Chris' 289 FIA build, #8833

[cnutting]

I picked up my 289 kit yesterday with the help of Mike Forte (thanks for the help Mike!). Everyone at FFR was great, and my pickup went very smooth. We also got to spend some time chatting with Dave Smith about a whole host of topics; mainly old cars, engines and other war stories. Next step is to organize and inventory everything. This will be next weekend since our daughter had an all day volleyball tournament today (her team won!).

More to follow...

[Mark Dougherty]

I'll be watching this one
Love the FIA

[Erik W. Treves]

Welcome to our little group :)

[WIS89]

Awesome! Can't wait to watch your build.

Please keep us posted on your progress.

Love the 289s!!

Regards,

Steve

[cnutting]

Thanks for the welcome. Attached are some pics from the pickup and after getting settled in the garage.
Mike Forte will be building up a '66 289 block with a Tremec TKO-600.

http://thefactoryfiveforum.com/attachment.php?attachmentid=51469&d=1457659545
http://thefactoryfiveforum.com/attachment.php?attachmentid=51472&d=1457659548
http://thefactoryfiveforum.com/attachment.php?attachmentid=51471&d=1457659547
http://thefactoryfiveforum.com/attachment.php?attachmentid=51470&d=1457659546

[2FAST4U]

Very cool. Welcome into the fold

Bill

[cnutting]

Most of this weekend was spent on inventory. I put the box contents into sheet protectors taped to each box. The we took the body off the frame and moved a workbench in between to lay out parts and sort hardware. Final step was taking off the aluminum panels. Our daughter did this while I flipped the plates on the UCAs and assembled the ball joints. The tolerances on those ball joints vary quite a bit; one threaded right in by hand, the other was a snug fit. Still had no problem seating it though.

Waiting on my LCAs to really start in on the assembly.

http://thefactoryfiveforum.com/attachment.php?attachmentid=51500&d=1457910862

http://thefactoryfiveforum.com/attachment.php?attachmentid=51498&d=1457910860

http://thefactoryfiveforum.com/attachment.php?attachmentid=51499&d=1457910861

[2FAST4U]

Looking like a great start

[ehansen007]

Welcome to the gang Chris! Time to nutt it up! Not sure why the LCAs are still a problem?

[cnutting]

Welcome to the gang Chris! Time to nutt it up! Not sure why the LCAs are still a problem?

I got some info on delivery of my back-order parts. They should all be in over the next couple of weeks. Rearend is due next week. In the meanwhile I have been test fitting the parts I do have. Assembled the front shocks, did a bunch of deburring/chamfering of spacers, chased some threads and applied anti-seize to the adjusters. I will assemble everything loosely, check the fits and then go back and torque once I'm happy with everything.

Probably start some of the drilling/deburring of the aluminum panels this weekend.

[cnutting]

I picked up my LCAs and a bunch of other parts. Installed everything, but something seems off:

http://thefactoryfiveforum.com/attachment.php?attachmentid=52052&d=1459024683

The adjusters on the upper control arms are in the same position, fully screwed in, but the spindles are pointed in different directions. One up, one down. If the adjusters are in the same position, shouldn't both spindles be angled roughly the same way? Am I missing something obvious?

Chris

[NukeMMC]

Measure the LCA leg lengths from bolt center to grease fitting and make sure they sent you a pair of the same length, not 1 standard width and 1 pin drive.

[cnutting]

Measure the LCA leg lengths from bolt center to grease fitting and make sure they sent you a pair of the same length, not 1 standard width and 1 pin drive.

Didn't even consider that... I checked all the mounting holes several times, but kept looking at the LCAs and something didn't look right.

Rough measurements say they are off by about an inch, so... looks like we have a winner.

Thanks Bruce!

[cnutting]

I received the correct LCA about a week ago as well as my sway bar which was on back-order. Everything is now assembled, torqued and marked. Looks much better now.

http://thefactoryfiveforum.com/attachment.php?attachmentid=52586&d=1460297372

I also received my rear axle. I will be using the three link, test fitting brackets now. I also am waiting for the brake brackets to cure, those were painted with POR-15. I haven't used this before, nice stuff.

http://thefactoryfiveforum.com/attachment.php?attachmentid=52588&d=1460297374

[WIS89]

Chris-

Things are looking good. You are right about POR-15, that stuff is BOSS!

Nice progress. I love watching the 289 FIA builds!

Regards,

Steve

[2FAST4U]

Excellent. I should have waited a bit longer and bought one instead of the nightmare is going thru

[cnutting]

Back from vacation and spent some time in the garage this weekend, boy did I make a lot of progress. That should have been the first warning sign....

I assembled the rear axle and incorporated some suggestions for the banana bracket. I ground off all the powder coating the mating surfaces, plus the exterior of cap, as well as on both sides of the cap. After talking with Jim from FFR, I decided to weld only the cap to the axle, the banana bracket will be bolted in place. I won't be running a lot of horsepower, this should be sufficient to prevent movement. Setting up time with the welder this week, then clean up, POR-15 and bolt in place hopefully this weekend.

http://thefactoryfiveforum.com/attachment.php?attachmentid=53496&d=1462234244

With that tackled, I decided to move on to the steering.

http://thefactoryfiveforum.com/attachment.php?attachmentid=53497&d=1462234245

http://thefactoryfiveforum.com/attachment.php?attachmentid=53498&d=1462234246

Zipping right along, get everything bolted in, go to align the tie rod ends and what? Ball joint stud doesn't fit quite right in the bracket? Could it be... Yep. Dummy installed them with the taper upside down. Off with the front brakes and hubs to resolve this and wham, rounded one of the front caliper attachment bolts during disassembly.

At this point I decided to listen to the manual and stop working because man was I frustrated. Nothing better than self-inflicted misery. So, grabbed a couple double IPAs and cleaned the garage instead. I'll fix it this weekend.

Chris

[2FAST4U]

Looking great!

[Mark Dougherty]

P/m sent
on progress

[jolsen42]

Excellent. I should have waited a bit longer and bought one instead of the nightmare is going thru

Oh puleese, You're kidding right. What did you expect? Yours will be so much more realistic than the Fact Five. That's the fun of doing what you are doing and what I did. Solving problems and creating a very unique and special replica. You've had some set backs, but you've beautifully solved them. SUCK IT UP. :mad: It seems The more things change, the more they stay the same. :(

John O

[WIS89]

Excellent. I should have waited a bit longer and bought one instead of the nightmare is going thru

C'mon now. I know you have had some frustration, but your build skills are amazing! Your build is truly special, and in it's own class.

I certainly appreciate your frustration, but I am blown away by your progress and skills!

Hang tough, I know it will be worth it!!

Regards,

Steve

[cnutting]

Quick update from last weekend. The welder came over and welded the cap for the banana bracket.
http://thefactoryfiveforum.com/attachment.php?attachmentid=53496&d=1462234244

Then, after some cosmetics and touch-up with POR-15 we lifted and installed the axle. Maneuvering the axle a little this way, then a little that way, a little up, a little down... hold it... bolts in. Yay! Then bolted up the rear shocks and panhard bar.
http://thefactoryfiveforum.com/attachment.php?attachmentid=54391&d=1464385497

Wow, starting to really look like something!
http://thefactoryfiveforum.com/attachment.php?attachmentid=54392&d=1464385498

Also finished off the pedal box, but alas no pictures. So... did it really happen??

This weekend, in between cookouts, I'll install the fuel tank and start routing brake and fuel lines.

[2FAST4U]

Looking great. Keep the pics coming

[cnutting]

This weekend was spent on fuel/brake lines as well as fitting aluminum panels (the instrument panel is just placed for giggles and some small motivation....).

http://thefactoryfiveforum.com/attachment.php?attachmentid=54614&d=1465176350

A little closer....

[2FAST4U]

Excellent progress

[cnutting]

Filled and bled the brakes today, used a combination vacuum bleeder and the more traditional method. Pedal travel is ~1" then hard as a rock. Held the pedal for a couple minutes with no change in feel. I'd say we are good.
Riveted the passenger side aluminum as well. I'm leaving the panels natural, going for the simple look. Other than cleaning off markings and major scratches I will let them form a natural patina. Will hopefully finish off the drivers side (minus the outer footbox panels) tomorrow.
Next on the agenda is cable runs. Could also use a little guidance on the 289 filler neck. The supplemental instructions are a bit light here. Same with the rollbar.

