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Thread: CV2065 MKIV Build Thread - Graduated!

  1. #201
    Senior Member cv2065's Avatar
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    Haven't updated in a while. We went on vacation to Utah/Colorado. If you've never Canyoneered, just make sure you're in relatively good shape. Thought I was going to have to be choppered out. Well, it wasn't that bad, but I was reminded that I'm not a 19 year old Marine anymore. Anyway, had a blast doing other things as well in Monument Valley and the Moab, like horseback riding, ATV'ing and Zip Lining. Here was our view from our cabin in Monument Valley.



    Pretty cool place, but was glad to get back to humid Florida.

    Anyhow, started back on the car and have gotten quite a bit done. First off, I finished off the dashboard. Had a few switches to add and am pleased how it came out. Nothing fancy, just standard stuff.



    When wiring the hazard switch, I connected the two pink wires to the middle prongs on the 6 pronged switch, then the blue and green turn signal wires to the bottom two prongs. Had it backwards initially, so I should have tested first, but not a big deal to switch back around. I wanted a red guard for the wiper switch right next to it, but could not find one to fit.

    Speaking of the dash, I have really been indecisive as to how I was going to mount it. I have the 3M interlock tape, but in the end, just decided to screw it in. I bought some black chrome button head screws from Albany County Fasteners that were a little pricey, but will look great and match my theme, as I am 99% positive that I'll powder coat all of my exterior chrome the same finish.

    Hard part was pulling the dash back far enough without jacking up any wiring and measuring for 5-2"x3/4" stainless angle brackets to rivet to the hoop. I have a local custom metal cutting place that had these cut for me in 10 minutes. This obviously should have been done beforehand as space is limited, but the good news is that I've added plenty of wiring so that the dash can pull back at least 6-8" from the hoop, so if I need to repair anything in the future, easy peasy.



    Only issue there was that the brackets on the corners had to be angled, especially on the glovebox side, as there was interference, even with just 3/4" lengths. All brackets are roughly 9.25" apart from center to end of each bracket, except for the last two that had to be moved a little closer.

    I'll put a little tape where each bracket is located and will mount the body for placement shortly.
    Last edited by cv2065; 07-04-2019 at 12:15 AM.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  2. #202
    Senior Member cv2065's Avatar
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    I also finished up the trunk area. As others have done, I first made some additional upper trunk side panels out of 0.040 aluminum to make the carpeting go on easier. Also makes the rear look very finished. I'm surprised that FFR doesn't include these panels. I didn't have these powder coated, as I was just covering them up right then anyway.





    I decided to insulate the entire trunk area for sound/vibration proofing. I don't really care about the additional weight. Everything is rock solid on the back end.



    Once the trunk was completed, I finally riveted in my last large piece of metal, which is the rear cockpit panel. I had already cut my speaker holes with rivnuts and proceeded to insulate. I did a triple check here to make sure that everything was run and tightened, as not as easy to access once this panel is in place.





    I also fitted the trans tunnel cover. I'll be covering with carpet, so not concerned with the rivet heads showing. The top plate that goes over the hole only fit when cockeyed to the right where it overlayed perfectly on the tunnel hole. The shifter clears through all gears. I'll be securing with 6 black chrome screws and washers (3 on each side). I already tapped for those. I may put some insulation for final install.

    I also replaced the two shifter bolts, as they were rusting. Again, not something I could get local as these thread in, so ordered the stainless version from Albany County Fasteners. Cup holders are next.
    Last edited by cv2065; 07-04-2019 at 09:31 AM.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  3. #203
    Papa's Avatar
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    Looking good! Where in Colorado did you get to on your vacation?

    Dave
    My Build Thread: http://thefactoryfiveforum.com/showt...ter-Build-9754
    (Most viewed Roadster build thread on this forum!)

    Delivered: 6/17/2017
    First Start: 12/30/2017
    Completed: 12/7/2019
    Legal: 1/30/2020

    Member of the Mile-Hi Cobra Club
    Dave's Cobra YouTube Channel: https://www.youtube.com/channel/UCbk...npK1UZHj4R-bYQ
    Agora 1:8 Scale Cobra Build: https://thefactoryfiveforum.com/show...l-Build-Thread

  4. #204
    Senior Member cv2065's Avatar
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    In doing the trunk, I had to start my stereo wiring. Based on where the amp and pancake sub will sit, decided to drill a 1.25" hole in the middle of the upper trunk, as well as 2 1/4" holes on both the right and left sides for the speaker wiring. Grommets for every hole. Had to go online for the larger one, as there is nothing of that size around here, even at Ace.

