NuHale 65 Coupe Build Thread - Drillin' and Clecos

[nuhale]

Wasn't planning on it this early in 24' but with the announced sale and potential for price increase I decided now better time than ever and jumped in first thing today. Deposit down with an end of May pickup planned. Looking forward to the build as even though I love my MKIV I really miss the building process.

Went with a 65 Base Coupe kit. Build plan has been underway and already have a good amount of parts but a quick list of build plan:

Base Kit
IRS
Front FFR LCA
TKX (unsure of gear)
Coyote (TBD on pullout or crate) I'm leaning towards a GEN 2 if I can find one reasonable.
Forced induction (pref centrifugal but fit will be issue)
Mustang cut out rear end (10k) with 3.55 differential (may swap to 3.31 gearing) brakes, spindles etc.
Forgestar F14 19"
Rear 15+ IRS single piston brake (13" rotor) and 2004 Cobra SVT Fronts (13" Rotor)

First question to the forum is on IRON vs. Alum Diff. I see lots of posts on this but with the power I'm planning guessing an Iron housing is ideal.

more to come but pumped to get going!

[JimStone]

Congratulations! I took the plunge today too! Coupe complete kit. I also wasn't quite ready, but FOMO kicked in with the sale and upcoming price hike

[cv2065]

Congrats!!

[GoDadGo]

I'm Jealous!
Congratulations!

[Kbl7td]

I have new in box front two piece spindles if you’re interested.

[nuhale]

Congrats!!

thx Chad- hope your build going well

[nuhale]

I have new in box front two piece spindles if you’re interested.

thx for the offer but the base coupe kit now comes with spindles... need Front LCA if anyone has.

[Al_C]

so will this be "cubcoupe" on the plate? oh wait, that's too many letters, isn't it.

[edwardb]

Congratulations! Love our Coupe. Only said that about hundred times now... For the IRS center section, when Factory Five first released that new design IRS, they said iron case only. Since then, they've changed that to say either iron or aluminum. Unless you're planning super sticky tires, like drag slicks or whatever, either is fine. Even then the center section probably wouldn't be the weakest link. Probably the CV axles. That's one of the first things the Mustang performance guys upgrade.

[nuhale]

As I went with the base kit still sourcing some parts. Picked up a set of rear IRS spindles, RF wiring harness, Brock racing mirrors amongst other small parts. Also planned on doing a full mustang cut out to supply the brakes, spindles and differential but with the deal I got on new spindles I'm probably going new differential (3.55). Still plan on used rear brakes and will rebuild and powdercoat. Lucked out on a Gen 2 coyote pullout with 12k miles. Still planning on a TKX but can be talked out of for a T56. I scored a new QT6080 bellhousing for half of what they are going for these days and with the T56 a grand more wondering if I will really see a value here or put the money somewhere else.

Picking up engine this week and will need a little work. Missing valve covers and as I'm planning a boost build (leaning towards VMP Loki/Odin or gen3r) plan to put in a boundary OPG/cam sprocket and considering pulling the heads to inspect pistons, and swap to ARP head stems. I've heard both sides of this and that they may not be needed. Will also swap pan and pickup and add B302 alt and a mustang compressor as I will add AC. No hydro pump on this one as plan to go with E-power steering. Opinions welcome!

[edwardb]

As I went with the base kit still sourcing some parts. Picked up a set of rear IRS spindles, RF wiring harness, Brock racing mirrors amongst other small parts. Also planned on doing a full mustang cut out to supply the brakes, spindles and differential but with the deal I got on new spindles I'm probably going new differential (3.55). Still plan on used rear brakes and will rebuild and powdercoat. Lucked out on a Gen 2 coyote pullout with 12k miles. Still planning on a TKX but can be talked out of for a T56. I scored a new QT6080 bellhousing for half of what they are going for these days and with the T56 a grand more wondering if I will really see a value here or put the money somewhere else.