Oh yeah... Also centered the rear end today. Put a square on the inner surface of the rear rims and measured to the 4" frame tubes. Adjusted until both sides were within ~1/16" of each other. Sound about right?
Tires due next week, then off to get them mounted and balanced.

[2FAST4U]

Fantastic progress. What tires and rims?

Bill D

[cnutting]

15" FFR Halibrand-style rims and Cooper Cobra tires. One of my must-haves were the raised white letter tires and 15" rims. But... to keep things DOT for Mass (and to keep the budget in line) I went with the Coopers. 245 front and 275 rear. Some day I may switch to the Goodyear polyglas, hopefully at the same time that I make the switch to the more traditional Weber intake...

[cnutting]

So this past weekend fixed an interference issue I had with the rear brakes as well as finishing off the cockpit aluminum. I left the rear wall off until I get the trunk aluminum done. Started in on wiring, I think this step will require lots of thinking and contemplation with some nice double IPAs...

http://thefactoryfiveforum.com/attachment.php?attachmentid=55839&d=1467846684

[2FAST4U]

Looking fantastic!!

[ehansen007]

15" FFR Halibrand-style rims and Cooper Cobra tires. One of my must-haves were the raised white letter tires and 15" rims. But... to keep things DOT for Mass (and to keep the budget in line) I went with the Coopers. 245 front and 275 rear. Some day I may switch to the Goodyear polyglas, hopefully at the same time that I make the switch to the more traditional Weber intake...

Well, get out that die grinder and some cookie pads and make your own tires with raised lettering son!


http://i897.photobucket.com/albums/ac177/ehansen007/289%20Build/A48F0944-12C8-4591-819A-96428F64436C_zps1qsk966a.jpg (http://s897.photobucket.com/user/ehansen007/media/289%20Build/A48F0944-12C8-4591-819A-96428F64436C_zps1qsk966a.jpg.html)

[David Hodgkins]

Well, get out that die grinder and some cookie pads and make your own tires with raised lettering son!


http://i897.photobucket.com/albums/ac177/ehansen007/289%20Build/A48F0944-12C8-4591-819A-96428F64436C_zps1qsk966a.jpg (http://s897.photobucket.com/user/ehansen007/media/289%20Build/A48F0944-12C8-4591-819A-96428F64436C_zps1qsk966a.jpg.html)

Showoff.

:)

[cnutting]

Nice! Mine would probably end up saying Goodyear Eagel on at least one of the tires....

[ehansen007]

Ha! I actually missed the foot with the wings on one tire. But nobody knows so don't say anything.. ;)

[michael pavon]

Really nice tires!
car looking great!
Best of luck :)

[Kennyr]

Nice lift. Is that a Bendpak MD-6XP? If so, what do you think of it?

Sorry to hijack the thread...

[cnutting]

Not much going on the last couple of weeks. I have a midterm exam due Sunday and that's pushed off car work. But, this gives me time to think about what's next. One of these tasks is the fuel filler routing. The kit from FFR has a combination of metal and (thin wall) rubber tubes to make up the filler neck. I'm thinking of just replacing the 289 parts with this:

http://thefactoryfiveforum.com/attachment.php?attachmentid=56241&d=1468630197

It will simplify things, but am I missing something important here...?

[cnutting]

Back at it after a couple weekends off to tend to school commitments. So close to being done I can taste it.
Went through the boxes to start in on cabling and what did I spy? A length of 2" softwall tubing. Thanks FFR! Now I can splice the 289 filler much easier.

Finished routing cables today. Seems fairly straightforward, but I'm sure that statement will come back to bite me. After that was don I started fitting aluminum in the trunk, those will get drilled and riveted tomorrow, then the rear cockpit wall. Also was test fitting the dash. I think this is going to come down to a balance between centering the steering shaft best I can against how much of the aluminum sticks up and where. First step was centering the dash, keeping the gauges as horizontal as possible:

http://thefactoryfiveforum.com/attachment.php?attachmentid=56949&d=1469923095

Then it was dropping the corners to the frame. Passenger side seems ok:

http://thefactoryfiveforum.com/attachment.php?attachmentid=56954&d=1469923099

http://thefactoryfiveforum.com/attachment.php?attachmentid=56953&d=1469923098

Middle seems ok based on what I have read:

http://thefactoryfiveforum.com/attachment.php?attachmentid=56948&d=1469923095


Drivers side seems high (maybe)?

http://thefactoryfiveforum.com/attachment.php?attachmentid=56950&d=1469923096

http://thefactoryfiveforum.com/attachment.php?attachmentid=56951&d=1469923097

What does the body actually sit on when mounted? Am I ok here, do I need to trim things? Can't really drop the DS without impinging on the steering shaft.

As a little motivation I popped in some gauges, switches and the dash support just to get a feel how it will look. Need to finalize placement of everything.

http://thefactoryfiveforum.com/attachment.php?attachmentid=56952&d=1469923098

Crappy cell phone picture, ugh.

[2FAST4U]

Beautiful. A truly inspiring build

[cnutting]

In between school assignments and family activities, I was able to run all the cables and button up the trunk and cockpit aluminum (note: the transmission tunnel cover is not riveted in yet, just placed):

http://thefactoryfiveforum.com/attachment.php?attachmentid=57521&d=1471196649

http://thefactoryfiveforum.com/attachment.php?attachmentid=57519&d=1471196648

While waiting for the engine and transmission, I assembled the dash. Fairly straightforward, gluing the dash pad down was easier than expected. After that I added the gauges and a Shelby badge. I was going to use the FFR supplied one, but his caught my eye and I went with it:

http://thefactoryfiveforum.com/attachment.php?attachmentid=57520&d=1471196649

http://thefactoryfiveforum.com/attachment.php?attachmentid=57518&d=1471196647

For further inspiration I put the seats in (not permanent yet). I went with the Kirkey low-back for the driver and the standard seat for the passenger. I will be putting in a seat track on the driver's side so our daughter can drive it too. She helped build, she gets to drive... Of course I then had to put the wheel on, just to fit check of course...

http://thefactoryfiveforum.com/attachment.php?attachmentid=57517&d=1471196646

http://thefactoryfiveforum.com/attachment.php?attachmentid=57516&d=1471196644

[WIS89]

Looks great Chris, nice work!

I like your seat choice. I think that the FIA cars look nice with the seats that way.

Nice progress!

Regards,

Steve

[ehansen007]

Looking good man! Keep it up.

[cnutting]

Thanks guys! After all the blood, sweat and curse words, it's nice to see this starting to look like what I imagined.

[ehansen007]

You may want to ditch those stock brake pads for something that works. I'm in the middle of this right now and I can tell you that ceramics aren't much better. I'm going to try the Napa Semi-Metallics next. I'll report back. I would go with my tried and true brake motiv setup which use cross drilled, slotted rotors with ceramics which work awesome but you'd see it though the wheels and it wouldn't look period correct.

[cnutting]

I already switched to the Hawk pads. Will those be good for regular driving with the occasional "spirited" outing?

[ehansen007]

I'm sure they will.

[Erik W. Treves]

Hawks will be nice! Mine made a huge difference

[cnutting]

Stopped by Mike Forte's yesterday and he has my engine block back from cleaning an inspection. Next up is machining and assembly. With that, time to get back into things in the garage to get ready for engine and transmission install. First up was prep on the side pipes. A little solvent and scotch-bright really brought out the stainless shine. Of course I then had to paint them... black.

http://thefactoryfiveforum.com/attachment.php?attachmentid=57912&d=1472348074

After that was wiring of the dash. It looks like I will be ditching the RF dash harness and sender harness as the 289 gauges have their own connectors. Very straightforward, probably just a couple splices into the main RF harness. After that I thought I would test fit the roll bar. The 289 supplemental instructions are vague at best, but once you see the parts, it's pretty obvious. My one suggestion to FFR (Courtnie, Dan??) is to update the instructions to mark and drill the 2" frame member and cut the floor pan before mounting the aluminum. Seems easier that way.