    Stereo wiring went as planned. The main power wiring was run through the large trunk hole and down to the trans tunnel. I ran it up the left side and out across the top of the passenger footbox, into the accessory hole to the distribution block. What was nice is that I was able to score flat RCA cables bundled as 6 together off of Amazon. This made it easy to stuff the 4 gauge wires for my sub and amp, as well as the RCA and remote wires all in the same 3/4" plastic tubing, which fit perfectly up under my fuel regulator and wiper motor. I'll be adding another clamp to secure it here shortly.





    I ran the front door speaker wiring through the left and right trunk grommets, down the 2" beams and out the bottom of the cockpit panel. From there I secured the wiring to the floor seams with metal waterproof tape and then exited out right before the speaker at the bottom of the door. I then snaked it vertically through the 2 3/4" beams exiting to the speaker, which I don't have hooked up yet. I wanted to keep the wiring inside the steel of the car so nothing could possible catch on the body.







    Rear speakers went in for fit and look great.

    Last edited by cv2065; 07-03-2019 at 11:47 PM.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  5. #205
    Senior Member cv2065's Avatar
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    Quote Originally Posted by Papa View Post
    Looking good! Where in Colorado did you get to on your vacation?

    Dave
    We flew into Salt Lake City...then drove to Glenwood Springs. Great town! From there we went to Durango, Monument Valley, Moab...then back to Salt Lake. 11 days total. Very cool vacation!
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  6. #206
    Senior Member cv2065's Avatar
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    Continued working on my stereo wiring. I'm just connecting it all now for functionality and will clean everything up later once the carpet is in the trunk. I got the idea of the head unit in the glovebox from Edwardb's thread, and although I'm not using the same unit, same principal and it looks great. I fired it up tonight and sounds really good. BT works great!



    The Kenwood amp is really bringing the speakers to life. I can't imagine not being able to hear it, and I haven't even hooked up the pancake sub as of yet. I did have one mishap as the sub power wire accidentally touched the foil sound proofing and zap, my stereo shut off. Thought I had fried something, but checked all of the fuses and they were good. Came back on after I gave it a couple of minutes..Whew!! Lesson learned to keep all bare wires in line of sight and secured.

    I'll post more pics as I get more pieces hooked up and in their final position. I plan to screw the amp and sub to a piece of carpeted MDF, so that I only have to secure that to the floor.

    I was also able to get my cup holders cut and installed into the trans tunnel cover. I decided not to use the dash support from FFR since I'm screwing the dash to my hoop brackets. The trade off was the cup holders, which I think I'd miss if they weren't there for drinks and lose items.

    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  7. #207
    BadAsp427's Avatar
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    Thump, Thump thump, Thump... Sip,,,, Ahhhhhhh!!!

    Mk4 20th Anniversary #8690 (#8 of 20) Purchased 8/18/18----Build Started 8/19/18
    Build Thread Click Here / Registry Entry Click Here / BluePrint Engines 347ci / TKO600
    Carb/Heater/Heated Seats/Cruise Control/Drop Trunk & Battery/Custom Cubby

  8. #208
    Senior Member cv2065's Avatar
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    Finally got my headers back from the ceramic coaters for the second time. They are a little more dull than the Satin finish they had the first time around. Maybe he used BBQ paint? LOL...Either way, was able to get the body on for the first time while I was waiting. I needed to fit my seats and dash.

    Placed the bulb seal on all of the designated spots. Only issue I ran into was the bulb seal that wraps around each trunk side kind of flops over and doesn't sit upright. I read a few other posts around this and some suggested cutting 'V's' in the part that attaches to the panels around the curve, but it didn't work very well. Jeff Kleiner said it is a common thing so I moved on. I'll be replacing the cut one with the body off.

    Also, when I put the Thermo Tec down on the areas that get bulb seal a few weeks back, it made the area too thick installing the bulb seal, so had to go back around and trim 1/4" around all of the edges of those areas.







    I was reminded in Edwardb's post to place a brace in the middle of the body when lifting. Almost forgot that. Lots of potential flex, so glad that I did. I cut up a lawn and garden trash bag and placed pieces over the bulb seal to allow the body to slide a little for adjustment so it didn't tear up the rubber. Still had a little damage on the trunk bulb seal, but think that was when the body was taken off.

    Body went on with really little issue. It sat a little low in the front and back until I placed on the quickjack bolts. Body kind of floats slightly above the engine compartment 3/4" tubes, with virtually all the weight on the firewall, which I believe is correct.