Picking up engine this week and will need a little work. Missing valve covers and as I'm planning a boost build (leaning towards VMP Loki/Odin or gen3r) plan to put in a boundary OPG/cam sprocket and considering pulling the heads to inspect pistons, and swap to ARP head stems. I've heard both sides of this and that they may not be needed. Will also swap pan and pickup and add B302 alt and a mustang compressor as I will add AC. No hydro pump on this one as plan to go with E-power steering. Opinions welcome!

I assume you know that 6060 bell is good for your TKX, but not the T56. That requires an 8080. That may sway your decision, I don't know. I love the T56 in my Coupe. Really like the two overdrive ratios. I like the reverse lockout, although maybe not appreciated by everyone since it adds a little work on the installation. The T56 shifts like butter. Something the TKO wouldn't do at the time I built mine. Unless modded, e.g. Liberty Gears which I did a couple times. The TKX by all accounts solves the shift issue. So that makes the decision a little harder. The T56 + Coyote fits into the Gen 3 Coupe without any drama. Bottom line for me, I would do a T56 again.

I had electric PS my truck. First time I've tried it after multiple builds with traditional hydraulic PS. I personally didn't care for the feel of it. I've heard others say the same thing. But others like it. Obviously, very subjective. My experience on my last two builds was the KRC pump with good quality racks. Outstanding setup.

[nuhale]

I assume you know that 6060 bell is good for your TKX, but not the T56. That requires an 8080. That may sway your decision, I don't know. I love the T56 in my Coupe. Really like the two overdrive ratios. I like the reverse lockout, although maybe not appreciated by everyone since it adds a little work on the installation. The T56 shifts like butter. Something the TKO wouldn't do at the time I built mine. Unless modded, e.g. Liberty Gears which I did a couple times. The TKX by all accounts solves the shift issue. So that makes the decision a little harder. The T56 + Coyote fits into the Gen 3 Coupe without any drama. Bottom line for me, I would do a T56 again.

I had electric PS my truck. First time I've tried it after multiple builds with traditional hydraulic PS. I personally didn't care for the feel of it. I've heard others say the same thing. But others like it. Obviously, very subjective. My experience on my last two builds was the KRC pump with good quality racks. Outstanding setup.

Thanks for the feedback Paul. I'm sure I'll seek you out in June at LCS to talk some more shop. I do know the details on the bellhousing. Just saw this one a few weeks ago and couldn't pass on it so even if I did make a change in my build plan I would offer it up to another builder. Still in disbelief that the QT bells have almost doubled in cost in just a few short years... such is life these days. Thanks for the e-power steering feedback. I have a Forte saginaw pump setup on my MKIV. I've been really happy with the feel. It powers my hydroboost as well. I have the manual rack from the roadster build so was considering just using that with the epower and save a few bucks. Certainly do some more research on the options. Not a huge thing to change but need to be aware of front engine belt space with considerations of a blower.

[Al_C]

Showing my ignorance here, but I have to ask this question: if you are concerned about the ability of the cam sprockets to handle the power you expect, what about the crank and connecting rods? I would think that the parts are matched to handle the same amount of power from the factory. Are the sprockets the weakest link?

[nuhale]

Showing my ignorance here, but I have to ask this question: if you are concerned about the ability of the cam sprockets to handle the power you expect, what about the crank and connecting rods? I would think that the parts are matched to handle the same amount of power from the factory. Are the sprockets the weakest link?

It can start a debate but a well-known weakness of the coyote is the oil pump gear. It's a cast part and has shown failure at high RPM situations. Many just swap it out with a billet gear from boundry. Common swap but have heard both sides of it. Not a huge change when engine in on stand and a cheap insurance policy. All other stock components are pretty durable and can handle boost. Only other area may be the ARP head studs which is another easy one if I'm getting into the engine.

