CM's MK4 build by Wallace18

[wallace18]

I mocked up and drilled for gas cap, tail lights, headlights, Turn signals/parking lights, trunk handle and license plate light. Build on hold till Radiator, roll bar, P/S fitting, seat tracks come off of POL from FFR.

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[wallace18]

Since I was in a holding pattern waiting on POL parts, I was able to deliver a DF Goblin I sold to a customer in NC. Also picked up a Dune Buggy kit I ordered a year ago. While I was gone for 2 days my wife told me a box from FFR showed up. It was just the radiator. But better than nothing. Today I was able to mount the engine turned shroud, fan, Breeze radiator kit and mock up transmission cooler. I am waiting on some black radiator paint and some hoses. Taking the weekend off .


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[zee]

Man you're moving fast!

[Railroad]

I really like the engine turned fan shroud!

[wallace18]

Finally got the P/S pump fitting from the PLO list. This allowed me to get to finish up enough for a first start up. I was able to install transmission cooler, fan and lines. Install P/S hoses. Fill engine and transmission with proper fluids. Start up went great. I programmed TPS to transmission computer. Wired up fans so both come on with electric fan switch and also manual switch on dash. No leaks up front. Transmission shifts fine on lift. I hope to go-cart next week, then start on body. However the Moser rear end is leaking form differential cover. This is the 3rd new Moser that leaks right away. I wish they would use a better gasket. Lucky for me I had a new gasket in stock. I will fix it myself. Here is short video.

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[wallace18]

This morning I fixed the leaking rear end gasket. I pulled off the chrome cover. Cleaned the surfaces and installed new gasket with Black RTV on both sides. Refilled rear end with proper fluids.

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[wallace18]

After lunch I was able to clean up body and coat the underside with truck bed liner. Hope to go-cart tomorrow.
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[wallace18]

Did a front end alignment this morning. Then hooked up a set of well used Quiet pipes I have laying around to do a go-cart test. Car ran very nice. Shifts great. Will even bark the tires on full throttle shifts in lower gears. I am very impressed with this engine/transmission combo. Makes for a really nice driver's car. As with any go-cart test a few things crop up. A small gas leak at a fitting. Just had to tighten 1/4 turn, OK now. Water leak from Factory Five coolant fill tube. I am going to replace it with an aluminum one I ordered today. Also gas pedal too close to brake pedal. I will get an aftermarket pedal for more clearance. I have never been a big fan of kits pedal. I will do a go-cart Video once these punch list items are fixed. I seem to be coming down with some sort of cough/cold. I will be taking it easy this week till I get better. Thanksgiving and all that stuff. I am only 2 months into the build so it is right on schedule.

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[wallace18]

I am about 98% better now. I was able to fix the few items from my first go-cart test. I drove car about 4 miles today. Runs great. Here is short drive way video my wife Marsha took. Enjoy!. Hope to start on interior and body this week. Cod weather though here next few days. May not be able to due to cold weather. Glue no workin good in cold, LOL.

[finleycraft]

Looking good, thanks for all the updates!

[wallace18]

Unfortunately the weather here is unseasonable cold. I can't do anything till the temps get above 65 or 70. So I just have to chill. No pun intended, LOL.

[wallace18]

Rough last 2 weeks for me. Got Covid 4 days before thanksgiving. Got over that. Then a unfortunate result from the covid was a terrible bacteria infection in my private parts area internally. Had to go to emegency room then 3 days in hospital. Got out 11am yesterday but at least 2-3 weeks of meds and rest before getting back to work.

[zarnold]

Terrible news, but good to hear your on the mend.

[wallace18]

After having to go to the hospital a second time for 2 days of antibiotics, I came home last Sat. I am 95% my normal self now, thank the Lord! I was able to install carpet and rubber seals so we can install body on this coming Sat. I have 3 other guys coming to help. I have some clean up of glue overspray and some caulking. Nice to get back to working on the MK4.

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[wallace18]

Last 2 days I got chassis ready for body install. Installed passenger seat, both sides seat belts. Got news that roll bar finally shipped. Still waiting on seat sliders for drivers seat. FFR not sure when they will come in. I ordered a set from Amazon. Can't wait forever on FFR. Tomorrow body on chassis!

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[wallace18]

The seat sliders from Amazon got here at 9:30 AM. I was able to install the driver's seat before we put on the body. At noon I had Bernie, Chris and all 3 of our wife's come over today . Us 3 guys put the body on the MK4. Then all 6 of us had Pizza and Dr. Pepper. Great day for sure.


