sorry for new builders as how vague the inventory sheets are now vs precovid.
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[wallace18]

Not going to do much today. It is my anniversary, 24 years with my wonderful wife/brake bleeder, Marsha. LOL. Did just a bit. I installed front panels and marked all rear panels for drilling. I will really get after it tomorrow.

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[wallace18]

Good day today. Got to talk to FFR and Craig. Missing parts are on the way. I was able to mock up all the trunk aluminum, passenger side foot box, firewall, drivers and passenger floors. Also mocked up Power brake booster and Fox body pedal cluster. Slight modifications to frame and front drivers foot box aluminum to fit P/B.

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[wallace18]

Finished up mocking up drivers foot box. Both sides ready for Lizard Skin external coatings.

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[egchewy79]

so you drill and cleco all the footbox pieces, then remove it to spray lizard skin? brilliant! I'm sure it makes it so much easier to spray and eliminates all that taping.

[wallace18]

so you drill and cleco all the footbox pieces, then remove it to spray lizard skin? brilliant! I'm sure it makes it so much easier to spray and eliminates all that taping.

Yes, I just assemble the boxes once off the car with a few tech screws and coat. It has worked well for me over several builds.

[wallace18]

Another really good day. I was able to finish up mocking up all the rear cockpit aluminum. Also made my own firewall brace. I first coated the foot boxes, firewall and 2 floors with Lizard Skin sound deadener, then the ceramic heat coating. All the rest of the aluminum I coated with truck bed liner.

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[wallace18]

I put a second coat of bed-liner on the underside of the other aluminum panels. I then installed the firewall, drivers side front foot box panel and both floor panels. Installed pedal fox body pedal box, booster and frame mod. Installed front suspension, front brakes, rear end and rear suspension. Taking the weekend off.

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[wallace18]

Installed the steering rack, u-joints, steering shafts and bearings. Siliconed & riveted the passenger foot box, inner drivers foot box panels, cockpit sides and rear corners. Also installed the brake light switch in the pedal box and adjusted it.

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[wallace18]

Short day today. I had dentist visit and church lunch. I was able to install fuel tank and fuel filter. Also installed front brake flex hoses and line between both front calipers.

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[FF33rod]

Holy crap you're trucking on this one!

Steve

[wallace18]

Today I installed rear brakes, lines and started on wire harness.

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[wallace18]

Had a few hours to work this morning. I finished up all the brake lines and mounted 1995 Mustang master cylinder. I mocked up and trimmed dash aluminum. Also installed some clamps on the front wiring harness. I am going to have a dental procedure this afternoon. Not sure if it will keep me from working a few days or not. Time will tell.

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[egchewy79]

Holy crap you're trucking on this one!

Steve

I remember looking over one of his threads when I first joined the forums, wondering to myself how he was getting so much done in such a short period of time.
I always tell my wife that my "next" build will be much faster

[wallace18]

I remember looking over one of his threads when I first joined the forums, wondering to myself how he was getting so much done in such a short period of time.
I always tell my wife that my "next" build will be much faster

When you have done 18 of them you get into a rhythm, LOL.

[wallace18]

Today I installed horns. Then mocked up dash layout. Then used DAP glue to install pad on dash. I will let time and a bunch of clamps finish up the pad glue job, LOL.

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[egchewy79]

just curious...do you consult w/ your clients about how they want the dash set up to look or how they want the interior finished?

[wallace18]

just curious...do you consult w/ your clients about how they want the dash set up to look or how they want the interior finished?

PM sent.

[wallace18]

Finished up dash, wired and installed. Tested all of dash stuff. A-OK. Installed some X-Mat on inside of fire wall.

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[wallace18]

Installed rest of rear aluminum panels. installed battery, hold down and cables. Filler rear end with proper fluids.

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[wallace18]

Cut holes in rear cockpit panel for speakers. Then I installed the sound deadening/heat mats inside the interior.

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[wallace18]

Tried to do some work this morning. I was able to finish up trunk matting. I also mocked up and trimmed transmission tunnel top. We had heavy rains last night and most of the morning. More rain on the way. Too humid in shop to do any more today. Did get a tracking # for the Blueprint engine/trans combo. Should be here tomorrow. Now waiting on FFR to send POL parts and then I can head towards the finish line, LOL.

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[wallace18]

While I was waiting on the Fed Ex truck I engine turned the radiator shroud and foot box removable cover. Also installed riv-nuts and mounted fan. Soon after the truck showed up.

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[wallace18]

Later I installed engine and transmission. I am going to have to move e-brake, trim some on the transmission and dust plate. Also I am going to have to custom make a rear transmission mount bracket. FFR unit hits transmission pan. All part of the fun, LOL.
Impressive #'s IMO for a base Blueprint 302.