The forward bar doesn't intrude much on the passenger side and may make entry/exit a bit easier.

http://thefactoryfiveforum.com/attachment.php?attachmentid=57911&d=1472348074

http://thefactoryfiveforum.com/attachment.php?attachmentid=57910&d=1472348073

http://thefactoryfiveforum.com/attachment.php?attachmentid=57909&d=1472348072

[cnutting]

Not much to show, but I *think* I'm in the home stretch for wiring. When we last left off I was ditching the RF dash harness and sender harness. Turns out I needed some of the dash harness so I ended up dissecting everything to incorporate all the changes:
* 289 FIA gauges
* Foot actuated high-beam switch
* 289 tail lights (need to splice in the FFR supplied trailer converter since the wiring on the tail lights is different than the MkIV)
* Power feed for the side marker lights

Fortunately the schematic is very comprehensive. I also connectorized the tail lights with weather packs. Next weekend will be connectors on the headlights, front turn signals and the side markers. Then I'm ready to put some test voltage into the system to make sure everything works, then fix whatever needs fixin'. Hopefully the magic smoke will not be released from the system...

[WIS89]

Chris-

Best of luck as you wrap up your electrical work. More importantly, here's to hoping there's no "magic smoke!!" Thanks for the laugh at the magic smoke comment -- good stuff!

Car looks great, and I have enjoyed following along.

Regards,

Steve

[cnutting]

No magic smoke, but some strange results that I need to track down. Couple tools, some more weatherpak connectors and upgrade parts showed up and well... you know how that goes....

http://thefactoryfiveforum.com/attachment.php?attachmentid=58827&d=1474414811

[2FAST4U]

Your car is so cool looking. Can't wait to see the finished product

[Raceral]

Very nice build... clean and neat.

[cnutting]

Thanks guys. Dropped out for a bit, I'm in my last class at school, scheduled to graduate in December and trying to not get distracted which is tough with a FFR in the garage. Here is a quick update.

The end of summer was spent with wiring and starting body prep including undercoating with bedliner. Not super interesting, but...

Just passed a big milestone last weekend. Mike Forte delivered my engine. A 1965 289 block converted to a roller cam. Transmission is a TKO 600 with the mid-shift kit. His dyno numbers are just north of 340, which is right where I wanted to be. Last Sunday turned out to be a nice day, so my wife and I decided to get it installed and here it is:

http://thefactoryfiveforum.com/attachment.php?attachmentid=60633&d=1478481799

http://thefactoryfiveforum.com/attachment.php?attachmentid=60634&d=1478481811

Next up will be making all the connections and hopefully a first start before winter really sets in, but the car really needs to take a back seat to schoolwork in the short term.

[2FAST4U]

Looking great!

[cnutting]

Slowly working my way towards a first start in the car. School is done, official graduation date is this Tuesday, so that's out of the way. However, winter in Boston slows things down since I hate the cold. Fortunately it hasn't been too bad this year (knock on wood) so I've been able to put in a couple hours here and there.


http://thefactoryfiveforum.com/attachment.php?attachmentid=63349&d=1485714247


Cooling system is ready for filling, I decided to blow out the budget a little bit more and go with the Breeze radiator mounts and hose/tubes. Happy with that decision. Electrical is done, going to wait until everything checks out before final dressing. Couple more connections to make on the oil lines and that's done and ready for fill. Then go through everything on the checklist again, schedule some time with Mike Forte so he can tell me what I missed/did wrong, then turning of the magic key...

[2FAST4U]

Looking FABULOUS!!

[cnutting]

Couple items complete today:

Installed the Metco safety loop. Very straightforward installation. Haven't done the final torque yet as I want to check clearances once the car is back on the ground. Also, not a huge fan on the parking brake cable with this loop. To keep the cables free of corners and sharp stuff, they want to run on the inside of the loop. However, any fragmentation from the driveshaft (if it let go) would probably damage the cables. So... need to think about this a bit.

Finally got a full power test on the electrical. After all the surgery to eliminate unneeded wires, relocate the high beam switch to the floor, graft in 289 gauges and the taillight converter I was a little worried that something wouldn't work. Taking it one step at a time, the lights came on (including parking lights!), the turn signals work, hazards work, high beams, horns, etc. Even the gauges power up and the gauge lights work too. The hardest part was adjusting the brake-light switch.

Coolant is filled, oil is filled, the only thing missing is to finish the throttle linkage, put some gas in and fire it up. Need to double check my list, 'cuz I feel like I'm missing something.

[japollon]

All sounds great Chris. Post more pictures when you can!!!

[cnutting]

After a successful first start, it looks like there is light at the end of the tunnel. Today I turned my attention to finishing off the throttle linkage from Mike Forte and then interior work. I made an adapter for the Kirkey drivers seat to the adjustable seat tracks. Pretty straightforward, one inch wide 1/4" steel bars to tie everything together. Then drilled both seat mounts. There may be some tweaking needed once the body is on, but I have a plan for that if need be.

The last thing was to start on carpeting. The back wall is done and the trans tunnel. I need to get another quart of DAP adhesive. This stuff works well, but the fumes are crazy. Had all the doors open in the garage to vent. Pretty happy with how things are coming out. Hope to finish the rest of the carpet next weekend.

http://thefactoryfiveforum.com/attachment.php?attachmentid=67048&d=1493584183

http://thefactoryfiveforum.com/attachment.php?attachmentid=67049&d=1493584183

Starting to look like a real car... ;)

[2FAST4U]

Great progress. If I had just waited a tad longer I could be driving one now. Instead I have a white elephant sitting in my garage.

[cnutting]

More carpeting today. All that's left is to close out the drivers footbox then place that carpet and the piece under the dash. Drivers seat attached to the sliders. Placed the seats, but haven't attached to the car yet. Next weekend, I'll probably get the body back on.

http://thefactoryfiveforum.com/attachment.php?attachmentid=67405&d=1494105788

http://thefactoryfiveforum.com/attachment.php?attachmentid=67404&d=1494105787

Ran the car again, love this sound...


https://youtu.be/rID7fZXRpog

[japollon]

Hey Chris,

I can see your LeMans gas cap in the picture. How do you plan to mount it permanently? I'm wanting to mount mine flush on the body like Erik Treves and Eric Hansen. Have you considered this?

[cnutting]

Good question...
I need to go back through their threads to see how much extra effort it was. The support from FFR is nice because the unit has a lot of heft, but I don't really like the idea of leaving a space.

[japollon]

I wonder if those guys modified the support? From the pictures, it appears they simply attached it to the surface of the fiberglass. Let me know what you find out. Having the cap recessed below the surface of the body just does not look right to me. I do not think that is how the original cars were.

[cnutting]

Another milestone today, got the body (kinda) mounted. However, this was a hard fought victory that is still not 100% complete. I've come to realize that many of the upgrades and mods for the MkIV do not translate directly over to the 289. Some might see this as obvious, but I guess I overlooked it. The 289 really is still a beta kit.

First was the radiator mount. I went with Breeze for the top and bottom mounts to take the strain off the radiator. I also went ahead and riveted in the aluminum panel that holds the oil cooler when I installed the radiator. I got the nose of the body over this assembly, but then had to disconnect the oil cooler panel from the radiator and the lower mount from the radiator to adjust the body to the correct position. Based on how this is all fitting, I might need to rethink how these parts all get reattached, and whether or not I can use the lower mount. Breeze makes great stuff and I will find a way to make it work here.

Once the nose was on, we dropped the aft end. Significant interference with the trunk aluminum. Worked through most of this, then had to remove the lower coupling nuts for the quick jacks (aka Kleiner mod) so the body would continue to drop. Then, the corners of the valence hit the gas tank. Got the passenger side over the flange, then was able to drop the drivers side. Now those corners hit the tank (as PeteH pointed out) and the body is now 1" too far back.

Trimming the body in addition to the aluminum on this kit is required to get the body into the correct position.

Now I know where to trim the body and will tackle that next. I will need to trim even more off the lower trunk aluminum and may need to redo the top coupler nuts in addition to the bottom. Lots of work needing to be undone and redone.