    Last edited by cv2065; 07-15-2019 at 05:45 PM.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  9. #209
    Senior Member cv2065's Avatar
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    Per Kleiner and dBats comments, as well as reviewing Shark's build thread, I was able to get the body pushed forward roughly 5/16" past the door latch brackets.





    I had trimmed the front and back roll a little prior to installation. The front was trimmed 1/4" and the rear 1/8". The rear cockpit wall seems to be perfect except for a 2" area that needs a little more evening out. The front also looks good except for about a 4" area that extends above the speedo. I'll have to go back and take a little more off there as its right up against the dash. Trunk has about 1/8" gap as well once the body was pushed up.



    Last edited by cv2065; 07-15-2019 at 05:39 PM.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  10. #210
    Senior Member cv2065's Avatar
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    Once the body was situated, I was able to fit the dash. I had put a few pieces of tape to designate where the brackets were on the back and where I needed to drill. I did learn that when fitting the dash, it only goes so high when you push it up into the body, so there's really no doubt how it fits or where it needs to go. Lots of questions there for me when the body was off on fitment. I thought the steering column would center up a little more in the hole but could be a combination of the new pillow block, RT turn signal or just where the body placed the dash, but the trim ring fits so it works.

    I measured for 5 evenly spaced screws across the dash and easily be able to remove if needed. I have about 3/16" below the hoop on the driver's side and 1/16" on the passenger side.







    Last edited by cv2065; 07-15-2019 at 09:16 PM.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

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  12. #211
    Senior Member cv2065's Avatar
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    For seats, I used Breeze's angled seat mounts. These were very easy to install, although I wish that they had come powdercoated, as they were already flash rusting in the box. I would typically have these powder coated myself, but didn't have any other items at this point and wanted to save some time, so I used the Rustoleum oil based spray can. End result was good but not a product that I'd recommend as it took a few coats to cover.







    I think with previous versions of this mount, one had an issue removing or adjusting the seat because you can't access the rear nuts. That was solved with having two plates. One mounts to the floor of the car. The second angled mount bolts to that plate, and then the seat bolts to the angled plate. So pulling the seat is a matter of lifting the seat cushion out and 4 bolts. Great design!

    Once installed I tried to center the seats in-between the seat belt brackets, give or take 1/4" or so. I then sat in them, and once satisfied with the seat to pedal angle, I locked it down. I've got about a 1" gap between the edge of the seat and the tip of the door latch bracket.





    With the headers back, I've just got to get them installed, re-install the side pipes and get my dash screwed down. Then we are ready for some go kart action.
    Last edited by cv2065; 07-15-2019 at 05:59 PM.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

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  14. #212
    Senior Member Fixit's Avatar
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    Hey... a couple of tips for ya on the Breeze seat mounts/parts.

    Learned by experience... if you're sitting sideways (legs hanging out the door) and you shift your overweight fatazz too far forward that 1/8" piece of masonite has no chance - It'll snap off clean with the front tube of the seat frame.
    I used the masonite (remains) as a template to cut replacements from 1/8" aluminum (an old road sign actually). Re-used the same screw holes, and rounded the edges over with a file and sanding block.

    I also secured the Velcro flap on the seat back (for the bottom cushion) to the seat frame tube with a couple of button head self-drillers.
    John D. - Minneapolis 'Burbs

    1965 El Camino - LT-1, 4L60e, 4wh discs, SC&C susp.
    2013 F-150 Platinum - Twin Turbo 3.5
    2018 Mk4 Roadster w/ Coyote - #9365 - Build Thread Delivery 7/3/18, 1st Start 1/4/19, 1st Road Mile 5/5/19, Legal 6/18/19, In Paint 2/25/21, Done (?) 4/2021

  15. #213
    Senior Member cv2065's Avatar
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    Quote Originally Posted by Fixit View Post
    Hey... a couple of tips for ya on the Breeze seat mounts/parts.

    Learned by experience... if you're sitting sideways (legs hanging out the door) and you shift your overweight fatazz too far forward that 1/8" piece of masonite has no chance - It'll snap off clean with the front tube of the seat frame.
    I used the masonite (remains) as a template to cut replacements from 1/8" aluminum (an old road sign actually). Re-used the same screw holes, and rounded the edges over with a file and sanding block.

