What was your most challenge part of your build(s)???

[Gmcole92]

I'm a couple weeks in and enjoying it immensely. I have had several small challenges to navigate but nothing that I haven't figured out. I have also done a couple dumb things that I will NOT repeat. I got thinking about what parts are going to prove to be the most challenging...

What were the top 2 or 3 challenges in your build? Where am I (a dude with no car experience) going to get really tripped up?

[jakester888]

Pedal disassembly from the donor. OMG. Pretzel shape contortion required to get that donor part out.
Second would be rear coil over spring install on the roadster - made me nervous and I could have easily lost an eye or limb doing it the way I did.

[Gumball]

In no particular order, the top three challenges during my build (which is weeks from being done) were:

Building my engine - first time I'd done that in over 35 years (and back then, it was with a shop teacher looking over my shoulder)
Bodywork - I never did that in my life... taught myself with a few books and lots of help from this and ffcars.com
Wiring - Like bodywork, I'd never done any wiring, so I had to learn everything from the basics on up.

[jakester888]

Wiring - Like bodywork, I'd never done any wiring, so I had to learn everything from the basics on up.

Have to agree on the wiring. I attempted to use the donor harness but found it impossible to figure out how to do it. I ended up spending money on the FFR chassis harness & Chuck's Electrics engine harness to replace the donor harness.

[Jeff Kleiner]

Different experience levels will result in different perceptions of what is or isn't "challenging". I've played with cars since before I was old enough to drive, worked on them as a hobby as well as for a living, modified and raced 'em, done restoration work and built street rod/hot rods from the ground up so can honestly say that I don't find building these cars especially challenging. For someone venturing into new territory I can certainly understand how they could feel challenged or intimidated though. Judging strictly by what I've observed on these forums over the years I think most builders who enter into it as "a dude with no car experience" probably find that plumbing (brakes, fuel, cooling system) and electrical are their biggest stumbling blocks. As an aside I recommend that the guys who don't have a great deal of experience find a build buddy nearby, ideally one who has done an FFR, to check up on your work every once in a while just to be sure you 're not leaving any booby traps for yourself. Sometimes the most dangerous thing is when you are like that old saying and "don't know enough to know what you don't know".

Good luck with your build!

Jeff

[stroked 6t5]

Hi all,
For me, being Canadian it was the wait. We had a depreciated dollar for years at about 35% so I can say the wait until 2011 when we were close to par was hell. I had always wanted a roadster but could't justify the upcharge. When the time came I was lucky enough to get the kit on sale and most of the parts as close to par as possible. Best model ever...
Regards,
Andy

[Gmcole92]

Jeff - you nailed my concerns. The wiring is top of my list...just fear of the unknown. The fuel system is probably second. Luckily I'm buying a crate engine and don't have to get into too much around the motor/trans...

[christenfreedman]

How about actually spending what I told my wife it would cost...Not going to happen!:)

[2bking]

X2 on the budget as being the most challenging. I quit adding-there are just some things you have to have regardless.

[frankb]

Like Jeff Kleiner, I have played with cars since before Moses freed the Jewish people from the Egyptians! My last experience was the complete restoration of a '70 Mustang that I sold to finance my roadster project. I am currently about halfway through the aluminum panel mounting and my biggest challenge so far is controlling my enthusiasm...that is keeping myself from working too fast! I need to be sure that I do this right the first time!

[edwardb]

Based on forum traffic and the kinds of questions asked, I have to think wiring is probably one of the most challenging aspects as some have said. Honestly, it's pretty basic electrical concepts which if you understand and can read a schematic, it's not that bad. But many struggle with it. Both of my builds have been with aftermarket harnesses, and just took it slow and easy checking each circuit with a light and/or continuity checker as I went. So minimal smoke and only a couple blown fuses. If someone isn't too comfortable with the concepts though, plus some creativity is required because the harness and gauges aren't quite plug and play (two different sets of instructions which don't exactly match), it can be challenging. I haven't tried working with a donor harness. Probably wouldn't go there myself.

[Norm B]

I don't know if the manual has changed since mine (7721) but some of the steps seemed out of order. For example, installing the rear cockpit aluminum before the upper trunk floor makes it nearly impossible to drill the front holes for the floor. I found that reading ahead in the manual and consulting the forum was important. My biggest challenge was curbing my enthusiasm and not going too fast. My high school shop teacher had a saying "why is there never time to do something right the first time but, always time to do it over". I lived that more than once during this project.

Norm

PS I painted it myself and that nearly did me in!

[rmcmicki]

Jeff's quote says a lot about where i struggled "don't know enough to know what you don't know". My wife once asked, so how do you know the tire wont go flying off when you are on the highway? Ummm no answer for that!

Also sticking to some sort of budget when all the cool shiny stuff shows up on the forum that you just have to have.

[emac]

I agree on the wiring. Yes, it is basic electrical, but people are using different gauges and want fan switches wired different, so you get some head scratching when you are wiring. Plus, I didnt find the manual very clear on several wiring sections.

[fordboy]

X2 on Jeff Kleiner suggestion to find a build buddy if you are a real novice. The added confidence of having an experienced gear head looking over your shoulder when you need it (and especially when you think you don't but really do) along with the great guys on this forum to go to for info is invaluable. The handful of guys that monitor this forum and offer tremendous advice, tips and mods are great resources.

[pc12cvs]

I'll agree with the trends here (for guys that aren't extensively experienced). The wiring seemed daunting, but if you take it one step (wire) at a time, eventually you'll see the light at the end, and with a little luck things will work out. As far as staying on budget, well, my initial estimates went out the window pretty fast. But it's your project, you're going to make it exactly the way you want it.

I'll offer an aside for some folks to laugh at/with me though: I took two entire weekends trying to get the pumpkin into position for the IRS. It was the 8.8 Ford Racing diff that FFR provided with the IRS completion kit. Powder coated frame, maybe a little over on the tolerances for the diff housing and I found the true meaning of perseverance. Tried all the tricks talked about in the Forum, followed the recommended approach in the manual. Even used an engine hoist trying to pull it through. Grinded on it for a bit too. Just didn't work. Finally, I pulled the girdle off (which I was hesitant to do because I didn't want to break the factory seal on a brand new diff), but I did it as a last resort. Leaned over the chassis rails and raised the pumpkin up by hand in about 8 seconds.

Needless to say, several beers were had after that...

Noel

[skullandbones]

I guess most people don't do their on bodywork so that will not be a consideration for the masses. If everybody did their own bodywork, I would say the wiring would take a very distant second place in difficulty. The problem with the body work is that it has a learning curve around eye hand coordination, judgment on whether something is flat or curved depending on what you are trying for, and all sorts of other nuances that take time and trial/error experience. I'm still in the middle of it. It's getting to feel better as I go along with the process but still there are ups and downs in the process depending on the day. I think patience is the most useful virtue for this task with persistence running a close second.

Good luck,

WEK.