Jazzman’s #8745 "Flip Top" Build

[Jazzman]

When I got up yesterday morning, I knew it would be a good day, but I never imagined how good. We were staying in a lovely bed-and-breakfast in Plymouth, Mass. Not a bad way to begin, but yesterday was special because my wife and I visited the Factory Five Factory in nearby Wareham. David (aka "Mad Dog) gave us a great tour. Even my wife was impressed. Their commitment to quality and service was incredible. We saw the whole place, even got to see EdwardB’s 20th Anniversary car all packaged up and ready to go.

After the tour, we sat down with Dan Golub. We worked through my build sheet, my goals, and all my questions. He patiently answered them all, even though I am pretty sure he has answered these same questions a thousand times!! I asked when he thought the next big sale was going to be, expecting “sometime this winter”. “About 2 hours” I was told!! He asked me if I wanted to know what the sale was going to be. “Sure”. Dave Smith told Dan to figure out a way to sell only five more Roadsters with all the same high quality special components as the 20th Anniversary Model, but without the special badging, the special 20th Anniversary gauge set, and without the special powder coated frame and engine bay parts. Since I really struggled with whether to buy the 20th Anniversary Model, this was a great opportunity of a second chance. Well, I am sure you can figure the end of the story – I jumped at the chance to get far more than I ever had planned at a very significant discount. He even threw in the IRS Center Section and Spindles (yes, the new take-offs that they bought from MPS!!) I certainly did not expect to place this order now. I fully expected to wait until early next year to take advantage of the next big winter sale. Oh well, I haven't stopped smiling yet! Delivery is slated for mid-October.

You need to understand that while I have been dreaming of building a Roadster for over two decades, and planning it for at least two years, I am not really a "gear head". I am a Financial Planner by trade, a carpenter by choice, and a musician at heart. I restored a 1967 Mercury Cougar over 25 years ago, but never got very deep into the mechanical side. I paid others to do that part. However, I have always had a great desire to get in and learn every nut and bolt on my car. And now, I will.

Jazzman’s MKIV Not-Quite-a-20th Anniversary Build Plan
The Goal: an updated reinterpretation of the classic AC Cobra. A modern reinterpretation of the 1965 AC 427 Cobra, incorporating current technology and engineering that improves performance, safety, convenience, comfort, and reliability. Primarily built for street-use and cruising. Must make the wife happy: i.e. noise is an issue!! Build the car Carroll Shelby might have built if he had access to our modern technology.

• Kit – Factory Five Racing – MK4 Roadster De-Badged 20th Anniversary Complete Kit.
• Engine – Coyote 5.0L
• Transmission – 5 Speed Manual, Tremec TKO-600/midshift mod., short throw shifter,
• hydraulic clutch from Forte
• .62 OD 5th Gear for “street” cruising at 75-80 mph
• Rear Suspension / Differential – Ford 2015 Mustang GT Independent Rear Suspension with 3.55 ratio
• Front Suspension - FFR Independent front suspension
  
• Dual Adjustable Deluxe Koni Coil over Shocks
  
• 2015 Front suspension Swaybar components
• Wheels – Hallibrand Replica Wheels, 18x9 front, 18x11 Rear
• Exhaust – Stainless side pipes, Possible installation of race mufflers in the header area
• Steering – Power steering – Ford 87-93 Ford Mustang V8, 3 turn ratio, Adjustable Heidt Valve
• Brakes – Willwood deluxe brakes.
• Interior –
  
• Traditional Big & Tall Seats.
  
• Breeze Seat mounts
  
• FFR GPS Enabled Gauge Set
  
• Exotic Solid Hardwood Burl dash over aluminum panel
  
• Matching wood shift lever knob
  
• 14” Leather wrapped steering wheel
  
• Stereo system, hidden equipment with ipad controls and blue tooth connectivity.
  
• Steering column mounted turn signal
  
• LED interior lighting:
  
•  Footbox lighting
  
•  Trunk light
  
•  Under door lighting to light ground as you get out.
  
•  Red Dash LED Gauge lighting
  
• Perhaps Air conditioning/Heating
• Body – Candy Apple Red or Midnight Blue Metalic with ghost stripes
  
• Dual Chrome Roll Bars – 1.75” Breeze Automotive Bars
  
• All LED lighting: Headlights, marker lights, turn signals.
• Prepare for the future installation of the Premium soft Top
• May install Hood Louvers to vent hot Arizona air.

I had originally considered attempting a tilt-front variation. However, upon reflection and wise counsel from people I trust, I decided that a man must know his own limitations. This project will have more than enough educational value and challenges for my first build. Maybe the second . . . **EDIT** My, how things change!!