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[wallace18]

Installed the front and back overriders. This located the body perfectly. Unfortunately there is 2 coolant puddles under the engine. One is the water pump gaskets are leaking. the second is coming out of the back of the engine and running down the dust plate between the engine and the transmission. There is no leaks at the intake or head gaskets. I am thinking possibly a leaking rear freeze plug. Contacted Blueprint and they agree with my diagnosis. So I get to pull the engine out. I will leave the transmission in the car. Should be an easy pull. I have coolant draining over night. 1 step forward and 3 steps back!

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[Mike.Bray]

Installed the front and back overriders. This located the body perfectly. Unfortunately there is 2 coolant puddles under the engine. One is the water pump gaskets are leaking. the second is coming out of the back of the engine and running down the dust plate between the engine and the transmission. There is no leaks at the intake or head gaskets. I am thinking possibly a leaking rear freeze plug. Contacted Blueprint and they agree with my diagnosis. So I get to pull the engine out. I will leave the transmission in the car. Should be an easy pull. I have coolant draining over night. 1 step forward and 3 steps back!

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Ugh, I had the same thing. My freeze plugs are screw-in type and the O-rings were bad, machine shop didn't remove them when vatting the block. And I used the wrong gasket on the water pump which made for a good size leak out the bottom of the pump. That one was easy, the freeze plugs required pulling the engine.

Good luck with it.

[wallace18]

After pulling the engine. There was no leak from the rear freeze plugs as I thought. The water pump and thermostat housing all leaked. I took them apart. No sealer was used on any of the gaskets. Not sure why. I cleaned everything up and used Ultra gray silicone sealant on all new gaskets. I am waiting on hearing back from Blueprint. Even with 17psi on my coolant system tester I cannot see where the rear leak was coming from. There is a small trail from the rear driver's side cylinder head gasket area. However with tester on it overnight no leak has showed up.

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[wallace18]

After going back and forth with Blueprint, they told me to torque the cylinder heads and intake and reinstall the engine. While I was waiting on them I installed the roll bar and mocked up the grommets. Today I put engine back in and installed side pipes. Car started right up and runs great! No leaks so far. Time will tell for sure. I have my fingers crossed and said a few prayers. Now I can get going on the body stuff and maybe get this finished up for paint and body work by the end of January.


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[wallace18]

No leaks on the floor so far! Yea! Today I installed and wired up front and rear lights. I use weather-pac connectors. I also installed fuel hose, mocked up rear and front spray shields. I will paint the shields with bed liner as soon as weather gets little better.

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[wallace18]

Finished up mocking up splash shields. Coated them with black truck bed liner. I pre-gapped trunk and installed with license plate light/holder. I started on driver's door. Weather getting very cold here next few days. Next Wednesday may be warmer. The week of the 8th seems to get warmer. Hope to get doors and hood done in next 2 weeks. Then windshield, mirrors and a few items and we may be done before the last week of January. It will be ready to go to paint/body shop.

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[wallace18]

Finished up both doors. Just roughed them in. Body shop will finalize the gaps and mounting. New strikers and door latches worked out well, IMO. Very cold here last few days. Tomorrow looks to be warmer. Hope to finish up hood, and windshield.

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[wallace18]

Finished up the hood. I slotted body underneath so the body and doors can line up. I mocked up side vents. Also sealed up inside front and rear wheel wells areas between body and foot boxes up front, body and chassis in the rear. Had to change a flat on my wife's Ranger. Then go get new tire, Ouch! Monday I will start on windshield.


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[wallace18]

Installed windshield, inside rear view mirror. Waiting on longer bolts for side mirror. Found out local body shop/paint shop will not do fiberglass cars. Owner will have to find shop near Naples to finish up car. Hope to have car done in next week or 2.

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[wallace18]

Installed door panels, door checks, lower door trim. Installed hood scoop hardware. Removed my builders steering wheel and installed new one from kit. Bad weather here today. I am batten down every thing. Possible tornados. Everyone stay safe that are in harms way.

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[wallace18]

Weather yesterday ended up not so bad for us here. Some small branches down and 2" of rain. Today I was able to install front and rear splash shields with tech screws. I also installed sun visors and wind wings. Getting very close to done.

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[wallace18]

Finished up some inside trim. Took it out for a good ride and had it weighed at a certified scale. 2400 lbs. Car ran great! Never went over 180 degrees and no leaks. Waiting on side pipe heats shields then it is ready to go to customer for body work and paint. Moved it to my small shop/garage.

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[wallace18]

Heat shields came in a couple days ago. It finally warmed up enough to install them. All done with CM's MK4. Hope to deliver it to him before the end of this month.

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[wallace18]

Yesterday I was able to deliver the MK4 to CM in Naples. It was a 600 mile round trip but worth it to see smile on Craig's face. He really liked how car drove and sounded. He is in process of finding a body/Paint shop to finish it up.


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