Had I trimmed the body first, I might not have needed to take as much off the trunk side aluminum, but there was really no way to tell until I was into it.

The body is in an ok spot now. When I think about it some more I will tackle getting it the rest of the way there. I also have photos of the interference issues that I will pass onto FFR in addition to some of my other suggestions in the hope that they update the 289 supplement.

I get it's a kit, but it really shouldn't be this difficult. Three hours to rough place the body (on my third attempt) seems a little long, maybe my expectations were too high, maybe some of my earlier decisions shot me in the foot.

Anyway... Here are some photos:

Driver side valence/gas tank interference
http://thefactoryfiveforum.com/attachment.php?attachmentid=68275&d=1495926272

Passenger side interference
http://thefactoryfiveforum.com/attachment.php?attachmentid=68274&d=1495926271

Note, these photos show the body above the final position, it's easier to see the interference this way.

And some nicer shots
http://thefactoryfiveforum.com/attachment.php?attachmentid=68273&d=1495926270

http://thefactoryfiveforum.com/attachment.php?attachmentid=68272&d=1495926269

[japollon]

Chris,

The body fitting on the 289 looks kind of like a nightmare. I'm not looking forward to it. I've read back through Erik and Eric's 289 build threads and they don't mention these fitment issues. I wonder if something has changed at FFR regarding the later versions of the kit? Joel

[cnutting]

Hi Joel,
Not sure I can blame the body 100%, I think some of my previous choices contributed as well. The Eriks are both experienced builders and may have done things in a more efficient manner. I do think there is an interference in the rear lower valence that people should be aware of and if it's addressed earlier in the build, there won't be as big of a problem. I'll add this to my 289 watch out list...

[cnutting]

There is still some cleanup needed, but after a decent amount of body and aluminum trimming the body sits about where it should. So now it's on to the rest of the fitting process. Next weekend I'll be starting into the doors, hood and trunk.

http://thefactoryfiveforum.com/attachment.php?attachmentid=68593&d=1496615895

http://thefactoryfiveforum.com/attachment.php?attachmentid=68595&d=1496615896

http://thefactoryfiveforum.com/attachment.php?attachmentid=68594&d=1496615895

[Erik W. Treves]

I miss my 289

[cnutting]

So, after my adventures with the body, I was expecting more drama with the doors and hood. Turns out, I was pleasantly surprised with the fit. Very little trimming was needed, the doors adjusted well. The gaps are a little tight, but this is a rough fit for now. Will go for the trunk this weekend, then some of the detail parts (vents, splash guard, fuel filler, side marker lights...). Then I will pull the body again and clean up the areas that I trimmed.

Passenger door:
http://thefactoryfiveforum.com/attachment.php?attachmentid=68923&d=1497225547

http://thefactoryfiveforum.com/attachment.php?attachmentid=68922&d=1497225546

Driver door:
http://thefactoryfiveforum.com/attachment.php?attachmentid=68919&d=1497225543

http://thefactoryfiveforum.com/attachment.php?attachmentid=68918&d=1497225543

Hood:
http://thefactoryfiveforum.com/attachment.php?attachmentid=68921&d=1497225546

http://thefactoryfiveforum.com/attachment.php?attachmentid=68920&d=1497225545

[squareback]

Any updates?

[cnutting]

Any updates?

Actually.... Yes.

Spent a little time on the trunk. This is roughly placed for now but needs more trimming for a good fit. I want to get things roughed in, pull the body and clean up the rear valence trim and the trunk aluminum. Then put the body back on and get the gaps a little better. I also placed the windshield and paused for a couple pics.

http://thefactoryfiveforum.com/attachment.php?attachmentid=69950&d=1499460643

http://thefactoryfiveforum.com/attachment.php?attachmentid=69948&d=1499460641

Also ran it again and drove it several feet. We are on a small street and one of my neighbors is not a car fan so didn't want to push it too much...

After that, I moved onto the door latches. PeteH noted that there was a big gap between the frame mount and the latch. I had the same issue. I checked out the FFR 289 car photos on their website and noticed that they used some latch parts that the MkIV manual says to discard. Emailed Courtnie, who sent me to Dan and he sent me the latest 289 supplement which documents how to assemble the door latches. The one I had (which didn't describe the latches) was dated 7/2015 (rev B), but the new one is (also Rev B) Feb 2017.

If you are building the 289 and do not have the 2/17 update, email FFR. Last I checked they still had the old rev in the download section on their parts page.

This is a crappy photo of how they look, the bracket compensates for the gap:

http://thefactoryfiveforum.com/attachment.php?attachmentid=69998&d=1499552916

That fixed, I moved on to some 289 detail parts; side marker lights, splashguard, bungee mounts and the grab bar on the front of the cockpit.

http://thefactoryfiveforum.com/attachment.php?attachmentid=69949&d=1499460642

http://thefactoryfiveforum.com/attachment.php?attachmentid=69947&d=1499460640

After many small successes, disaster surely must have been around the corner, right? With that in mind, I decided to tackle my radiator issue.

Part of the issue with fitting the body had to do with what seems to be the smaller nose area of the 289. I thought the Breeze radiator mounts and radiator tubes would be fine. Yes and no. Turns out the angle for the 289 radiator is more shallow than the MkIV. The Breeze upper and lower radiator mounts coupled with the oil cooler just wouldn't fit if installed for the MkIV. I took them apart to fit the body and pondered what to do until this week. To get everything to fit properly, I needed to pick up the bottom of the radiator, but the lower tube hit the frame. I emailed Mark, he sent out a new hose section with a few more inches on the straight length (great customer service btw!). I also needed to shift the radiator top up, so I re-mounted the Breeze upper mount on top of the 3/4" frame piece.

Next task was to locate the oil cooler mount aluminum on the body, then rotate the radiator up to meet it. I put a couple 1/4-20 bolts in to hold it all together and a couple more to hold the oil cooler aluminum to the body. Everything now fits, and I can disassemble things if I run into interference with taking off and putting on the body. I ended up having to remove the hood, all the radiator hoses and the horns to accomplish this. No blood though, so I must be getting good at this. The jury is still out as to whether or not I can use the Breeze lower mount. It's wicked tight in there and I still need to put in the FFR nose mount. I have some thoughts though, more to follow...

And there I stopped. Many small issues and one big issue checked off this week.

[squareback]

Looks good. Great info about the door latches. What splashguard is that?

[cnutting]

Thanks. I got the splashguard from Nick Acton; Acton Custom Enterprises.

[japollon]

Chris, Are the front and rear splash shields that are included with the kit used on the 289? The fronts attach to the F-panels and the rears to the frame I think.

[cnutting]

Hi Joel, there is a set of 289-specific wheelwell splash shields with the kit. Haven't made it that far yet...

[PeteH]

Hi Chris,
Looking great! I am just one step ahead at the moment. Have the gaps trimmed, front of door tips filled to match the cowl, and have about 75% gel coat block sanded. Body has to come off once more to finalize trimming of that rear valence so it doesn't squeak. Some areas of the jambs need filling as they fall away from the line in a few areas, left front side area of trunk opening, right rear side area of hood opening, and both lower door openings, passenger at rear lower half, and driver front lower area. Look close at the trunk lid, mine has a bit of a peak at the front center, and a slight flat spot to the right of that that'll need filling. Haven't blocked the rear lower section of body or trunk yet. I have the front splash panels cleco'd in place for now, and have just test fitted the rear wheel well panels. Looks like there will be some gaps that will need caulking. The passenger rear panel for the rear of the wheel well is not cut out to go around the fuel pipe, so presume not 289 specific. Doors, sills, and front fenders ahead of the doors will need quite a bit of filling and blocking to get straight. Hood will need some fill in the area where the latch handles go. There are two dips in the body, one on each side behind where the rear hood opening curves on each side that'll need filling.
I'll let you know what else I find as I block sand so you can look closely at yours when you get to that stage.

[smoothy58]

Hi Chris-
Can you share where your shifter handle came from? Looks perfect and lower than the one on the FF 289 demo I saw this past week at EAA Airventure.
Thanks!

