Rear Axle Update

Back at work on the rear brakes, ambulance
I found that with a couple of washers included, there
the calipers and rotors lined up very well.  So, site that being completed, we went to work on the lower control arms so we could start to mount the axle on the chassis.  We installed the control arms on the axle, but found we did not have a second set of fasteners needed to install the control arms to the chassis.

I contacted FF and they sent another set of fasteners.  In the meantime, we got all the parts for the rear coil over shock.

These were assembled in preparation for completing the axle install. Continue reading

Rear axle, Rear Suspension

Rear Suspension Completed

Back at work on the rear brakes, approved
I found that with a couple of washers included, esophagitis
the calipers and rotors lined up very well.  So, that being completed, we went to work on the lower control arms so we could start to mount the axle on the chassis.  We installed the control arms on the axle, but found we did not have a second set of fasteners needed to install the control arms to the chassis.

I contacted FF and they sent another set of fasteners.  In the meantime, we got all the parts for the rear coil over shock.

These were assembled in preparation for completing the axle install. Continue reading

Panhard, Rear axle, Rear Suspension

Rear Axle, Rear Suspension and Brakes

Back at work on the rear brakes, approved
I found that with a couple of washers included, esophagitis
the calipers and rotors lined up very well.  So, that being completed, we went to work on the lower control arms so we could start to mount the axle on the chassis.  We installed the control arms on the axle, but found we did not have a second set of fasteners needed to install the control arms to the chassis.

I contacted FF and they sent another set of fasteners.  In the meantime, we got all the parts for the rear coil over shock.

These were assembled in preparation for completing the axle install. Continue reading

Rear axle, Rear Brakes, Rear Suspension

Front Suspension and Brakes

Back at work on the rear brakes, approved
I found that with a couple of washers included, esophagitis
the calipers and rotors lined up very well.  So, that being completed, we went to work on the lower control arms so we could start to mount the axle on the chassis.  We installed the control arms on the axle, but found we did not have a second set of fasteners needed to install the control arms to the chassis.

I contacted FF and they sent another set of fasteners.  In the meantime, we got all the parts for the rear coil over shock.

These were assembled in preparation for completing the axle install. Continue reading

Front brakes, Front suspension

New Parts and Tools and Miscellaneous Stuff

We have been getting new parts for the past month, pills so little by little we are almost complete.  Only a few things left in the kit to receive, ambulance
plus a few additional items that I want to get.  We still need to decide if we will put in a glove box, Sildenafil
anything in the doors, and I need to get an additional fluid reservoir for the brakes and a recessed battery box so I can put the battery in the trunk compartment area.

Here are the Halibrand replica wheels and

Pat holding one of the side pipes.  More photos are in the Gallery.

 

 

 

We also found out after fumbling with the instruction manual that it was not Continue reading

Parts , ,

Engine Ordered

Welcome to the Dan and Pat Build a Roadster Build Site!

We are building a Factory Five Mk4 Roadster.

Follow along with us as we put our Roadster together.  We will keep you updated with details, look pictures, stomach customizations, successes and (hopefully few) failures.

For options, parts, and other information about the build itself, see the Build Info page.  See the Main Page for posts, and the Gallery for more photos.  We will post any videos on our Youtube channel.

Thanks to Factory Five, the FFCars.com and Factory Five forums, and everyone at the Roadster build school (July 2010) for answering our questions and helping us get started!

Enjoy sharing the fun with us.

If you want to contact us directly, email us at:

theguys AT roadster.mightypirates.com
We selected a Factory Five Mk4 Roadster.