After our tour and big decision, we were starving. We went to The Gateway Tavern, and enjoyed the best Lobster Rolls I have ever eaten. I now had time to reflect on the morning. I really must take a moment to thank my precious bride of 27 years for her support of this decision. Without her immediate and unwavering support, I am quite sure I would not have taken this step this soon. I also must thank my many “friends” on this forum who have patiently answered my questions with great wisdom and insight: EdwardB, SkullandBones, CarlW, DaleG, David Hodgkins, 2bKing, too many others to name. Your encouragement and support have given me the confidence to undertake this daunting project. Finally, I want to thank Dave Smith (who I, sadly, did not get to meet yesterday, he was out of town) for creating this fine company. Your commitment to excellence and innovation, the culture of mutual support, permeate all those who have come in contact with you.

The next step is to receive your constructive criticism of my Build plan. As always, You are my trusted team of advisors. I look forward to your evaluation. Thus begins my Journey!

*** 8/22/2017 EDIT: ***
Table of Contents by Post Number:

Air Intake: #477
Battery Box (FFMetal in trunk) #70, #94, #167-168, #176, #604
Bell Housing: #376, #440, #458
Brake Lines: #109, #112, #123, #132, #141, #165
Brake Rotors: #97-108,
Brakes, Rear: #155, #157, #739-740, #746
Brake Bleeding: #230, #232
Body work: Begins at #184-186, #193, #196, #210, #222, #223, #234, #246-248, #254-255, #258, #262, #265, #268-275, #279-282, #285, #288, #292, #298, #327, #333, #574, #608, #627-628, #629-630, #635, #694, #714, #719, #735-736, #740, #752, #754, #770
Bolt Markings: #77, #80
Buss Bars: #170
Bumper Mounting, Front: #640-644, #649-654, #659, #669, #673
Carpet: #693, #727, #730, #760-
Clutch: #165, #364-366, #370, #375, #440, #441, #450, #453, #458
Clutch Bottom Switch: #348
Clutch, Hydraulic actuator: #453, #461-465
CV Axels: #155
Dash Board: #485, #488, #493, #501-502, #515, #519, #619
Differential: #40, #64, #137, #148
Differential Vent: #137, #148
Drive Shaft: #484
Drive Shaft Safety Loop: #181, #484
Elephant Ears (Custom Split): #320-321
Engine: #340, #352-363, #375, #434-435, #441, #442, #459, Install: #470-471, First Start: #543-558,
Engine Lift Plates: (Coyote) #480
Engine Mounts: #408, #442, #450
Exhaust Pipes: #524
Fibreglass: #236-238, #255, #292
Frame Dolly: #20
Front Hubs #71
Fuel Filter: #112, #120
Fuel Lines: #112, #120, #127-#128, #137, #159, #161, #387-392, #411, #477
Fuel Pressure Regulator: #387-392, #408
Fuel Tank: #64
Heim Joints: #78
Headers: #461
Heater Hoses: #520
Hood Fabrication: #247
Hood Latches: #315-318, #323, #327-328, #334, #598, #639, #673
Hood Scoop: #298, #751
Ignition System: #487, #497-500, #525, #538, #559
IRS: #40
Leatherwork: #692, #729
Lights: #598, #692
Master Cylinders: #58, #165, #604
Master Electrical Cut-off Switch: #169, #171-174
Paint: #592, #674-
Pedals: #58, #437, #467
Quick Jack (rear) modification: #54, #64
Radiator: #502, #507-509, #510-512, #521, #524-#533, #535-537, #539, #541-542
Reservoirs, Fluid: #121-122, #228-229, #485, #502-506, #515
Ribs (hood stiffeners): #258-259, #265, #282, #284, #288, #304
Roll Bars: #629, #635-637
Seats: #618-619
Seat Belts: #618-619, #740
Seat Heaters: #726
Sheet Metal: #64, #70, #77, #145, #149, #194, #197-199, #205-209, #487, #519, #587, #602-604, #746, #759
Shocks: #71
Side Vents: #299
Spindles, Rear: #138
Sound/Head suppression: #59
Starter: #442
Steering, Power: #85, #90, #91
Steering, Power Pump: #410-411, #510, #521, #534
Stereo/Speakers: #689, #726, #743
Sway bar (Front): #56
Sway Bar (Rear): #78, #79
Suspension, Front: #35, #49, #71, #85, #91, #94, #112
Suspension, Rear: #460
“Teeth” and “Jaws”: #246, #248, #289, #302, #324, #333
ThermoTec: #59
Tilt Front Hinge system: #211-217, #220, #227, #235, #285, #306-308, #501, #607, #659
Tires: #220, #230
Towing: #624
Transmission: #340, #362, #519
Truss Fabrication and mounting: #196, #226 #235, #262, #299, #302, #608, #746, #751
Trunk modification (Dropped Trunk): #85, #86, #87, #94, #145
Trunk Supports, Hidden: #693
Windshield: #758
Wiring: #152-156, #175, #180, #345-346, #367, #393, #409-411, #417-418, #421-433, #436, #441, #458, #477, #480-481, #497-500, #519-522, #525, #538, #541-542, #566-568, #580, #609-616, #659, #662-668, #692, #739, #743, #747

So what would I do differently? LET'S SEE!!

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