[cnutting]

Howdy. I got the shift handle from ********** Accessories. It's intended for the 289s.
Chris

[smoothy58]

Thanks Chris!
Keep up the good work!!

[cnutting]

Reached another milestone today; I disassembled the body buck and officially returned control of my wife's side of the garage. Cleaned of course, sorta...

http://thefactoryfiveforum.com/attachment.php?attachmentid=73827&d=1505697250

This means that I have placed the body on the car for the final time. Final time for me that is, the next time it comes off will be at the body shop. I believe that I could tackle this myself, but I'm not sure I want to. And... I will forever be over critical of my work if I did do it.

So... I can confirm that trimming the body is necessary as PeteH described. Dropping the body on yesterday took ~20 minutes including removal of the gas cap. So much easier.

Today was spent reassembling things, hood, trunk and doors. Some minor tweaking will take place, but I'm pretty happy with the rough fit. I'm assembling everything in case I decide to register it in the spring and drive in gel-coat whilst saving for body work/paint. Assembly continues next weekend, followed by the alignment.

Here are some pics:

http://thefactoryfiveforum.com/attachment.php?attachmentid=73826&d=1505697249

gloves cover the overly long bolts that will be replaced.

http://thefactoryfiveforum.com/attachment.php?attachmentid=73828&d=1505697251

http://thefactoryfiveforum.com/attachment.php?attachmentid=73829&d=1505697252

http://thefactoryfiveforum.com/attachment.php?attachmentid=73830&d=1505697253

[PeteH]

Congrats Chris,
It looks great as an almost complete roller. I'm sure you have a sense of satisfaction at turning the corner for the final straight. The more I see them coming together, the more motivated I get to finish!

[japollon]

Chris, as with Pete...congratulations. It makes me even that much more motivate to move forward. The pictures are really helpful by the way!!

[chuckster]

Looks great Chris. We're all chasing you now.

[cnutting]

Thanks guys. Lots off ups and downs with this build. I'm sure there are a few "opportunities" left that are lurking, but I think I can handle them.

Looking forward to seeing some photos of your cars!

[cnutting]

Reassembly continues, found myself having "one of those days". You know, those days when you put a tool down, turn around for a second and it's gone. Same with a part or subassembly. Then it pops up when you decide to do something else.

Today was mostly gremlin hunting in the electrical system. Not sure what's happened, but systems that worked great, no longer do (fan, turn signals, hazards). I did have minor success today, the side marker lights work (for now...), so let there be light.

http://thefactoryfiveforum.com/attachment.php?attachmentid=74877&d=1507425028

Tomorrow is another day...

Got some more run time in, here's video from last week.


https://www.youtube.com/watch?v=mI19anQRyYw

[japollon]

Chris, I always enjoy hearing your motor run. It gives me faith!!

[Mark Dougherty]

looking and sounding great

[PeteH]

Chris,
Looks and sounds great. Love to hear it run. It's going to be hard to take apart to do bodywork!

[cnutting]

Thanks guys!

Yes, it will be a lot of work taking it apart before paint, but this way I can make sure everything fits the way I would like and all the holes are drilled before it goes. All the lighting is connectorized, so that should go easy.

Plus it gives me the option of registering it and driving in gel coat if I need to save a bit more for the body work and paint.

[Vspeeds]

Looking good! Sounds good!

[Bguetter]

Sounds great! It’s always tough to judge sound and noise levels through video. From what i’ve Been told the 289 sidepipes are LOUD. Has that been your experience? I was already researching welding in some type of muffler.

[cnutting]

Yes, they are load. Louder than I expected. But, so far so good with the neighbors. For the most part, they all love it and can't wait until it's done. Only had one run in so far, but this guy has a history in the neighborhood shall we say. But it's ok when his little dog yaps for hours on end at all hours. I'm not super concerned.

I might consider changing them out some day.

[chuckster]

On the advice of Tony at FFR I got a set of cats to use instead of j pipes. I’m going to wrap them in header wrap or somewhat camouflage them. The boys at FFR say this is an affordable way to quiet these pipes, and having heard the showroom car run, they are LOUD. I also have the j pipes if I’m not happy with the look/sound of the cats.

[Bguetter]

On the advice of Tony at FFR I got a set of cats to use instead of j pipes. I’m going to wrap them in header wrap or somewhat camouflage them. The boys at FFR say this is an affordable way to quiet these pipes, and having heard the showroom car run, they are LOUD. I also have the j pipes if I’m not happy with the look/sound of the cats.

Interesting. I think i may go ahead and get the cats and replace the j-pipes. Flowmaster makes an inline muffler that i may weld in as well, but i’ll Try the cats first. I’m a few months away from getting the engine in, so i have some time to figure it all out.

[cnutting]

Interesting. Did they give a part number for the cats?

[chuckster]

I’ll try tp get that part# for you.

[chuckster]

13873. LH side catalytic converter

13874. RH side catalytic converter

Hope this helps.

[cnutting]

Thanks!

[japollon]

Who is the manufacturer associated with those part numbers?

[BrewSki302]

Do these black simple side pipes come with the 289 kit? I'm wondering if I can use this same look on a Mark IV?

[cnutting]

The single pipes come with the 289 and are stainless. I painted them black since that's the look I wanted for the car.

[Bguetter]

Who is the manufacturer associated with those part numbers?

I believe those are factory five part numbers.

[chuckster]

That’s right FFR part #s. They have a standard fittin for headers on one end and the connector for the FFR side-pies on the other

[KW33]

Nice video of the engine start. Looks and sounds great!

[cnutting]

Couple updates, getting ready to register the car this spring so working cleanup items.

The alignment is done, I'm glad I went through this myself, it was a good learning experience. I've also mounted all the exterior items and rough fit the doors, hood and trunk lid so that all the holes are drilled before paint. The car will be going in for paint over the winter. To get it ready, I've been disassembling everything and marking some areas that need extra attention. The shop will take the body and chassis, but will remove the body for paint and re-mount it when done. I really didn't want to handle a freshly painted body.

I've also resolved one of my last gremlins, the hazard lights. Everything worked electrically in the car, but the rear hazards would only work if the brake was pressed. Not a huge deal, but MA has become stricter with inspections and I wanted everything working properly. I tested everything and it appears that the converter has enough voltage drop to not light the LEDs. The LED taillights provided with the kit drop out at under 8 volts which is a significant drop. Activating the brake switch provides enough extra voltage to light the LEDs.

I also contacted the manufacturer of the converter and they said the units are not compatible with LEDs.

I ended up purchasing two of these units to replace the converter:

http://thefactoryfiveforum.com/attachment.php?attachmentid=76623&d=1510525687

Wiring is simple, one signal wire goes on the input side. The signal wire on the rear harness attaches to the output side. Use one diode module per side. The brake signal attaches to the other input, run a jumper between the two modules to get brake signal on both lights.

That's it, problem solved. Fully functional hazards now.

Now my next big dilemma is color. Originally I wanted Princess (Viking) Blue, then I thought about a black/yellow scheme like csx 2128. Now? Not sure, but I will have to decide soon. Next update will probably be several months from now once paint is done, then we'll see where I ended up....


UPDATE: 3/2020 The diode approach is quick and easy but the rear turn signals don't function when the brake is pressed. Swapped to this unit:

https://www.amazon.com/gp/product/B005S572FI/ref=ppx_yo_dt_b_asin_title_o07_s01?ie=UTF8&psc=1

[PeteH]

Thanks for sorting this problem out Chris. On to Amazon!
Did you have to separate the front signals so they do not come on with the brake?

[cnutting]

The diodes are there to prevent back-feeding the system, so you shouldn't see that issue Pete.

[japollon]

Perfect Chris. Placed my Amazon order yesterday. Thanks for sorting this out for us. Joel

[cnutting]

New Year, new update. Today was sad, because my garage is now empty:

http://thefactoryfiveforum.com/attachment.php?attachmentid=79304&d=1515957560

But... that means the weather was good enough to bring the car to the shop. Loaded the trailer this morning, it was a balmy 17 degrees:

http://thefactoryfiveforum.com/attachment.php?attachmentid=79306&d=1515957584

Got to drive it around a bit in the process. Really happy with how it drives. Noise is still a bit on the loud side. Might need to do something about it....