    I also secured the Velcro flap on the seat back (for the bottom cushion) to the seat frame tube with a couple of button head self-drillers.
    Thanks for the tips John. I was considering replacing with a couple of pieces of thick plexyglass that I have, but may use some aluminum as you suggested. Even though I painted them, as you say, the masonite won't last.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  16. #214
    Senior Member cv2065's Avatar
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    First off, want to thank Carl (BADASP) for making a trip to my house this weekend. He helped me tune a bit then ready for the first go kart! Went to dinner Friday night. Cars and Coffee in the AM on Saturday and Go Karting Saturday afternoon. Thanks Carl!

    Before Carl arrived, I was able to get the dash fully installed. I thought if I'm going to use screws through the dash, then they will be a part of the decor, not just a fastener. The 10-32 black chrome button heads with black SS finishing washers did the trick. They look great!





    As I mentioned, the headers came back and installed them. After starting the engine a few times I'm convinced that they are indeed ceramic coated and not BBQ paint. They look great as well.



    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  17. #215
    Senior Member cv2065's Avatar
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    Moving on to the steering wheel. I have the RT turn signal mod and it went on simple enough. What I didn't realize was with the manual suggested location of the upper steering shaft was way too long for the steering boss and had to be pushed in about 3-4". Luckily, I lubed the shaft when installing initially and it moved pretty easily. Carl's palm was used as a dead blow. Spaced the turn signal housing 1/16" from the steering boss and looks great. Russ Thompson does a great job here. Now just need to wire it all up.



    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  18. #216
    Senior Member cv2065's Avatar
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    Whipped out the vacuum gauge and dialed in the electric choke and the 427 is a monster. Thanks again for the help here Carl! Has been a while since the car was off jack stands and forgot how low these cars are. No room for a low profile jack and 2x4 to lift on the 4" cross member, so had to place the tires on 2x4's to get the jack and wood out. Plenty of room for a 1x4..but it does creak a lot..

    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  19. #217
    Senior Member cv2065's Avatar
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    So now for the fun stuff....Go Karting! Getting ready to come out of the garage. Engine sounds amazing. Some of the local kids stopped by when they heard the engine. Absolutely nothing has the sound of a push rod engine. Thought I was having an issue going into first..but I was in first, so rookie move in getting used to the new trans.

    https://youtu.be/xq-Ptjioxjk

    Next up was around the block. Man isn't that a great sounding Hyundai? This circle rarely gets car traffic, but of course, when I'm out I'm getting it from front and behind.

    https://youtu.be/dsuN9Ly12jA

    Last lap:
    https://youtu.be/vQlSUWuelVk

    So, not a long maiden voyage (about 1.5 miles), but enough to get a feel for it somewhat. Great job to the videographer Carl. A few takeaways:

    1. Need to get some different shoes. Goosing it when you're not planning to goose is not cool.
    2. Brakes were a little spongy so need to bleed a little again.
    3. Remember to secure the fuel tube before go karting....
    4. The mechanical linkage is super sensitive. Might have to look for a stronger throttle return spring.

    Other than that, it was awesome. As soon as I center the steering wheel and bleed the front brakes again...more go karting to come! Until then, nice picture of two Cobras at once!

    Last edited by cv2065; 07-24-2019 at 10:06 PM.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  20. #218
    Papa's Avatar
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    Looks and sounds great! How many Carl's are there? He's everywhere.
    My Build Thread: http://thefactoryfiveforum.com/showt...ter-Build-9754
    (Most viewed Roadster build thread on this forum!)

    Delivered: 6/17/2017
    First Start: 12/30/2017
    Completed: 12/7/2019
    Legal: 1/30/2020

    Member of the Mile-Hi Cobra Club
    Dave's Cobra YouTube Channel: https://www.youtube.com/channel/UCbk...npK1UZHj4R-bYQ
    Agora 1:8 Scale Cobra Build: https://thefactoryfiveforum.com/show...l-Build-Thread

  21. #219

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    Looks and sounds good! Good work
    Sigurd
    Type 65 Gen 3, 347 Fi, Tremec, IRS, Wilwood, AC, PS

  22. #220
    BadAsp427's Avatar
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    Quote Originally Posted by Papa View Post
    Looks and sounds great! How many Carl's are there? He's everywhere.
    Yup.... I've been getting around the South East... I just can't stop driving this thing... Just bumped over the 7000 mile mark on this trip to work with Chad on his... Chad has a great build going and it was a pleasure tweaking the carb a little and bringing that 427 to life... The response to the throttle on that BluePrint engine is exceptional.

