Bob's MK4 Build

[BobsMK4]

The first part of my thread did not post for some reason. My name is Bob Safran and I'm from Richmond, Texas. Richmond is a small suburb on the west side of Houston. Ever since I laid my eyes on a Cobra, I wanted one in the worst way. I didn't think that I would ever have the opportunity to own one, but FFR made it possible. After finishing a complete restoration of my 66 Mustang, I needed a new project. A MK4 roadster was the perfect project. After researching kit cars for more than a year, I decided to go with Factory Five. I ordered my complete kit in January 2014 for delivery in May. In April, I attended the FFR Build School up in Michigan. The 3 day school was most excellent and I came away with 5 pages of build tips. I left with having the confidence that I can actually build this car.

If there is anyone in the Houston area that has built an MK4 or MK3, I would like to get together and see your car. I am very much interested in how each and every person has modified their build to their own taste.



I have been reading all the Posted Threads for the last 10 months. I guess it's about time that I take the time to post a Thread of my own. I received my MK4 Complete Kit at the end of May. At this point in time, I've pretty far along in my build. The only part that FFR owes me are the Halibrand Wheels. The only main parts that I need to buy are the battery and tires.

In addition to the complete kit, I added the following options:

SS side exhaust
Wind Wings
Sun Visors
Floormats
Battery Cut-off switch
Chrome Roll Bar
8.8 Rear Axle
Rear Brake Set
Powdered coated Frame
Body Cutouts
Windshield Wiper Kit
SS Front & Rear Bumpers
Halibrand Wheels

I have purchased several additional parts from the various Vendors. I'll just list the main ones in this post because the total list is very long.

Additional Parts:

Engine compartment battery mounting kit
Glove Box
Cubbie Hole
Louvers
Door Panels
Fan Shroud
Radiator cowl cover
Dead pedal kit
Side exhaust heat shields
Hydraulic clutch kit
Gas pedal kit
Seat frames
FFR carpet kit for trunk
Fire extinguisher

I bet you're waiting for the best part "The

[BobsMK4]

I'm sorry about my 1st post. The last part didn't post! The best part is the engine which was built by The Engine Factory. I decided to go with a small block 302 making 350hp. The engine is absolutely beautiful. I'll add pics on a later post. I want to thank all you guys for the many posts of your builds and the ideas they gave me for my build.

Merry Christmas,
Bob Safran

[2FAST4U]

http://i23.photobucket.com/albums/b373/GT40_Bill/imagejpg1_zpsc6ddde33.jpg (http://s23.photobucket.com/user/GT40_Bill/media/imagejpg1_zpsc6ddde33.jpg.html)

[BobsMK4]

3678336782

[2FAST4U]

Now we're talking. Looks great!!

[BobsMK4]

Here are more pics from my build.36804

[rmiller64]

Nice Job Bob It looks great!

[BobsMK4]

Found more pics of my build!

[2FAST4U]

Excellent! I really like the black panels with contrasting rivets.

[seagull81]

Bob,
Very nice work. Thanks for the pictures.
That aluminum stiffener at the top of the dash, is it screwed or riveted to the front firewall? I hope screwed. You might want to remove the dash at some point in the future.

[BobsMK4]

The center dash brace is screwed to the firewall. I have more pictures for your viewing pleasure. The engine bay is just about ready for the engine to be installed. Hopefully that will be be soon. Once I receive my 6 month back ordered wheels from Factory Five, I can move the chassis into position to install the engine. Until then, I keep busy working on the body mockup of the lights, gas filler assemble, vents and Louvers.

[edwardb]

Your build is looking great. One comment. I notice your fresh air vent hoses going from the F panel to the foot box. Through the area where the exhaust headers will be located. Last year at the London show a guy parked in front of me with his brand new Mk4. He mentioned that his fresh air vents started to blow hot air during the drive over. We looked, and the bottom of the hoses were melted through from heat radiating up from the headers. I don't know any details, but just thought I would suggest you keep those up as high as you can and as far away from the headers as possible.

[BobsMK4]

I am also worried about the material of the vent hose. I realize that it will be fairly close to the exhaust header on the drivers side. I have been looking for a different hose material that will with stand a higher temperature. Thanks for the concern!