[Al_C]

It can start a debate but a well-known weakness of the coyote is the oil pump gear. It's a cast part and has shown failure at high RPM situations. Many just swap it out with a billet gear from boundry. Common swap but have heard both sides of it. Not a huge change when engine in on stand and a cheap insurance policy. All other stock components are pretty durable and can handle boost. Only other area may be the ARP head studs which is another easy one if I'm getting into the engine.

Thanks, Bryan! I appreciate the explanation. Thanks for indulging me!

[cunfewzed]

I'm feeling you on the sale, wasn't exactly ready to start my build, but I'm about to put down a deposit too before I have to pay $5k more a year from now.... Damn marketing lol

[nuhale]

Parts are still arriving daily. Looks like I'll be driving out to Wareham just before Memorial day to pick up my coupe. Put some feelers out for an engine and ended up buying a "donor" engine from D-Mark performance here in Chicago area. It's a gen 2 coyote with around 12K miles on it. The previous owner wanted a 1000+HP monster built so they did a forged/sleeved block with performance heads. They used his existing engine as a donor to all the parts. I bought what was left over. Did inventory and much parts needed but in the end I will get a low mileage gen 2 with upgraded parts. Actually having fun going through all the engine schematics/service manuals to get the hardware and parts. Picked up the engine yesterday and got it on the engine stand.



Pulled out the micro camera and took a inspection peek in the cylinders. A little carbon build up and the cylinder walls look really good.





Opened up my new oil pump and replaced with a boundary OPG. My son and I did a quick experiment dropping the gear and was surprised to see that it does snap with a drop. 2 drops and it snapped in half. I didn't swap this gear on my roadster engine. I know this has been debated in many forums but as long as I'm rebuilding this engine and it's open, why not swap...

[nuhale]

Got the call from FFR this week that my coupe will be ready in just a few weeks. Squared up so ready for pickup memorial day weekend. Going to also swing by Mike Forte and pickup a T56 magnum and meet him in person after years of phone conversations.

Made some progress last couple days. Went with the spectra F12B tank. My roadster tank fuel pickup cup just has a hole in the size to allow fuel to enter. This one has a nice bottom form that looks like it will give a better fill and reduce slosh. I notice when my tank is around 1/4"ish" and I get on it that the engine is starved of fuel. Looks like this one will be improved. Took some time degreasing the surface and giving it a couple coats of POR15.



I wasn't planning on pulling the heads of the engine but got a heck of a deal on some ARP head studs. Given the state of the engine now is the best time to do it. Got everything pulled apart, inspected and cleaned up. Used a dremel brass cup brush to clean up the pistons and valve with WD40. All shiny and clean with new ford performance head gaskets and ARP studs. Destroyed the cam phaser filters getting them out so waiting on new ones to arrive to keep progressing. Overall everything looks great. Plan to do a leak down test to appease my OCD. Picked up a harbor freight kit but the M14 adapter doesnt fit the deep spark plug socket so waiting on an adapter to complete. Will update results once I get the part.

[cv2065]

Looks like a lot of fun!!

[Jeff Kleiner]

Looking good buddy!

Jeff

[nuhale]

Received the adapter and had a free hour tonight so just did the leak down test on the Gen 2 coyote. Results pretty darn good. As written the engine is a pull out donor that was reported to have around 12k miles. This gives me big peace of mind to move forward. Just a small plug for the harbor freight tester. I've used the older one and that one is a POS to say the least. This one is either a dead on knock off of the OTC or made by same supplier. It is identical in every way. Works great!

[Al_C]

Good news! Oh wait, didn't you say something about OCD? Never mind. On another note, how many miles do you have on your Mark IV? I bet these two engines are close, mileage-wise. I'm glad this is working out for you and I think the coupe engine is going to be incredible! I think this whole adventure is really worthwhile!

[nuhale]

Good news! Oh wait, didn't you say something about OCD? Never mind. On another note, how many miles do you have on your Mark IV? I bet these two engines are close, mileage-wise. I'm glad this is working out for you and I think the coupe engine is going to be incredible! I think this whole adventure is really worthwhile!