    CV2065 - BluePrint Engines 427ci Carb.jpg

    Mk4 20th Anniversary #8690 (#8 of 20) Purchased 8/18/18----Build Started 8/19/18
    Build Thread Click Here / Registry Entry Click Here / BluePrint Engines 347ci / TKO600
    Carb/Heater/Heated Seats/Cruise Control/Drop Trunk & Battery/Custom Cubby

  23. #221
    Senior Member cv2065's Avatar
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    Quote Originally Posted by Papa View Post
    How many Carl's are there? He's everywhere.
    LOL...I know right! Carl is the man!
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

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  25. #222
    Senior Member cv2065's Avatar
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    Got my power steering rack centered tonight. I used Karlos' method from a thread back in 2015. Very helpful!

    https://thefactoryfiveforum.com/show...etup-Procedure

    I also centered my steering wheel. This was not easy, as I have my flange bearing on the outside of the footbox as prescribed by the instructions, and there is very little movement to get the lower u-joint out of the steering adapter. Doing it over again, as others have done, I would have probably mounted the flange bearing on the inside of the footbox to get another 3/16" latitude, but its all good. Steering wheel is now centered. Just have to get some string and even out the tie rod on both sides.

    On my first go kart, I realized that the front brake lines were rubbing the wheels at full turn. So I bought some 90 degree fittings from Summit. These are Earls #966303ERL and seemed to do the trick.







    Just have to get these bled again and we're ready for some more go karting!
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  26. #223
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    Yeah, that does look much better...

    Mk4 20th Anniversary #8690 (#8 of 20) Purchased 8/18/18----Build Started 8/19/18
    Build Thread Click Here / Registry Entry Click Here / BluePrint Engines 347ci / TKO600
    Carb/Heater/Heated Seats/Cruise Control/Drop Trunk & Battery/Custom Cubby

  27. #224
    Senior Member cv2065's Avatar
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    Made a final list of odds and ends that I need to get done before getting the body back on. One thing that wasn't anticipated was the stress on the bottom lip of the plastic dash. I have 4 under dash supports that were clicko'd to the 2" beam where shown in the instructions. However, when I moved the dash down to secure to the brackets on the 3/4" tube so that I would have access to the dash screws when the body was on, it put a lot of stress on those brackets because they needed to move down about an inch with the dash. The plastic lip doesn't seem to be that strong, so I reinforced it with two 41" pieces of 1" wide aluminum on top and bottom. Secured with 1" black SS 10-32 bolts, then installed the dash support on top of those instead of to the plastic lip. Maybe a little overkill but this made for a rock solid dash install and once painted black, it installed flush and looks like a part of the dash.





    Also, finished up my Breeze seat bracket installation. Mark suggests not riveting the bottom seat plate over sound proofing, so outlined the plate and peeled back the Thermo Tec. As long as that stuff has been on, its REALLY difficult to remove. I had to use a hammer and putty knife to get it all pulled back. All good to go and the plates are now secured to the panels and frame.



    I went ahead and stained the leather on my door straps and seat belts. I had some of the black dye from another project left over. I have a blacked out theme, so needed to get this done.





    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  28. #225
    Senior Member D02G's Avatar
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    Quote Originally Posted by cv2065 View Post
    Continued working on my stereo wiring. I'm just connecting it all now for functionality and will clean everything up later once the carpet is in the trunk. I got the idea of the head unit in the glovebox from Edwardb's thread, and although I'm not using the same unit, same principal and it looks great. I fired it up tonight and sounds really good. BT works great!



    The Kenwood amp is really bringing the speakers to life. I can't imagine not being able to hear it, and I haven't even hooked up the pancake sub as of yet. I did have one mishap as the sub power wire accidentally touched the foil sound proofing and zap, my stereo shut off. Thought I had fried something, but checked all of the fuses and they were good. Came back on after I gave it a couple of minutes..Whew!! Lesson learned to keep all bare wires in line of sight and secured.

    I'll post more pics as I get more pieces hooked up and in their final position. I plan to screw the amp and sub to a piece of carpeted MDF, so that I only have to secure that to the floor.

    I was also able to get my cup holders cut and installed into the trans tunnel cover. I decided not to use the dash support from FFR since I'm screwing the dash to my hoop brackets. The trade off was the cup holders, which I think I'd miss if they weren't there for drinks and lose items.

    What did you use for cup holders and where did you get them? I'm trying to decide which ones to get...