[DaleG]

You could wrap the hoses with exhaust wrap' should do the job, and won't show: http://www.summitracing.com/search/part-type/exhaust-wrap?SortBy=Default&SortOrder=Ascending&tw=exhaust%20wrap&sw=Exhaust%20Wrap.

[BobsMK4]

I looked at high temp hose that's good for 550 degrees. For 12 ft of hose, it's rather pricey at $80 to $120. However, I think it's the safest way to go. I might even wrap the exhaust headers in that area near the body. The hose that comes with the fresh air kit is too flimsy to wrap. Thanks for the tip.

[DaleG]

36932I think Earl's vents come in two different hose options, one heavier duty than the other; I have the heavier duty option, I believe.

[BobsMK4]

36932I think Earl's vents come in two different hose options, one heavier duty than the other; I have the heavier duty option, I believe.

I wasn't aware there was a choice in the type of hose material that was included in the fresh air kit provided by Cobra Earl. I have sent Earl an email and asked him what maximum temperature the hose is good too. At this time, I'll just leave the hoses that I have for mockup purposes.

[MPTech]

Bob, I'm currently re-doing my vent hose (whoever said you can mount the vent on the top of the MK4 DS footbox without a serious modification was incorrect!). I've re-located it to the front of the DS footbox similar to your posts and I'm also concerned about the heat. Don't want to melt the hose and don't want to heat up my cool / fresh air!
I'm considering fabricating an aluminum heat shield coming off of the lower 3/4" frame, and installing a second piece of aluminum on that to create an air-gap and better support the tubing, so it't not flopping around.
I'll be making a cardboard template and cutting it out of some scrap aluminum this week.
May be a little over-kill, but better safe than sorry. Once you get the body on, accessing / replacing this tubing is a pain.

Great progress on the build, keep us posted. And thanks for the PICs, always enjoy seeing what others have done. I think this makes everyone's builds better!

[BobsMK4]

Bob, I'm currently re-doing my vent hose (whoever said you can mount the vent on the top of the MK4 DS footbox without a serious modification was incorrect!). I've re-located it to the front of the DS footbox similar to your posts and I'm also concerned about the heat. Don't want to melt the hose and don't want to heat up my cool / fresh air!
I'm considering fabricating an aluminum heat shield coming off of the lower 3/4" frame, and installing a second piece of aluminum on that to create an air-gap and better support the tubing, so it't not flopping around.
I'll be making a cardboard template and cutting it out of some scrap aluminum this week.
May be a little over-kill, but better safe than sorry. Once you get the body on, accessing / replacing this tubing is a pain.

Great progress on the build, keep us posted. And thanks for the PICs, always enjoy seeing what others have done. I think this makes everyone's builds better!

I don't think it's over kill. It's better to be safe than sorry! Please post some pictures when you get your design worked out. I'll decide what to do with mine after I get my engine and headers installed.

[BobsMK4]

Until I get my wheels and can move the car into position to install the engine, I've been keeping busy test fitting the headlights, parking lights, front vents, emblems, Louvers, gas cap assembly, tail lights, license plate light and trunk latch. I also enlarged the holes for the front and rear bumper grommets.

[Sed Temple]

Bob
I am very new on this site and have been following your very impressive progress, i am building a FFR Mk4 with a Coyote & IRS down in the Dominican Republic, unfortunately i do not have the resources down here or the ease of nipping down to the local auto parts shops for items - i was wondering if you were to be so kind to forward some info on some of your additional parts such as the fresh air kit, side exhaust shields & glove box - namely brief specs and where your purchased them? Sorry to be a pain, any help would be much appreciated!