Just under 11k I think. I’m gonna try and bring her home from storage this weekend if the weather holds. Aren’t you in Texas Al?

[Al_C]

Aren’t you in Texas Al?

Nope. Too many conflicts, and too long a drive. I will be at LCS, though!

[nuhale]

About a week out from driving out to Boston to pick up the coupe from FFR and Trans/random parts from Mike Forte. Some of the purchasing has slowed due to work travel and other projects (mostly getting garage ready). Have my MK4 home from winter hibernation and got through some of the annual maintenance there. Finished getting the Gen2 coyote reassembled and painted. Really happy with result of the Ford corp blue Eastwood ceramic engine paint I used with black engine dress and powder coated oil pan. Much of this not really seen but really like the little details that I didn't do on the roadster. I plan to use a Holley low ram intake, but TBD based on some other decisions that need to be made or what will fit.







Build Plan as of May
BASE KIT
- Gen 2 Coyote 11k mi (rebuilt/upgraded) ARP head studs, Boundry OPG, upgraded timing chains/tensioners, Moroso oil pan
- Tremec T56 6spd
- Quicktime 8080
- IRS
- 13" Fox Mustang Cobra Front "Big Brakes" Hawk HPS Pads
- S550 Rear Brakes Hawk HPS Pads
- Super 8.8 3.55 rear end
- McLeod RST twin disk clutch
- Speedhut FFR gauges
- F/R Sway Bars
- Added front LCA
- Koni Coilovers
- FFR AC/Heat
- Side windows
- RF wiring harness
- Specialty Power Window WWK-2 wiper kit
- Brock racing side mirrors
- Rear S550 (new) IRS spindles
- Power steering (Leaning towards TSP 84053BK-KT - Kit that uses saginaw pump)

Other than the engine, no donor parts. Lots of debate around complete vs base kit. I opted to go base and buy what I need. Will document the process as with the roadster I changed out a ton of components.

TBD
- Supercharged? Not sure what I'll do or what I can fit
- Holley Low Ram intake
- Interior - leaning towards Kirkey 65' road race seats with custom leather
- Forgestar 19" wheels F14
- Denny's driveshaft
- Tires

[JimStone]

Pretty awesome. I'm picking my Coupe kit up next week too - Friday

[nuhale]

Pretty awesome. I'm picking my Coupe kit up next week too - Friday

Same. Friday before noon is plan. Depends on how long I spend chatting with Mike Forte.

[nelsond003]

My kit gets picked up tomorrow and delivery is supposed to be Friday-Sunday. I'm sure I'll find out tomorrow.

[JimStone]

Same. Friday before noon is plan.

Cool! I'll be there at 10am. See you there, haha

I'm hoping to meet Dave Smith. Hopefully he's available

[nuhale]

Been a slow start and already falling behind with the thread. Picked up the coupe on 5/24. Built a dolly with plan to just have them set the chassis/body on, strap down and winch into trailer. Well it didn't go to plan as I measured everything except the darn height clearance of my serpent express. Dave and team to the rescue and we got it safely in with a little ol' fashioned elbow grease. Besides the embarrassment (and hold up to the next pickup) all went pretty well. Was running behind so missed out on getting a factory tour. Next time I guess.





Quick stop by Forte to pickup a T56. Was great to stop in and meet Mike in person after years of chatting on the phone. If you get a chance stop by his place. A gear-heads playground for sure.



Did the run back to Chicago in one go. 16.5 hours with stopping for gas/food. The Serpent Express pulled great. Have some upcoming trips coming up to LCS and out west to Colorado so was good to get the trailer out. Did some minor service on the trailer adding a tongue box, some new wiring and LED lights in prep for the trips. All worked great. Given that we just set the coupe on some 4x4s in the trailer I had to call in some help to get her out. Thanks to Sten, Leif, Jimmie and David for the help! Came out no problems using the engine crane and some dollies.