The car is safely in the body shop, they will start in on it next week. This is the same shop that painted the Hot Rod Truck and the red Type 65 for FFR.

[cnutting]

Got a nice surprise yesterday from the body shop; pictures of the first round of priming. Next week they will continue on with final fitting then more blocking and priming. Target for shooting color is the first week in March. Getting closer....

https://thefactoryfiveforum.com/attachment.php?attachmentid=80963&d=1518663233

https://thefactoryfiveforum.com/attachment.php?attachmentid=80962&d=1518663221

https://thefactoryfiveforum.com/attachment.php?attachmentid=80961&d=1518663211

[PeteH]

Looks great Chris, it's getting there. I wet sanded mine with 600 grit this week but notice some imperfections that will most likely require another round of primer/block sand at least on top the front fenders. Taking a halogen light tomorrow for closer inspection in the glare. Have the doors, inside trunk, and hood painted in color and clear coated. Waiting for warmer weather for rest of it. It will take me two long days to do all the striping, color and clear coat I think. The exhaust fan for paint booth sucks heat right out of the building pretty quick.
Pete H.

[japollon]

Hey Chris! Great progress!! Both you and Pete are way ahead of me. It's been cold out here and I have been lazy! Still, my motor will go in over the next few days. Your car looks great.

[cnutting]

Received another update yesterday. I think I've lost track how many times they have taken the body off and put it on again. Next weekend I will take a drive down there and approve the final paint color. Really getting excited now...

https://thefactoryfiveforum.com/attachment.php?attachmentid=81983&d=1520101835

https://thefactoryfiveforum.com/attachment.php?attachmentid=81982&d=1520101826

https://thefactoryfiveforum.com/attachment.php?attachmentid=81981&d=1520101818

[WIS89]

Chris-

You must be really stoked! The car looks great, and I am sure you are ready to see some color.

I look forward to the next update where we get to see how cool the color will be.

Thanks for the update!

Regards,

Steve

[japollon]

Looks great Chris....color??

[cnutting]

Thanks guys. Going with the Viking Blue. Similar to the FFR demo car, but they used a newer Toyota blue.

[mike forte]

Hi Chris,
You've been busy! I guess I'll be seeing you driving in the next few months..
BTW, Thank you for your business and if you need anything, I'm just the next town away..

[cnutting]

Hi Mike,
Yes, should be soon. Hard to believe it's been 2 years since we picked it up. You've been a huge help, I'll let you know when it's close to being back.
Chris

[Vspeeds]

Looking good Chris. Do you have the standard width axels and are you using the standard FFR 15” bolt on wheels? Your wheels fit the body really good. Most, if not all the 289 photos I see are using the narrow width with pin drive wheels.

[cnutting]

Yes, those are the standard wheels. Wanted to try and stay in budget. Hasn't really worked that well....:)

[cnutting]

Checked in on the car yesterday. Looks really good. Happy with the paint sample too. Heading for the spray booth late this week/early next.

[cnutting]

While I'm waiting for paint, I've started thinking about the next steps in the process. Part of this is which direction did I want to take to reduce the sound of the exhaust. Personally, I love it. Fits the race car image. Realistically, I need to take it down a notch. Thought about going with inserts, thought about going with the catted j pipes. Then I got a message from Bob Boig. They are local and have systems for the MKIV, I have their cooling pipes already. We discussed the 289 application and long story short, I've offered up my car as a test mule and gave Bob a pipe for research. More to come, but there will be a quiet pipe option for the 289.

[chuckster]

Hey Chris. When you tak to him again, tell him he’s got another customer. I fired mine up last weekend with the catted j pipes. Sounds great, but still too loud. If he doesn’t come up with something, I may give my welder my j pipes and a couple of Magnaflo 14159’s and see how that works. Go carting my 289 this Sunday before the next snowstorm.d

[cnutting]

I will let him know. Bob's been great to work with.

[CobraboyDR]

I will let him know. Bob's been great to work with.I would be interested in their solution to quieter pipes.

From what I can tell, the 289 pipes are unbaffled so make quite the racket. Quieting them would be a big + in my mind. Loud pipes can get annoying and make for unhappy neighbors.

[cnutting]

The body is in the polish stage, tomorrow they will be moving towards reassembly. Targeting picking the car up a week from Saturday, then it's the home stretch. A bunch of stuff to put back on, double check my alignments and torques, then the infamous Mass registration process. Somewhere in there I need to get the car over to Bob Boig for exhaust work.

Pic from last week in clearcoat:

https://thefactoryfiveforum.com/attachment.php?attachmentid=83235&d=1522358828

And a couple pics from today in polish:

https://thefactoryfiveforum.com/attachment.php?attachmentid=83462&d=1522712043

https://thefactoryfiveforum.com/attachment.php?attachmentid=83463&d=1522712052

[cgundermann]

Awesome, love your color scheme!

Chris

[Vspeeds]

Wow! Thats a great color combo

[cnutting]

Thanks guys! Went with vintage Ford colors, Viking blue and springtime yellow.

[wareaglescott]

looks great. Cant wait to see it all put together

[japollon]

Just looks perfect Chris! Great work and great choices on your part. Looking forward to more pictures of the finished product. Joel

[cnutting]

Had a small delay on pickup but that's ok. Weather is awful here in Boston anyway, some light snow today and rain expected all day tomorrow. Last Friday it was 70, go figure...

The car is ready, it's back on all four wheels and I'm looking forward to next weekend.

https://thefactoryfiveforum.com/attachment.php?attachmentid=84070&d=1523669460

https://thefactoryfiveforum.com/attachment.php?attachmentid=84071&d=1523669471

[Scubasommer]

Had a small delay on pickup but that's ok. Weather is awful here in Boston anyway, some light snow today and rain expected all day tomorrow. Last Friday it was 70, go figure...

The car is ready, it's back on all four wheels and I'm looking forward to next weekend.

https://thefactoryfiveforum.com/attachment.php?attachmentid=84070&d=1523669460

https://thefactoryfiveforum.com/attachment.php?attachmentid=84071&d=1523669471

Looks awesome!!!
Home stretch

[chuckster]

Thanks for the tip Chris. Solved my lighting problem. FFRshould include these in all 289 kits as the unit they give you does not work with the included LED taillights.

[cnutting]

Excellent, happy to help!

[David Hodgkins]

Outstanding build!

Better put those spinners on before the wheels fall off!!!

I slay me...

;)

[cnutting]

Outstanding build!

Better put those spinners on before the wheels fall off!!!

I slay me...

;)

Thanks!

I made sure to add an extra static fluid reservoir to help keep the wheels on. Improved my mileage plus gave me 10 extra hp... :p

[cnutting]

Picked the car up from the body shop yesterday. The ride home was interesting, had a few people blocking traffic on the Mass Pike to take a look. Happy to get home in one piece!

Spent today mounting the windshield, the rollbar and some other odds and ends. Next week I will continue with the wheel well aluminum, then some underside work.

https://thefactoryfiveforum.com/attachment.php?attachmentid=84735&d=1524447405

https://thefactoryfiveforum.com/attachment.php?attachmentid=84734&d=1524447388

https://thefactoryfiveforum.com/attachment.php?attachmentid=84733&d=1524447379

[CobraboyDR]

Picked the car up from the body shop yesterday. The ride home was interesting, had a few people blocking traffic on the Mass Pike to take a look. Happy to get home in one piece!

Spent today mounting the windshield, the rollbar and some other odds and ends. Next week I will continue with the wheel well aluminum, then some underside work.

https://thefactoryfiveforum.com/attachment.php?attachmentid=84735&d=1524447405

https://thefactoryfiveforum.com/attachment.php?attachmentid=84734&d=1524447388

https://thefactoryfiveforum.com/attachment.php?attachmentid=84733&d=1524447379Spectacular!

[japollon]

Wow Chris, what a beautiful 289 FIA. All of your time and effort has paid off. There are precious few examples of this particular style of car and yours is certainly at the top of the list.

What's the latest on the Boig side pipes?