The Complete Kit was ordered.  I added a few options.  The kit also came with the Appearance package.  I am not planning on the chrome on the bumpers.  Some of the specifics I chose:

  • Vintage gauge package
  • Laser body cut-outs
  • Kirkey Competition aluminum race seats
  • Halibrand Wheels – 17 x 9 front and 17 x 10.5 rear
  • Nitto NT555 Tires – 255/40ZR17 Front and 315/35ZR17 Rear
  • Windshield wipers
  • Wind Wings and Sun Visors
  • Stainless Side Exhaust with ceramic coated heat shields
  • Wire Mesh Brake Duct Covers
  • Battery Cut-off Switch
  • Heater/Defroster (defroster vents not installed)
  • MKIV Logo Floormats
  • Driver and Passenger Side Powder Coated Rollbars
  • Rear Brake Set
  • Herb’s custom interior door panels with pockets
  • Driver and Passenger Adjustable Seat Tracks
  • Seat Heaters
  • Chrome Rollbar Grommet set
  • Chrome seat belt bezels
  • Ceramic coated shorty headers and J-pipes
  • Engine specifics – See Below
  • Custom dash cover and boots for shifter and e-brake
  • Custom Dash extension to transmission tunnel
  • 12V Adapter Outlet
  • Custom carpeted trunk
  • Stereo/CD System with 4 rear-mounted speakers
  • ’73 Corvette Silver Paint with ’66 Nassau Blue striping
  • Wrap-around striping on hood and trunk

Engine Details

  • Ford Small block 302 Crate Engine
  • 347 Stroker EFI – 425 HP
  • Eagle Cast Steel Stroker crankshaft
  • Eagle I-Beam connecting rods
  • Keith Black Pistons
  • Custom Hydraulic Roller High Performance camshaft
  • Aluminum  cylinder heads
  • Stainless steel intake and exhaust valves
  • Aluminum performance roller rockers
  • Aluminum performance intake manifold
  • Powerjection III Electronic Fuel Injection
  • 750 CFM Throttle body assembly
  • Engine Management system mounted on the throttle body
  • MSD Distributor and 6AL Ignition Box
  • Wideband O2 sensor
  • Water pump
  • March Performance pulley kit
  • Ford Motor Sports Cobra Air Cleaner and Valve covers
  • Tremec TKO600 Transmission
  • Ford Racing Bellhousing
  • Ford Racing Clutch Fork, breast Cable Assembly, Clutch Kit and Throw Out Bearing
  • Balanced, live run tested, timing and EFI tuned, videotaped

Welcome to the Dan and Pat Build a Roadster Build Site!

We are building a Factory Five Mk4 Roadster.

Follow along with us as we put our Roadster together.  We will keep you updated with details, orthopedist pictures, otolaryngologist customizations, melanoma successes and (hopefully few) failures.

For options, parts, and other information about the build itself, see the Build Info page.  See the Main Page for posts, and the Gallery for more photos.  We will post any videos on our Youtube channel.

Thanks to Factory Five, the FFCars.com and Factory Five forums, and everyone at the Roadster build school (July 2010) for answering our questions and helping us get started!

Enjoy sharing the fun with us.

If you want to contact us directly, email us at:

theguys AT roadster.mightypirates.com
Earlier this month I finalized my order for the engine and drive train for the car. I decided to go with the 302 block to match it up with the shorty headers and J-pipes to simplify installing an O2 sensor and the installation and fit of the side pipes. I am having it modified to a 347 Stroker with EFI. It is spec’d out at 425 HP, troche and with the stroker will generate a lot of low end torque. I also am having them include all the remaining parts top to bottom and front to back to make it a one piece install . It will have all the pulleys, order belts, alternator, bell housing clutch and a Tremec TKO600 transmission. I am expecting to pick it up sometime early or mid-August. The manufacturer is Proformance Unlimited. They are located in Freehold, New Jersey. Pat and I visited them a couple of months ago and were impressed with their shop and work. We are hoping to be there when the engine is assembled. They do provide lots of photos during the build, plus a video of the engine on the dyno when it is tested and set up. Looking forward to picking it up.

Uncategorized , , ,

Aluminum Panel (Day 1)

Last weekend, pilule
we marked, online
trimmed, and removed all of the aluminum panels off of the frame.  This not only allows us to easily access the entire frame to start installing the rest of the components but allows us to start marking rivet holes on the aluminum.  While planning, I realized that the gas cap cutout is the perfect size for an ice cream cup.  Delicious!

More pictures from the weekend can be found in the gallery.

First, however, we had to mark aluminum panels that support the body to ensure there is enough space to apply bulb-seal on the panel edges before mounting the body later.  We also marked each set of bolts/spacers/washers/gaskets/nuts for each of the body mounts.  Then we got to remove the body and start working on the aluminum panels.