  29. #226
    Senior Member cv2065's Avatar
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    Quote Originally Posted by D02G View Post
    What did you use for cup holders and where did you get them? I'm trying to decide which ones to get...
    These seem to be pretty popular on the forum and fit perfectly.

    https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  30. #227
    Senior Member cv2065's Avatar
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    As I've seen in past threads, I did the door latch modification last night. I understand the need for the carriage bolt as when pulling my first assembly apart, it nearly fell apart by itself.

    Installed the SS 5/16-18 carriage bolts (3/4" long), grinding the seat about 1/16" for the washer to fit flush and the head of the carriage bolt. Kleiner and CraigS also recommended removing the spring in a previous past post, so did that as well and the action is nice and smooth. Put back together, but may pull the cover off again later for powder coating.



    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  31. #228
    Not a waxer Jeff Kleiner's Avatar
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    Make sure that the plunger retracts fully. It's pretty common for the tip to still stick out 1/16" or so. If it does just file it off so that it's flush. Also before installing the striker put a chamfer on the hole and the plunger will engage easier.

    Jeff

  32. #229
    Senior Member cv2065's Avatar
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    Quote Originally Posted by Jeff Kleiner View Post
    Make sure that the plunger retracts fully. It's pretty common for the tip to still stick out 1/16" or so. If it does just file it off so that it's flush. Also before installing the striker put a chamfer on the hole and the plunger will engage easier.

    Jeff
    Thanks for the tips Jeff. I did notice that about the plunger on both sides. I'll file that down.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  33. #230
    Senior Member cv2065's Avatar
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    Have been getting some odds and ends stuff completed over the past week or so. I wanted to start testing my lights, but needed to do some surgery on the front harness first. I didn't really like the wiring hanging below the radiator, so reconfigured the harness to run behind the top of the radiator to make it visually more pleasing. I'm not sure why RF does not do this out of the box, as the channel on top of the radiator is perfect. Took the better half of a day to get this done, but definitely worth the time. I also liked bringing the fan connector to the top to get it out of the way. I zip tied it to the fan, cut down the blue fan wire, and it lined up nicely. The radiator cover will hide it all, but it looks great.

    Down the driver's side:


    Across the top behind the 3/4" radiator support tube:


    Down the passenger side:


    Tested the harness and the parking and headlights work great. One caveat was that I did not have my hi beam switch hooked up, so the headlights did not work on first try. BadAsp reminded me that you needed that switch hooked up to complete the circuit, and he was spot on. I did buy some replacement headlights (was inspired by Papa), and got some of these Lucas vintage pieces. Just really like the way that they look.

    Last edited by cv2065; 08-18-2019 at 09:01 PM.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  34. Likes Papa liked this post
  35. #231
    Senior Member cv2065's Avatar
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    As I've said, I'm going for the complete blacked out look on #9380, which means that I had to go through another large batch of powder coating small trim pieces. I got rid of my last powder coater and am at a new shop. Cool older gentleman from Boston that has been around the PC block a few times and is really fair on pricing as well. Here's what I took to him to make the blacked out 'package':

    Headlight Trim Rings (2), Headlight Trim Ring Brackets (2), Shifter Trim Ring (1), Rear Tail Light Trim Rings (4), Turn Signal Trim Rings (2), Gas Cap Assembly (1), Wheel Spinners (4), Wheel Spinner Threaded Inserts (4), Wheel Lug Covers (4), Windshield Trim (2 Pieces), Radiator Cowl (1), Roll Bar (2 Pieces), Grill Mesh Trim Pieces (2), Hood Latches (2), Trunk Latch (1), Roll Bar Trim Rings (3), Side Mirror w/Support (2 Pieces), DW Side Mirror Bracket (1), Seat Belt Trim Rings (4), Quick Jack Rods (4), Shifter Handler (1), License Plate Housing (1), Rear view Mirror (1)

    Everything will be an Ink Black Gloss to match the wheels. We went over each piece independently. Nothing threaded will be powder coated. Spinner Threaded inserts will be taped off where only the outer portion is black. $300 for the lot. Not bad at all.

    I ran into a couple of caveats when preparing everything. The side bullet mirrors do come apart but the front part that rotates has a plastic piece inside, and would not do well for powder coating. Another issue is the rear license plate bracket. As the cover will come apart, but the rest is riveted and has some sensitive pieces, so will do that one by hand. The last challenge was getting the chrome bezels off of the rear tail lights. The light pretty much as to be completely disassembled and will need to be done before installing weather packs, as I had to pull mine off. Took lots of pictures so I remember where everything goes!



