Starting a new GEN 3 Daytona build

[michael everson]

I will be picking up a new GEN 3 Daytona for a customer at the end of the month. Look forward to building FFRs new kit. Here are a few details on the build.
Coyote engine package with a TKO transmission
2015 IRS supplied by FFR
optional carpet kit
17 inch wheels by FFR
Heat and A/C by FFR

I will be updating this thread as I move along with the project. Hopefully what I learn will help others on there project.
For now here are a couple of shots of the new engine.
Mike

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[wareaglescott]

What does the optional carpet kit cover? Is it some sort of expanded package or does the kit not normally come with carpet?

[KDubU]

Very cool. I will be following along.

[wallace18]

Sounds like a great build! Please detail A/C and P/S installs if the build includes those 2 items.

[edwardb]

Will follow closely! Mine is about two months away.

[John Dol]

Nice Mike, you know we like pics!

John

[nkw8181]

Lead the way!

[Mark Dougherty]

fantastic mike you will like it I am sure

[Erik W. Treves]

Sweet!

[michael everson]

Picked up the kit today at Factory Five. They guys there are great. Took good care of me and the kit.
Here are some pics of the pickup. I plan to start the build on Tuesday.


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[michael everson]

Here are a few progress pics. I am kind of going into this blindly because there is no assembly manual for it yet. relying on my previous experience, older manuals and people like Henry that have already started theres.

I started by refitting all of the aluminum and drilling all the rivet holes. I have most of the aluminum done. Just a few panels left that I need to figure out there placement.

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most of the IRS is installed. Waiting on the lower toe link which is back ordered. Fuel tank is also installed. no surprises with either installation.

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I gathered up a bunch of parts to be powder coated black. This is most of them. I am sure there will be more as I open other boxes.

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All powder coated.

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[65 Cobra Dude]

Have fun Mike. One recommendation - the aluminum that goes beside the engine that has the square cutout for the exhaust that can be seen clearly with your picture of the frame on the lift - I recommend you cut that square straight up to let the heat out. Actually, Jim recommended it to me and I concur. I can send a pic if you need one.

Henry

[carlewms]

Mike,

Thanks for sharing ... totally off topic but what lift are you using?

Carl

[michael everson]

-Carl. It a snap-on mid rise lift
Mike

[Erik W. Treves]

Mike you probably need to wait on the nose pieces of metal the bolt to hood.... I would fit them first before coating... not sure if they have been updated from beta.... but mine had to be "adjusted"... with welder and cutoff wheel

[michael everson]

Thanks Eric.
Mike

[John Dol]

Nice progress Mike!
Tell us more about that maroon car on the lift. Looks Ferrari-esque

John

[michael everson]

John. Its a California spyder replica that I am installing a drivetrain in.
Mike

[michael everson]

I now have the fuel tank in, the rear brakes mounted and installed the rear brake lines. there is no clear way to run these so I just did what looked best. Hopefully there wont be any issues with interference.


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Pedal box is installed. Make sure before you install the pedal box that you put the master cylinder cap on first. the right side one will not go on once its mounted.

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E brake handle all assembled and ready to install

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[GoDadGo]

Mike,

I look forward to watching your build, especially because I am hoping to do a Type 65 after my son graduates from college and youngest daughter gets married. Both of these events will likely occur within the next 2-4 years, well maybe 5 for my son, but you get the picture.

The level of detail that you and other Master Builder/Craftsmen put into these cars shows what you can do when you start with a fantastic foundation that only comes from Factory Five Racing.

Again, I am looking forward to watching your most recent build progress.

Steve

[michael everson]

I got most of the parts today from Factory five to finish assembling the suspension. It is now ready to be a roller once I have tires.
Here is a couple of pics of how I rough aligned the IRS suspension using the frame as a reference. This is just so it rolls easily.

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Here are a couple shots of the front suspension installed. No surprises here. Same as the Roadster.

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And now a few shots of the pedal box with the Coyote switches installed.

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[michael everson]

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[John Dol]

Great progress Mike, make sure you don't kick the California of the jack stand when your turning back the odometer!;)

John

[Vette1972]

Mike,
Looking forward to following your build. It is a super combination. Good Luck!
Len

[chmhasy]

Mike, when I rough aligned my IRS MKIV I did a similar procedure. I set my drive height from the spindle center to the bottom of the frame, then I used a laser mounted to the brake rotor and measured to the frame along the length of the car similar to what you are doing with the long level but with a laser light. I also rough set IRS camber by leveling the frame, drawing a vertical line from a plum line on the garage door then I used the laser mounted to the brake rotor and set the angle off the door line

[michael everson]

Here are a few pics of how I ran the brake lines. Hopefully they wont interfere with anything else. Hard to know on my first kit.