Cheers
Sed

[MPTech]

Absolutely impressive build and progress! (no way you just got your kit this month!!?? holy sh!+ (never mind I see you've been at it since May, STILL Impressive progress)

Anyway, I see you're doing the front bumper mod, good choice & highly recommend. Don't know if you were planning it, but there is also a rear bumper mod (makes removing the bumpers and body MUCH easier! and a license plate mod (so you can mount a standard / American plate (unless you plan to run Euro plates :eek:)

Have you seen all of the mods / build info on the other site? There is a wealth of info there! (Looks like you also did the PS FB mod, that's a great one that your passengers will REALLY appreciate, but they don't know it!! :cool:)

I'm going to try to finish up my DS Fresh-air vent re-do this week, I'll try to post some picks with the heat-shield. Nothing fancy, but I do tend to over-think and over-build all of my projects. Hey, it's what I LIKE to do. :p

[MPTech]

.. some info on some of your additional parts such as the fresh air kit, side exhaust shields & glove box - namely brief specs and where your purchased them?

there may be more sources:
fresh air kit: Cobra Earl CobraEarl.com (http://www.cobraearl.com/products/) Complete Touring FootBox Fresh Air Vent System with an additional cable set and Hard side style Hose - Please specify brake duct boots - $207 Shipping included

side exhaust shields - DrummerMike on the FFcars forum, PM him (do a search for examples and many great reviews / recommendations)

glove box - Alex Glovebox Alex's Custom Roadster Interiors (http://acroadsterinteriors.com/Index.html) order well in advance, may take a while, but worth the wait!

[DaleG]

Also, peruse the site's of these commonly used forum Vendors for a start: Check-out the "VENDORS button at the top of the page for more.

http://www.ffmetal.com/
http://www.breezeautomotive.com/search.php?search=35201
http://www.darkwatercustoms.com/
http://www.**********accessories.com/catalog/
http://www.norcal-cobras.com/store/russ_garage/russ_garage.htm
http://www.whitbymotorsports.com/UInvList.asp
http://www.replicaparts.com/

[BobsMK4]

Absolutely impressive build and progress! (no way you just got your kit this month!!?? holy sh!+ (never mind I see you've been at it since May, STILL Impressive progress)

Anyway, I see you're doing the front bumper mod, good choice & highly recommend. Don't know if you were planning it, but there is also a rear bumper mod (makes removing the bumpers and body MUCH easier! and a license plate mod (so you can mount a standard / American plate (unless you plan to run Euro plates :eek:)

Have you seen all of the mods / build info on the other site? There is a wealth of info there! (Looks like you also did the PS FB mod, that's a great one that your passengers will REALLY appreciate, but they don't know it!! :cool:)

I'm going to try to finish up my DS Fresh-air vent re-do this week, I'll try to post some picks with the heat-shield. Nothing fancy, but I do tend to over-think and over-build all of my projects. Hey, it's what I LIKE to do. :p

I went ahead and ordered on EBay 3"x12ft high temp (550 deg) silicon flex duct for $59.95 + $20 shipping. This substantially less then high temp hose that I've found so far.

I also did the rear bumper grommets mod as well. I'm at a quantry as to what to do with the rear license plate. So far I have not decided to do the license plate mod. I did take an old plate and drilled a hole in it to see how it would look. Although it is probably illegal, I like the best.

[BobsMK4]

Bob
I am very new on this site and have been following your very impressive progress, i am building a FFR Mk4 with a Coyote & IRS down in the Dominican Republic, unfortunately i do not have the resources down here or the ease of nipping down to the local auto parts shops for items - i was wondering if you were to be so kind to forward some info on some of your additional parts such as the fresh air kit, side exhaust shields & glove box - namely brief specs and where your purchased them? Sorry to be a pain, any help would be much appreciated!

Cheers
Sed

I purchased most of my parts from ********** accessories and Breeze Automotive. They both have a wide range of parts that you can modify your MK4. For fresh air kit and glove box, see below post.

[CraigS]

That looks like the simplist license plate mod of all. I realize that in many/most states modifying a license plate is technically illegal. But, I think that if you use your head, make the mod as invisible as possible, don't cover the plate w/ one of those plastic things you will probably be fine. Looking at yours, you could probably trim the white edge off all the way around. That would gain you at least 1/2 an inch and no one would notice unless parked next to another car. Then a small half circle notch to clear the shank of the handle and you'd be good. I am not sure that covering that much plate w/ the entire base of the handle is a good idea though.