    One thing that can't be disassembled unless you break the soldering tab is the grounding on the tail light itself. Powder coater said that he could wrap in some high heat tape and protect it when heating it up. If he's not right, then I'll just re-solder but would make it easier.



    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  36. #232
    Senior Member cv2065's Avatar
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    Also got a chance to cut my mounting board for the stereo and amplifier. 3/4" MDF from Lowes. Easy enough and everything fit fine by cutting 34 x 35 x 15. I made sure that the board could slide out when needed and not get caught up on the roll bar tubes. I still need to carpet the rear trunk area as well as the mounting board.

    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  37. #233
    Senior Member cv2065's Avatar
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    And best of all, had a few go kart trips this weekend. First time was solo and can feel the trans loosening up where all gears run easily. The BP 427 fires up on the first key now that the carb is tuned and sounds like a beast. The lope is fantastic.

    My wife came the second time and after the riot act was read from the mother in law, we had a nice short trip and now I'm up to a whopping 4 miles. Neighborhood roads are too short but I did get into 4th when I peeked out onto a main highway for about 1/8 of a mile. Sound from the phone is terrible, but good time. And Daisy Princess is not my screen name....

    https://www.facebook.com/daisyprince...749084431/?t=2
    Last edited by cv2065; 08-18-2019 at 09:41 PM.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  38. #234
    BadAsp427's Avatar
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    Quote Originally Posted by cv2065 View Post
    And best of all, had a few go kart trips this weekend. First time was solo and can feel the trans loosening up where all gears run easily. The BP 427 fires up on the first key now that the carb is tuned and sounds like a beast. The lope is fantastic.

    My wife came the second time and after the riot act was read from the mother in law, we had a nice short trip and now I'm up to a whopping 4 miles. Neighborhood roads are too short but I did get into 4th when I peeked out onto a main highway for about 1/8 of a mile. Sound from the phone is terrible, but good time. And Daisy Princess is not my screen name....

    https://www.facebook.com/daisyprince...749084431/?t=2
    So cant see the video... guessing cause I'm not friends on FB with Daisy Princess

    Mk4 20th Anniversary #8690 (#8 of 20) Purchased 8/18/18----Build Started 8/19/18
    Build Thread Click Here / Registry Entry Click Here / BluePrint Engines 347ci / TKO600
    Carb/Heater/Heated Seats/Cruise Control/Drop Trunk & Battery/Custom Cubby

  39. #235
    Senior Member cv2065's Avatar
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    Couple more things off of the final checklist before the body goes on. First, the Metco Driveshaft Loop was installed. I did not have to install with washers. After reading a couple of posts, I thought this would be necessary, but I have about an easy inch worth of clearance between the top of the loop and the drive shaft. An issue I did have is interference with the e-brake cables. They rub the side of the loop. I'm not too concerned with it at this point.





    I have never liked the look of the circular adapter that has to be riveted to the top of the trans tunnel cover. If you are covering with leather it will most undoubtedly come through the fabric. Plus, with the offset nature of the TKO600, the hole does not align perfectly over shifter assembly.

    So, enter the FFMetals trans tunnel cover. It's much thicker gauge metal than the FFR version so it doesn't bow when you put your arm on it. I was able to cut my offset hole about 3/4" from the original center position to the passenger side, and it now fits over the shifter perfectly. Also, the FFMetal cover is virtually identical to the FFR cover, so it was easy to retrace my cup holder holes. In fact, I moved them both inboard about 1/8" so that they no longer interfered with some of my tubed wiring going through the trans tunnel.



    Finally, I received my honeycomb radiator protector from Speedway. Cut it to size with an Exacto Knife, then spray painted with some Satin Radiator Black Paint from Eastwood and installed.

    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  40. #236
    Boydster's Avatar
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    Keep up the good work! I like that radiator honeycomb.
    ---Boyd---
    MkIV #9042 build thread
    www.boss427.us
    427W, TKO600, Moser 3.55 rear.
    Delivered Feb 2017, Graduated Nov 4, 2019

  41. #237
    Senior Member cv2065's Avatar
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    So took some time off this week to catch up on things. Fortunately, Hurricane Dorian decided to stay off the coast of Florida, so we were not impacted much at all. Unfortunately, she's making her way up the coast to the Carolinas this evening. I hope everyone up there stays safe, have acquired all of your needed supplies and keep the hatches secured, as she looks like a rough storm.