[Boig Motorsports]

Chris, Would you like to test our design for quieter sidepipes maybe next Saturday? We're working on the fabrication this week! I may be able to come to you.

Boig Motorsports

[cnutting]

Thanks for the compliments!

No photos in today's update, but we do have some data. Bob Boig stopped by this morning with a prototype pipe. He basically cut out the center section and welded in a new piece as well as fitted some baffling upstream and downstream. He also brought an analog sound meter and a temporary muffler extension to really quiet down the driver's side pipe during testing.

Using the meter at chin height in the driver's seat, we took baseline numbers on the stock passenger pipe. We planned to test at idle (~900 rpm), 2000 rpm and 3000 rpm. Meter showed ~92 dB at 900, ~98 at 2000 and i stopped it at 2500 since we were about 102 dB and my finicky neighbor was outside. For reference, pain starts at ~120dB..

Next we bolted up the new passenger pipe and saw ~10 dB knockdown across the range. That cuts the volume roughly in half. Pretty impressive for a 3 inch pipe with no obvious modifications. We could easily chat during testing which was more difficult with stock.

So... Bob took my driver's side pipe and will make that the same as the passenger. I'll pick them it up next week, repaint both and reinstall.

The welds by the way, were very well done. I think we agreed that these will be known as quiet-er pipes since they technically are still loud, but much more tolerable.

[CobraboyDR]

Thanks for the compliments!

No photos in today's update, but we do have some data. Bob Boig stopped by this morning with a prototype pipe. He basically cut out the center section and welded in a new piece as well as fitted some baffling upstream and downstream. He also brought an analog sound meter and a temporary muffler extension to really quiet down the driver's side pipe during testing.

Using the meter at chin height in the driver's seat, we took baseline numbers on the stock passenger pipe. We planned to test at idle (~900 rpm), 2000 rpm and 3000 rpm. Meter showed ~92 dB at 900, ~98 at 2000 and i stopped it at 2500 since we were about 102 dB and my finicky neighbor was outside. For reference, pain starts at ~120dB..

Next we bolted up the new passenger pipe and saw ~10 dB knockdown across the range. That cuts the volume roughly in half. Pretty impressive for a 3 inch pipe with no obvious modifications. We could easily chat during testing which was more difficult with stock.

So... Bob took my driver's side pipe and will make that the same as the passenger. I'll pick them it up next week, repaint both and reinstall.

The welds by the way, were very well done. I think we agreed that these will be known as quiet-er pipes since they technically are still loud, but much more tolerable.Great!

Would have been interedting to do a before and after dyno run.

How much ground clearance do you have?

[cnutting]

Set my ride height at about 4.5". Bob took some measurements of the pipe to ground, but I don't recall what he said. If I get out to the garage today I can take some...

[Boig Motorsports]

The clearance of the side exhausts to the ground won't be any different than the original FFR sidepipes would be as one of the "Quieter Pipes" design requirements was to try to keep the original 3" sidepipe diameter. This was to maintain the current design sidepipe's clearance to both the body, and ground. With modifications to the front and rear sections, and to the center muffler section of the sidepipe, we were able to reduce noise an approximately 10 db across the board as Chris's post reports.

By the way, Chris's build is GORGEOUS! One of the best FFR's I have seen!

Chris, thanks for the chance to work with you.

These "Quieter Pipes" will be available for FFR F.I.A./USRRC cars soon.

[GoDadGo]

Impressive, Simply Impressive!

Excellent Work, Excellent Execution!

If you aren't proud, then something is wrong with you.

[cnutting]

Thank you. I just tried to learn from the real experts out there. The team at Mike's Restoration really brought it together with the paint.

[cnutting]

Knocked off a couple more items on the list. Roll-bar is permanently mounted. As is the nose aluminum and door sills. All of the lights are in and functional. Fuel filler is 90% mounted. I added some edge trim to the body where it pokes through to clean it up a bit. I also mounted the new pipes from Boig. Fired it up today, big difference in the volume! The tone is good too. Very happy with these new pipes.

The last things on my list are wheel well aluminum and double checking all my torques and alignments. Need to bolt in the seats too and aim the headlights/trim them out.

Here are some pictures:

https://thefactoryfiveforum.com/attachment.php?attachmentid=85800&d=1526422902

https://thefactoryfiveforum.com/attachment.php?attachmentid=85801&d=1526422917

https://thefactoryfiveforum.com/attachment.php?attachmentid=85799&d=1526422893

https://thefactoryfiveforum.com/attachment.php?attachmentid=85802&d=1526422936

[monster7]

I don't have a FFR, but also looking for a quieter 289 Sidepipe! This is what i'm looking for!
My 289 FIA:
87216

Is it possible to have a sound vid with the quiter pipes?

BTW, this is a very nice 289 you have!!

[cnutting]

Thanks!
I don't have one but it's on my list since I've received several requests. I'll try to get one up this week.

Like your 289. Is that an ERA?

[WIS89]

Chris-

I know I have shared my admiration for your build before. However, I have to reiterate that your car looks simply amazing!!

I love the color, the accent stripe, and everything about the finishing touches. She is a really great example of the FIA car, and you should be stoked to be nearly finished.

Congratulations on approaching the finish line of your build. I have really enjoyed following your build, and admired your craftsmanship; beautifully done!

I look forward to seeing her all done, and checking out all the details!

Regards,

Steve

[monster7]

Thanks!
I don't have one but it's on my list since I've received several requests. I'll try to get one up this week.

Like your 289. Is that an ERA?

No, it's a 289 FIA from HAWK UK with an '85 302 Roller

[cnutting]

Looked that up today. Nice kit, yours came out quite sharp, a real good looking car!

[cnutting]

Is it possible to have a sound vid with the quiter pipes?

I finally got some video and posted a before and after in the main forum.

https://thefactoryfiveforum.com/showthread.php?28786-289-Boig-quieter-pipes

In other news.... I think I'm done. When I say done, I mean as far as my checklist of things to assemble, mount, adjust, etc. I'm sure I will find ways to "improve" the build, but let's say I've reached the basic level of completeness. Here are a couple pics:

https://thefactoryfiveforum.com/attachment.php?attachmentid=87467&d=1529289073

https://thefactoryfiveforum.com/attachment.php?attachmentid=87465&d=1529289017

https://thefactoryfiveforum.com/attachment.php?attachmentid=87464&d=1529289001

The last items were aiming and trimming of the headlights and mounting the door panels. The door panels are from **********, but they needed to be modified to fit the 289 style doors. I should at some point make a list of all the typical MKIV mods/upgrades that needed to be tweaked for the 289.

Starting the registration process. My paperwork was reviewed and approved by the State Police today, towing the car down to their facility Friday for VIN assignment.

[Boig Motorsports]

Good luck Friday! Your build is breathtaking!

Bob

[stevo7896]

That is beautiful ,classic look in every way !! Nice touch with the painted louvers .

[CobraboyDR]

Your build is spectacular!

Yes, I'd love to see a list of mods needed between a Mk4 and FIA...

[chuckster]

Hi Chris, did Leo do your paperwork review? I had my paperwork review on Weds. and Leo was just great. I’m trailering mine down on Monday for VIN assignment. I look forward to reading about your experience, good luck today.

[cnutting]

Yes, Leo did my file. He is great to work with! I got my assigned VIN this morning, he mentioned that another car would be down there Monday, now I know who that is.

Much easier process than I expected.

[chuckster]

Congrats,if you haven’t got insurance yet, your current broker can write you a policy through Grundy’s. Mine did, and with a 5k a year mileage limit and a 40k agreed value the cost is only $385/yr. I’m hoping to be registered and on the road by the end of next week.

[jolsen42]

I finally got some video and posted a before and after in the main forum.

https://thefactoryfiveforum.com/showthread.php?28786-289-Boig-quieter-pipes



https://thefactoryfiveforum.com/attachment.php?attachmentid=87467&d=1529289073

https://thefactoryfiveforum.com/attachment.php?attachmentid=87465&d=1529289017

https://thefactoryfiveforum.com/attachment.php?attachmentid=87464&d=1529289001



Love it!! Absolutely beautiful job.