Later, when we are ready to drill holes in the aluminum before mounting the panels to the frame with rivets, we won’t have to re-mount the panels to line up the frame members.  We can just drill, mount using the original screw holes using Clekos, drill the remaining holes in the frame using the aluminum holes as guides, and mount the panels using rivets (the kit comes with 1200!!!).

We marked all panels with a letter that we wrote in a notebook to keep track of where the panel attaches to the frame.  We also drew a line across each seam between panels to more easily identify which panel goes on top of the other and simplify which order the panels should be reapplied after months and months in a pile on the body buck.

We also added a cutout mark on the top of the driver foot box so we can easily access the pedals, master cylinders, clutch, and throttle cables once the car is finished and the body is mounted.  We gave about 1.5” of space around the cutout where we will later use rivnuts instead of rivets so we can use bolts to mount the panel.  We will cut a piece of the driver foot box front panel that we don’t need to make the removable access panel (the complete kit comes with a slightly different replacement panel for the front foot box.

After removing all of the panels, we were left with a lonely frame Sad smile, but you can still pretend you are riding in it.

Up next is the front suspension (probably after a few weeks).  First day doing running gear!

Aluminum Panels , , ,

Inventory Finished!

Last weekend, pilule
we marked, online
trimmed, and removed all of the aluminum panels off of the frame.  This not only allows us to easily access the entire frame to start installing the rest of the components but allows us to start marking rivet holes on the aluminum.  While planning, I realized that the gas cap cutout is the perfect size for an ice cream cup.  Delicious!

More pictures from the weekend can be found in the gallery.

First, however, we had to mark aluminum panels that support the body to ensure there is enough space to apply bulb-seal on the panel edges before mounting the body later.  We also marked each set of bolts/spacers/washers/gaskets/nuts for each of the body mounts.  Then we got to remove the body and start working on the aluminum panels.

Later, when we are ready to drill holes in the aluminum before mounting the panels to the frame with rivets, we won’t have to re-mount the panels to line up the frame members.  We can just drill, mount using the original screw holes using Clekos, drill the remaining holes in the frame using the aluminum holes as guides, and mount the panels using rivets (the kit comes with 1200!!!).

We marked all panels with a letter that we wrote in a notebook to keep track of where the panel attaches to the frame.  We also drew a line across each seam between panels to more easily identify which panel goes on top of the other and simplify which order the panels should be reapplied after months and months in a pile on the body buck.

We also added a cutout mark on the top of the driver foot box so we can easily access the pedals, master cylinders, clutch, and throttle cables once the car is finished and the body is mounted.  We gave about 1.5” of space around the cutout where we will later use rivnuts instead of rivets so we can use bolts to mount the panel.  We will cut a piece of the driver foot box front panel that we don’t need to make the removable access panel (the complete kit comes with a slightly different replacement panel for the front foot box.

After removing all of the panels, we were left with a lonely frame Sad smile, but you can still pretend you are riding in it.

Up next is the front suspension (probably after a few weeks).  First day doing running gear!
Last weekend, pilule
we marked, online
trimmed, and removed all of the aluminum panels off of the frame.  This not only allows us to easily access the entire frame to start installing the rest of the components but allows us to start marking rivet holes on the aluminum.  While planning, I realized that the gas cap cutout is the perfect size for an ice cream cup.  Delicious!

More pictures from the weekend can be found in the gallery.

First, however, we had to mark aluminum panels that support the body to ensure there is enough space to apply bulb-seal on the panel edges before mounting the body later.  We also marked each set of bolts/spacers/washers/gaskets/nuts for each of the body mounts.  Then we got to remove the body and start working on the aluminum panels.

Later, when we are ready to drill holes in the aluminum before mounting the panels to the frame with rivets, we won’t have to re-mount the panels to line up the frame members.  We can just drill, mount using the original screw holes using Clekos, drill the remaining holes in the frame using the aluminum holes as guides, and mount the panels using rivets (the kit comes with 1200!!!).

We marked all panels with a letter that we wrote in a notebook to keep track of where the panel attaches to the frame.  We also drew a line across each seam between panels to more easily identify which panel goes on top of the other and simplify which order the panels should be reapplied after months and months in a pile on the body buck.