    As mentioned, I was able to focus on a few things this week, including some electrical side areas that I didn't yet take care of. Under dash lighting was first up. I selected a waterproof light strip off of Amazon. Very nice quality and comes in just about any color light you want and even has little scissor icons to cut in case you want to shorten it up. I selected Red to match the car. Comes with 3M red backing and adhered very well to the 2" tube. Only thing is that if you pick black, it still comes with white connection wires. Nothing that some spray paint can't remedy, but I got mine here: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

    I couldn't decide how to route the wiring, so I drilled vertical holes into the 2" beam to send them right behind the dash. Very clean install. Hooked up to the courtesy light wiring from the harness and lighting looks great.





    One thing to note that I didn't see in the instructions is the grounding wire that goes to the headlight switch, that activates the courtesy lamps when you turn it counter clockwise. The first time I hooked it all up, I was getting zero. Carl (Badasp) helped me out here as the ground wire connects to a stud sticking off of the side of switch itself. Very easy to miss, and hard to get the ground wire attached. Thanks Carl! Here's a pic:

    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  42. #238
    Senior Member cv2065's Avatar
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    As I continued my electrical, I had a few grounds going to a stud under the dash. Being that it started to look unsightly I installed a ground terminal bus bar right behind the steering wheel. Plenty of room for what I have and to grow. Drilled and tapped the 2" beam with 10-32 SS screws. I got mine here: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

    Once hooked up, it was very clean and organized.





    I installed my USB port as well as dimmer switch to the under dash bracket towards the driver's door. I don't have heater so wired it directly to that connection. Wire is only hot when the car is on, but that's OK. Worked like a champ. Dimmer switch works nicely as well.

    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  43. #239
    Senior Member cv2065's Avatar
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    Mike Everson's nose aluminum was next. I had this piece powder coated gloss black and it really looks sharp. On test fitting I had to trim it just a very tiny bit with a flap disc but the instructions state that might be necessary depending on your individual setup. It was very easy to install with the bulb seal. If you want a really clean install at the nose of the car, this is the piece to have. I did call Mike regarding installation, as he recommended installing after the body was on, which makes sense, but I did test fit it and drilled my holes for easy install later.





    I also made a quick pitstop back to the stereo setup. I carpeted the board that I had made for the amp and sub. Came out fantastic! I also decided to use the wired remotes for both the stereo itself as well as the bass controller. I should have made this decision before I wired everything up as I had to spend an additional couple of hours rewiring, but all came out great.



    Here's the wired remote that will go into the tunnel cover:

    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

  44. #240
    Senior Member cv2065's Avatar
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    Finally got back everything from my new powdercoater. Nice to do business with someone that actually has a passion for what they do and a personality to match. If anyone needs a PC guy in Central Florida, this is your new friend. Anyhow, everything came back stellar except for three things, which two I already knew in advance. One was the hood and trunk handles. Apparently these have some plastic parts in them and as for powder coating and a heated oven...No Bueno. So, I'll be using some epoxy primer and paint for those pieces. Have some 2K stuff coming from Eastwood.

    Second was the windshield frame. The inside channel sides of the bottom bracket had been powder coated and I believe was causing an alignment issue on reassembly. I also ordered a new gasket as the original had broken at one of the corners.

    As for the third issue, it was in regard to the tail light bezels. You really have to be careful taking this stuff apart, as its not the highest of quality. I had two cracked reflector screw bulkheads that I had to repair, a bulb receptacle spring that would not retract and then there was the grounding wire. Unfortunately, the ground wire for these 4 tail lights is integrated into a cam at the bottom of the light housing. This makes it impossible to powder coat without destroying the ground wiring..at least according to my PC guy, and he tried a few things (high temp tape, etc.). There is also a tab that sticks out from the grounding cam. If you break that off, it makes for a much longer repair. Looks like this:



    Good news is that the bezels look fantastic in gloss black once I got them all repaired, back together and tested. 9380's blacked out look is coming around!





    One thing about the turn signal bezels. They are a press fit and I'm not sure that they were meant to come off more than a time or two. Mine are already loose and I'm confident that they would fall of in no time if driving around. Unless anyone has a better solution, I had planned to put some silicone in the contact areas to keep it from coming loose.
    Last edited by cv2065; 09-05-2019 at 07:15 AM.
    MKIV Roadster - #9380 - Complete Kit - Delivered 7/17/18 - SOLD 5/2023
    Build Thread #1: https://thefactoryfiveforum.com/show...V-Build-Thread
    MKIV Roadster - #TBD - Complete Kit - Delivered 11/6/23 - In Progress
    Build Thread #2: https://thefactoryfiveforum.com/show...Build-Thread-2

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