Been traveling a bit for work so any free time has been spent getting the roadster ready for the LCS trip. Got thru some inventory of the base kit. I will document this as didn't really know 100% what was excluded in detail. Got the front end in with the rack, susp etc. Using a BBB 1010107 refurb rack with energy suspension 4.10103R bushings that I painted black. Had a hell of a time getting the rack extenders on and tightened down but it all worked out. Went with the 13" SN95 "Cobra" big brakes from Powerstop. Same as what I did with the roadster. Really nice setup for the price. Not sure I'll keep the red... will depend on the final color choice.





LCS is next week so looking forward to seeing a bunch of you folks. Hoping to get more time with this after my LCS and Colorado trips coming up through the 4th.

[JimStone]

Congrats on the kit!

I was the next pickup after you. Sorry you didn't get to do the tour. Dan Golub showed us around, then Dave. We had a great time. Was worth the drive, for sure.

[Al_C]

I look forward to an update when I see you in OH! I was wondering if maybe the coupe might be ready... This is a really exciting project. I'm envious!

[nuhale]

What a month... Lots of miles across the country. Picked up the coupe from Wareham, LCS then a vacation out to Colorado. Serpent Express certainly got some action. Not much work has been done on the coupe project other than the front end. Continue to make some calls on the build. Just today decided on the slave hyrdo clutch from Forte over a internal Tilton or like. Just like the idea of not having to remove the trans if something goes wrong.

LCS was a great time as always and seeing many of you. Was a little on the hot side but we made the most of it. Nice to have my MKIV in the FFR booth this year. Hate to think about it but this is kind of a last hurrah as I may be considering a sale to make room in the garage (ping me if interested).







Quick turn around after LCS and took the roadster out to Colorado. For all you Colorado folks I am jealous of what you have in your backyard for driving. Amazing time with friends driving the mountains near Granby, Vail, Breck areas. Been over by Camp Hale in the winter a few times but never in summer. What a sight and grabbed a framer of a pic of the roadster. Did have a slight run in with the Grand County Sheriff where I received my first ticket in 25 years. Doing burnouts in Grand Lake area is not welcomed apparently . My friends surprised me with putting me in the Vail 4th parade where I pretty much lead off the parade with the Emergency/Ambulance teams. Ton of fun driving through the tight streets of Vail giving the folks some revs. Clutch was quite unhappy at the end but it was worth it. Ready to get back to work on the Coupe project with the rear end IRS going in next. More progress to report soon.

[Jeff Kleiner]

...Did have a slight run in with the Grand County Sheriff where I received my first ticket in 25 years. Doing burnouts in Grand Lake area is not welcomed apparently...

Darn out of state hooligan with a loud car

Jeff

[nuhale]

Some progress to report. Completed pre fitting and drilling all the aluminum panels. Decided to use a few techniques on this build to lessen the powder coat cost. Using the gold foil/fiberglass adhesive sheet on panels facing the engine for a nice aesthetic and hoping some function (thanks Erik). Most of the panels in the engine bay other than the gold footboxes off to powder which going with a matte wrinkle finish.



I will be using sound deadening material in the cab I picked up on amazon. Will be using a combo of 80/120mil rubber/foil sheet with some additional sound deadening mat. More to come on this front. For any of the panels that are slightly seen in wheel wells or under car (ie underside of tunnel) I will be using a vinyl adhesive material. I did some testing on it and it holds up pretty well. Goes on like vinyl signage or car wrapping with some soapy water that gets squeegeed out. 50' roll was $30 so easy decision. I'll attach some photos when I get the panels wrapped.



Just some other odds and ends for engine etc. Keep finding those deals. Picked up a new BOSS302 alternator kit for half. Looked kinda strange on my blacked out gen 2 coyote so break out the POR15 and a little time to paint.



Next up is finishing the fuel and brake lines. Will be using Nicopp brake and AN flexible PTFE braided line. Moving along nicely. Hoping to get to first start end of October but that work thing keeps getting in the way.