We also added a cutout mark on the top of the driver foot box so we can easily access the pedals, master cylinders, clutch, and throttle cables once the car is finished and the body is mounted.  We gave about 1.5” of space around the cutout where we will later use rivnuts instead of rivets so we can use bolts to mount the panel.  We will cut a piece of the driver foot box front panel that we don’t need to make the removable access panel (the complete kit comes with a slightly different replacement panel for the front foot box.

After removing all of the panels, we were left with a lonely frame Sad smile, but you can still pretend you are riding in it.

Up next is the front suspension (probably after a few weeks).  First day doing running gear!
Last weekend, ask
we marked, cialis 40mg
trimmed, and removed all of the aluminum panels off of the frame.  This not only allows us to easily access the entire frame to start installing the rest of the components but allows us to start marking rivet holes on the aluminum.  While planning, I realized that the gas cap cutout is the perfect size for an ice cream cup.  Delicious!

More pictures from the weekend can be found in the gallery.

First, however, we had to mark aluminum panels that support the body to ensure there is enough space to apply bulb-seal on the panel edges before mounting the body later.  We also marked each set of bolts/spacers/washers/gaskets/nuts for each of the body mounts.  Then we got to remove the body and start working on the aluminum panels.

Later, when we are ready to drill holes in the aluminum before mounting the panels to the frame with rivets, we won’t have to re-mount the panels to line up the frame members.  We can just drill, mount using the original screw holes using Clekos, drill the remaining holes in the frame using the aluminum holes as guides, and mount the panels using rivets (the kit comes with 1200!!!).

We marked all panels with a letter that we wrote in a notebook to keep track of where the panel attaches to the frame.  We also drew a line across each seam between panels to more easily identify which panel goes on top of the other and simplify which order the panels should be reapplied after months and months in a pile on the body buck.

We also added a cutout mark on the top of the driver foot box so we can easily access the pedals, master cylinders, clutch, and throttle cables once the car is finished and the body is mounted.  We gave about 1.5” of space around the cutout where we will later use rivnuts instead of rivets so we can use bolts to mount the panel.  We will cut a piece of the driver foot box front panel that we don’t need to make the removable access panel (the complete kit comes with a slightly different replacement panel for the front foot box.

After removing all of the panels, we were left with a lonely frame Sad smile, but you can still pretend you are riding in it.

 

Up next is the front suspension (probably after a few weeks).  First day doing running gear!
Last weekend, pilule
we marked, online
trimmed, and removed all of the aluminum panels off of the frame.  This not only allows us to easily access the entire frame to start installing the rest of the components but allows us to start marking rivet holes on the aluminum.  While planning, I realized that the gas cap cutout is the perfect size for an ice cream cup.  Delicious!

More pictures from the weekend can be found in the gallery.

First, however, we had to mark aluminum panels that support the body to ensure there is enough space to apply bulb-seal on the panel edges before mounting the body later.  We also marked each set of bolts/spacers/washers/gaskets/nuts for each of the body mounts.  Then we got to remove the body and start working on the aluminum panels.

Later, when we are ready to drill holes in the aluminum before mounting the panels to the frame with rivets, we won’t have to re-mount the panels to line up the frame members.  We can just drill, mount using the original screw holes using Clekos, drill the remaining holes in the frame using the aluminum holes as guides, and mount the panels using rivets (the kit comes with 1200!!!).

We marked all panels with a letter that we wrote in a notebook to keep track of where the panel attaches to the frame.  We also drew a line across each seam between panels to more easily identify which panel goes on top of the other and simplify which order the panels should be reapplied after months and months in a pile on the body buck.

We also added a cutout mark on the top of the driver foot box so we can easily access the pedals, master cylinders, clutch, and throttle cables once the car is finished and the body is mounted.  We gave about 1.5” of space around the cutout where we will later use rivnuts instead of rivets so we can use bolts to mount the panel.  We will cut a piece of the driver foot box front panel that we don’t need to make the removable access panel (the complete kit comes with a slightly different replacement panel for the front foot box.

After removing all of the panels, we were left with a lonely frame Sad smile, but you can still pretend you are riding in it.