John O

[cnutting]

Just got my plates, Woohoo! Ran into some difficulty with insurance but got it straightened out. That has actually been the hardest part of the registration process so far. MSP inspection was smooth, RMV was smooth as well.

After lunch I'll throw the plates on, go get gas, calibrate the speedometer then off for inspection and the obligatory reject sticker. Last step will be a trip to the MAC for my emissions exemption.

[cnutting]

After a bit of back and forth with the inspection station software (and some much appreciated help from the Commonwealth!) I got my sticker.

https://thefactoryfiveforum.com/attachment.php?attachmentid=88405&d=1530839564

Yes, it's a reject, but that is part of the process with these cars. Since my engine is a 1965 block, I will get an exemption from our Motorist Assistance Center (MAC). Then it will convert to a legit stickah (as we call it in Boston).

Tomorrow will rain so I can tweak my driveline to get rid of some vibration and make my appointment with the MAC. One last step to take...

[cnutting]

Got a bunch of bugs ironed out and have been putting in some miles. Completed the Mass inspection process today and am now 100% legal and emissions exempt.

My last project is to pull my speedometer and send it to Speedhut for GPS conversion.

It's been a long road, but finally done.

Time for a garage sale to find a new home for all those parts that I didn't need...

[cnutting]

Here is a ~200 mile update. I've been following a bit of a test plan; drive a little, tweak a little, drive some more. Like ADM Meyer's adage from the Aegis days; Build a little, test a little, learn a lot. I've graduated to taking the car to work (~12 miles each way with a short blast on the highway). I think I have everything dialed in to where I would like it and am real happy with how it performs around town and on the highway. Stable and predictable. Fast when I want it to be.

Following are a couple pics from tonight's outing. First few are at Newton City Hall, the last two are at the old Watertown Arsenal:

https://thefactoryfiveforum.com/attachment.php?attachmentid=92501&d=1535933410

https://thefactoryfiveforum.com/attachment.php?attachmentid=92502&d=1535933419

https://thefactoryfiveforum.com/attachment.php?attachmentid=92503&d=1535933427

https://thefactoryfiveforum.com/attachment.php?attachmentid=92504&d=1535933435

https://thefactoryfiveforum.com/attachment.php?attachmentid=92500&d=1535933397

https://thefactoryfiveforum.com/attachment.php?attachmentid=92499&d=1535933386

[KDubU]

She looks awesome! Yup, bugs are going to happen and eventually she will be rock solid.

[wltrmtty]

Congratulations on a beautiful build. Like giving birth, I'm sure memory of the pain fades as you hold your baby.

[Jimtmich]

Beautiful and glad to see you are driving it!

[Vspeeds]

Chris
Just was re-reading your thread. Regarding the body fitment issues: I too have the oil cooler. Do you think it would be better to not have it hooked up while in the go karting stage and then attatching it after the body is on?
Eddie

[CobraboyDR]

Chris, your build is simply fantastic!

[cnutting]

Thanks!

Unfortunately it's all covered up for the winter, but it was fun while it lasted.

[cnutting]

Chris
Just was re-reading your thread. Regarding the body fitment issues: I too have the oil cooler. Do you think it would be better to not have it hooked up while in the go karting stage and then attatching it after the body is on?
Eddie

I made everything removable to help with the fitment process. The cooler aluminum panel bolts to the radiator and then to the body. Bit of juggling but not too bad.

[Vspeeds]

Chris
Do you have a picture of how you routed the oil cooler lines?

[cnutting]

It's been a while since i posted. Here it is September, might still have another couple months left in the driving season, but you can already feel winter on the way. Ugh.

Been posting updates on Instagram all summer, but wanted to update the build thread with a sort of what did you do this summer. Almost at 1000 miles, and the car is running fine.

I started the season by updating the lower control arms on the 3link with the Breeze ones. Huge difference, wish i installed these from the get go. Summer drives took us to local farm stands, ice cream shops and a brewery.

https://thefactoryfiveforum.com/attachment.php?attachmentid=113879&d=1567873902
https://thefactoryfiveforum.com/attachment.php?attachmentid=113883&d=1567873963
https://thefactoryfiveforum.com/attachment.php?attachmentid=113885&d=1567873990
https://thefactoryfiveforum.com/attachment.php?attachmentid=113884&d=1567873977
https://thefactoryfiveforum.com/attachment.php?attachmentid=113876&d=1567873833


Many commutes to work and a take your classic car to work event.

https://thefactoryfiveforum.com/attachment.php?attachmentid=113882&d=1567873950
https://thefactoryfiveforum.com/attachment.php?attachmentid=113880&d=1567873922

Also entered my first real car show at the Endicott Estate, an old mansion which is currently a museum/function space. This show usually has over 1000 cars. Surprisingly i took 2nd in the kit car class. The car next to mine is a beautiful ERA 427 S/C. Those wheels are actual Cobra sunburst wheels. The previous owner of the wheels had two cobras, both with sunburst, that he swapped for Halibrand replicas.

https://thefactoryfiveforum.com/attachment.php?attachmentid=113881&d=1567873935
https://thefactoryfiveforum.com/attachment.php?attachmentid=113873&d=1567873796
https://thefactoryfiveforum.com/attachment.php?attachmentid=113874&d=1567873811

Hopefully your summer driving was great! Counting down the days until spring...
https://thefactoryfiveforum.com/attachment.php?attachmentid=113875&d=1567873822

[CobraboyDR]

I started the season by updating the lower control arms on the 3link with the Breeze ones. Huge difference, wish i installed these from the get go.How would you describe the difference?

Have you encountered any speedbumps yet? I'm curious about clearance issues.

[cnutting]

I deal with speedbumps at work and they are typically not an issue so long as you plan your approach and keep it slow. We work on an Air Force base so the limit is 15 and people don't get too upset.

The breeze arms give more side to side flexibility. It's almost like a semi independent suspension now. Cornering is more planted on our rough Boston area roads.

[Tarmac]

Chris,
It's really a gorgeous car you have built... the color and everything about it is nicely done.

Paul

[cnutting]

Thank you Paul!

[cnutting]

Just finished the annual maintenance and did some upgrades. Added the fan shroud from Breeze. Another great product, but I strongly suggest doing it during the build. Adding it after the fact was tough since everything is packed in. Also changed out my tailight diodes that replaced the FFR supplied converter. Went with this unit from Tekonsha

https://www.amazon.com/gp/product/B005S572FI/ref=ppx_yo_dt_b_asin_title_o07_s01?ie=UTF8&psc=1

Now the turn signals function when the brake is pressed. A big downside to the diode approach I first used.

[Vspeeds]

Chris
Thanks for the part #.

[Zach Bohn]

Did FFR precut the hole for the gas tank Monza cap?

[Zach Bohn]

Do you mind sharing the mounting dimensions for the door lights? Thank you in advance.

[John289]

Did FFR precut the hole for the gas tank Monza cap?

I was just reading through this thread, again, and noticed this wasn't answered. This the response I received on 8/9 from Mike DiGiorgio at FFR. I am electing to not have them do the cutout for the cap, it will allow me greater flexibility on location and most likely I will not use their mounting attachment and mount directly to the body.

From Mike,

believe it or not, I did not know that we did not do the gas-cap cut out on a 289,

I spoke with the production team, From this point forward we are cutting the gas cap opening slightly smaller in diameter than the final cut will need to be, ( 4inch diameter, gas cap is 4.5-5 inchs) This will allow final clearance by the customer

At the time of your kit being produced, you should have the gas cap cut out.

[2FAST4U]

Your car is simply stunning!

[cnutting]

Sorry for the lack of response! FFR "traced" the location with the CNC, but cutting it was up to me. I'll try and get some measurements on the marker lights for you.

[Zach Bohn]

Thank you for the response. Funny, I wrote Mike right after I received my Kit and he stated we don't cut the opening for the 289 gas cap (they did not cut the opening in the front of the hood scoop either).

[Zach Bohn]

Thank you

[cnutting]

They are about 7-3/4" up from the bottom of the door and about 4-1/2" from the front edge of the door. Best part is they were all different on the originals, so you can't really be wrong. ;)