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[wallace18]

I have lots of other stuff going on this week. I try to get some MK4 work in here and there. Today Marsha helped me bleed the brakes. Came out super with a great pedal! I installed some wiring to engine and trans. I removed e-brake and brackets. I will do a top of the tunnel style like North race cars used to sell. Also installed oil, water sensors and wires as well a vacuum line to power brake booster.

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[wallace18]

I was able to find time today to install TPS unit on Holley carb. I really feel this should have been included with the engine/transmission combo from Blueprint. I did email them to that point. For as much as my customer paid for that combo this should have come with it, as the transmission computer will not operate without it. Whew, that felt good getting of my chest, LOL. Install was not too bad but it did require patience and some tweaking to make it work properly. I am sorta waiting on some parts from Summit to help install the Automatic and other parts not included with the kit. I have obligations tomorrow and hope to work back on the MK4 on Friday.

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[wallace18]

Today I was able to make my custom tunnel mounted emergency brake handle assembly. IMO it is way better than the FFR unit and a must with the 4R70W transmission in this build. The handle came from a brake tube company of all places and was only about 47 bucks. I added a summit e-brake cable kit. Less than half the price of using LOKAR stuff. I also started the wiring for the 4R70W transmission and mounted the aftermarket computer. I am waiting on a cable shifter and some other stuff to try to get the transmision stuff done. Also still waiting on POL parts.

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[wallace18]

I am going to an oral surgeon today to have a bad #30 tooth removed. Not sure how long this will lay me up. Still waiting on some POL parts as well as shifter and such.

[wallace18]

Today I installed billet carb bracket, lokar throttle cable and wired TPS to transmission computer. Installed headers, RemFlex gaskets and Stage 8 bolts. Also started install of transmission cooler hoses. Still waiting on some POL parts from FFR.


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[wallace18]

Started on the Lokar shifter. I ended up using the top mount method. Also wired up Lokar neutral safety switch vs using transmission one. Some parts came in late today. I should be able to make more progress tomorrow.

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[wallace18]

I finished up wiring all the wires to the transmission for safety switch and sport shift mode. Also finished up shifter cable and adjusted everything for proper shifting. CM decided to use some new Cobra air cleaner and valve covers I had laying around. They look 100% better than the Blueprint chrome stuff, IMO. I am very particular about valve cover gaskets, hardware and ignition wire routing and clearance from headers. I installed studs and top of the line FelPro gaskets for the valve covers. Also install billet wire looms and heat socks so wires don't melt from headers. Looks and works so much better. Taking weekend off for a big car show.

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[JDLSantos]

Today I was able to make my custom tunnel mounted emergency brake handle assembly. IMO it is way better than the FFR unit and a must with the 4R70W transmission in this build. The handle came from a brake tube company of all places and was only about 47 bucks. I added a summit e-brake cable kit. Less than half the price of using LOKAR stuff. I also started the wiring for the 4R70W transmission and mounted the aftermarket computer. I am waiting on a cable shifter and some other stuff to try to get the transmision stuff done. Also still waiting on POL parts.

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Great project!!

I am curious about the handle brake, e-brake wire routing and the distand between the handle brake and the bracket that hold the e-brake wires

[wallace18]

Great project!!

I am curious about the handle brake, e-brake wire routing and the distand between the handle brake and the bracket that hold the e-brake wires

The handle came from Inline tube, the emergency brake parts came from a Summit e- brake kit. The cables are in the same bracket holes FFR uses. once you mount the handle you cut off the cables the appropriate amount. The brass connector sometimes has to be drilled out for cables to pass thru.

[wallace18]

Mocked up the top of transmission tunnel top. I used a cardboard template. Also mocked up under dash unit for radio, wired radio and speakers. Plays really nice! Not sure how you will here it with those side pipes, LOL. I also mocked up cover to enclose FFR e-brake opening. Hope to mount radio and cover lower dash unit tomorrow.


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[wallace18]

Installed the radio in the custom lower dash unit after I covered it in the same stuff the dash is covered. Also made a custom charcoal canister for the gas tank vent line. Finished installing passenger side transmission tunnel cover for FFR e-brake hole. I am running out of stuff to do on the chassis . Till the POL parts come in I am going to start trimming the body and fitting lights, ETC. tomorrow.


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[wallace18]

Worked on the hood, scoop, ETC. Bolted up the hood hinge assemblies and headlight assemblies. FFR needs to look carefully at their hole jigs for the hood. Holes were not even close to correct for the riveted metal brackets for the hood. Lucky I could fix it without much trouble. Taking tomorrow off. Friday will work on trunk and body.


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