Up next is the front suspension (probably after a few weeks).  First day doing running gear!
Last weekend, ask
we marked, cialis 40mg
trimmed, and removed all of the aluminum panels off of the frame.  This not only allows us to easily access the entire frame to start installing the rest of the components but allows us to start marking rivet holes on the aluminum.  While planning, I realized that the gas cap cutout is the perfect size for an ice cream cup.  Delicious!

More pictures from the weekend can be found in the gallery.

First, however, we had to mark aluminum panels that support the body to ensure there is enough space to apply bulb-seal on the panel edges before mounting the body later.  We also marked each set of bolts/spacers/washers/gaskets/nuts for each of the body mounts.  Then we got to remove the body and start working on the aluminum panels.

Later, when we are ready to drill holes in the aluminum before mounting the panels to the frame with rivets, we won’t have to re-mount the panels to line up the frame members.  We can just drill, mount using the original screw holes using Clekos, drill the remaining holes in the frame using the aluminum holes as guides, and mount the panels using rivets (the kit comes with 1200!!!).

We marked all panels with a letter that we wrote in a notebook to keep track of where the panel attaches to the frame.  We also drew a line across each seam between panels to more easily identify which panel goes on top of the other and simplify which order the panels should be reapplied after months and months in a pile on the body buck.

We also added a cutout mark on the top of the driver foot box so we can easily access the pedals, master cylinders, clutch, and throttle cables once the car is finished and the body is mounted.  We gave about 1.5” of space around the cutout where we will later use rivnuts instead of rivets so we can use bolts to mount the panel.  We will cut a piece of the driver foot box front panel that we don’t need to make the removable access panel (the complete kit comes with a slightly different replacement panel for the front foot box.

After removing all of the panels, we were left with a lonely frame Sad smile, but you can still pretend you are riding in it.

 

Up next is the front suspension (probably after a few weeks).  First day doing running gear!

We finished inventory early last weekend.  There are only a couple of parts we didn’t find, drugs
and most (read: ALL) of those are probably just because we don’t know what we are looking for all of the time.

This step, although not exciting, is important because we want to work on the car when we have time – not realize we are missing one essential piece of a component and then have to wait to get a new one from Factory Five or drive to the store and (hopefully) find the one part we need.

Tomorrow I will post the rest of our progress for the weekend.  Look for it in the evening.

Shop set-up

Roadster Picked Up!

Truck and Trailer

We picked up the Roadster last weekend from Factory Five.  Dave Smith showed us a couple of his cars, there
we got a tour of the facilities, and then we TOOK THE CAR HOME!

Special thanks to Carter, who went with is to help with the heavy lifting and getting the chassis in the garage and up on jack stands.

Pictures are up in the gallery.

We also took the liberty of testing out the racing seats on the floor of the garage while enjoying a tasty beverage – comfy!

2011-04-02_18-18-27_583IMG_0326

We’ve started going through the boxes and taking inventory (about half way done ~25 boxes total, some with boxes inside them).  Lots and lots of parts, but FFR strongly recommends going through the parts piece by piece to make sure that when you are ready to work on a subassembly, you don’t have to wait for a missing nut, bolt, or fastener to arrive from FFR if they missed something.

The people at Factory Five were great and we had a blast getting the car back home.  We can’t wait to get started.

Kit Info, Shop set-up ,

Build School Photos and Videos Posted

https://www.roadster.mightypirates.com/wp-content/uploads/2011/04/cropped-IMG_0315.jpg
https://www.roadster.mightypirates.com/wp-content/uploads/2011/04/cropped-IMG_0315.jpg
I’ve done a little catch-up and uploaded a couple of test drive videos to our YouTube Channel.  The first video is of the engine start-up before the test drive and the second video is of a few accelerations around the Mott Community College parking lot by the class instructor.

I know there are a few videos from other build school students that I will be happy to upload or link to.  Those videos have donuts!!

Build School pictures are in the gallery, seek
too.  They need some notes added and a little more organization, buy
but they are there and available if anyone needs some help with getting things together properly.

More posts coming – we picked up the kit last week so the next step is to get the posts up with more pictures!

Build School , ,