[BobsMK4]

That looks like the simplist license plate mod of all. I realize that in many/most states modifying a license plate is technically illegal. But, I think that if you use your head, make the mod as invisible as possible, don't cover the plate w/ one of those plastic things you will probably be fine. Looking at yours, you could probably trim the white edge off all the way around. That would gain you at least 1/2 an inch and no one would notice unless parked next to another car. Then a small half circle notch to clear the shank of the handle and you'd be good. I am not sure that covering that much plate w/ the entire base of the handle is a good idea though.

I'll try trimming another old license plate to see what that's going to look like. I just don't like the modified version with the plate resting on the trunk handle.

[MPTech]

I did the license plate mod (via Jeff Kleiner) and added a slightly modified Shelby plate frame. I cut the center section out to set up higher and around the plate light and trimmed the plate slightly on the bottom to set above the trunk handle (the Shelby frame had a slight moon-cutout to go around the trunk handle as well.

http://i9.photobucket.com/albums/a78/MPTech/IMG_2803_2_zps2e3479b2.jpg

[CraigS]

I saw another that I thought was a good one but can't find a pic right so I'll try to describe it. He cut an aluminum plate that was the shape of the light assembly and then added an inch or so below. Screwed the plate to the trunk in the standard hoes in the lid and then screwed the light to the plate. This allowed him to move the light up just enough to clear the plate.

[BobsMK4]

I did the license plate mod (via Jeff Kleiner) and added a slightly modified Shelby plate frame. I cut the center section out to set up higher and around the plate light and trimmed the plate slightly on the bottom to set above the trunk handle (the Shelby frame had a slight moon-cutout to go around the trunk handle as well.

http://i9.photobucket.com/albums/a78/MPTech/IMG_2803_2_zps2e3479b2.jpg
Your plate modification looks really good. I have plenty of old plates to experiment on. Can you post closer pictures of both the light and trunk handle?

[MPTech]

Sure! What do you want to see?

[BobsMK4]

I was able to zoom in enough to see how you notched the bottom of the plate cover. It certainly is better than having the plate sit on top of the trunk handle. I don't need any more pictures. Thanks!

[pcww]

The license plate with the notch is available here: http://hillbankmotorsports.com/shelby-50th-license-plate-frame-en.html
This looks like a good solution. Comments?

[BobsMK4]

I don't think it's over kill. It's better to be safe than sorry! Please post some pictures when you get your design worked out. I'll decide what to do with mine after I get my engine and headers installed.

I went ahead and replaced the thin vinyl hose that came with the Fresh Air Kit with a heavier high temp silicon hose good for up to 550 degrees. I still plan to fabricate and install an insulated aluminum plate on the drivers side between the exhaust header and the 3" fresh air hose. This should make it safe enough that the heat from the exhaust header will not melt or possibly catch on fire.

[Sed Temple]

Outstanding - thanks

[BobsMK4]

I have a question regarding the size of the fuel line. The FFR complete kit provided a 5/16" diameter fuel line. My engine is a small block 302 with 350 hp. It has an Edelbrock 650CFM carburetor. According to The Engine Factory, they recommend a 3/8" diameter fuel line. Earlier in my build. I installed the FFR provided 5/16" diameter fuel line. I'm hoping that wasn't a mistake and I have to switch it out.

[edwardb]

Assume you're describing a mechanical fuel pump without a return line. I had a much warmer 306 on my Mk3 with the stock 5/16 FFR line. Never a problem. I would leave it.

Now that Edel carb on the other hand...

[BobsMK4]

Thanks for the advice. Yes the engine has a mechanical fuel pump with no return line. What don't you like about an Edelbrock carb?

[edwardb]

Thanks for the advice. Yes the engine has a mechanical fuel pump with no return line. What don't you like about an Edelbrock carb?

I personally don't have any experience with them, so take this response accordingly. I have read a number of threads on the other forum about guys trying to get them to run well on these cars. Seems to be not the best fit for the light weight, quick acceleration and turns, etc. But some still stick up for them. Hope it works out for you.

[BobsMK4]

After deciding on how I was going to modify my license plate light, I finally finished it today. I went with the notched light with LED lights. I had to notch the bottom of the plate just a 1/4". I was pleased with the outcome.