This pic shows the brass block I made up to transition from inside to outside the foot box. It is just two unions that I turned down half the length to fit into the hole in the brass block. I then brazed them in place for an air tight seal.

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Here it is with the lines attached.

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This pic shows the rear line running down the foot box and out to the tunnel.

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And here is how I ran the front lines.

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Also shown in these pics if how I mounted the battery. I moved to a bit further forward to get it tucked out of the way.

[wallace18]

Mike you sure do nice work! Thanks for the pics.

[65 Cobra Dude]

Nice work Mike, as usual! Are you going to be putting in a front sway bar? If so, I think the battery may get in the way.

Henry

[michael everson]

Henry. No sway bar. Good catch though.
I will take to the customer and see if its in his future.
mike

[michael everson]

Week 2 update
I got the Coyote drivetrain installed. It took me about an hour to install it myself. I used 4 straps on the header bolts and the angle was perfect to slide it in.

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After the drivetrain was in, it was time to fit the body. I like to do this early so I'm not waiting on the body shop at the end. All of the electrical, interior and other stuff will be done while they do body work and paint.

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Note the near perfect fit of the door. Anyone who has done an older one knows how important this is.

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The first door took me about 6 hours. The second just 2 hours.

The nose took about a day to get just right including the latches and nose pivots.

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[michael everson]

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[michael everson]

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Dave and his crew really went all out in the design and engineering of this Coupe. Its going together so easy.
Mike

[adubbelde]

Looks pretty awesome.

[65 Cobra Dude]

Beautiful work Mike. You are an animal when it comes to speed of build! Awesome job!

Henry

[wallace18]

Mike does the Gen 3 nose fit better than the Gen2?

[michael everson]

Wallace. No comparison. Every thing about this car is easier. Probably the hardest part for me was figuring out where to run the brake lines.
Mike

[edwardb]

Looking good! Man, you're flying. Good to hear about the body fit.

[Vette1972]

Mike,
Super build! Amazing how fast it is going. Thanks for the great detail. This is fun to watch.
Len

[John Dol]

Wow Mike, you'll have it to paint before me!!

John

[Erik W. Treves]

Very nice Sir! Moving right along!

[michael everson]

Erik. Did you have to trim the lower nose to clear the radiator when the nose is open?
Mike

[Erik W. Treves]

Yes! I had to do about 2inches to clear all the radiators I had up there

[michael everson]

Excellent. Didn't want to do something stupid this far in.
Thanks

[Erik W. Treves]

lol... looking good...you are cruising!

[michael everson]

Week 3 update. Didn't get much done this week as another project came back from paint and needed to be finished. I did get the following things done.

Tires and wheels mounted and balanced. (ones in previous pics were borrowed from my car)
Tail lights mounted
head lights and turn signals mounted.
fuel filler mounted.
I started to fit the fog lights but did not care for the size of them. With the customers permission, I am going to swap them for the original Mustang ones. They are about an inch bigger in diameter and will fill the cavity better.

Here are a few pics of the progress.


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The new LED tail lights are kind of cool. should be much easier to see them at night.

[Vette1972]

Mike,
The Coupe is looking good! Nice progress for 3 weeks into the build. Any unexpected problems so far?
Len

[John Dol]

Mike ,

I have a set of fog lights if you are interested.
I cut the original mount and put a bolt through the center of the rear housing.

John

[michael everson]

Len. Nothing. Its going together so easily.
John let me knw what you want for them.
Mike

[Jeff Kleiner]

...Its going together so easily...

And without a manual no less :)

Jeff

[GoDadGo]

Mike,

Thanks for sharing your account of this build.
Though I've only seen the new Type-65 at last year's "Cruising The Emerald Coast" seeing your assembly really shows the great engineering put into the kit and really showcases your abilities.

Steve

PS: I'd love to build one o these down the road, but it will be a few years if it happens.

[WIS89]

Mike-

Great progress so far. I am blown away how fast you are putting this together. I really appreciate all the details; I have been enjoying being along for the ride.

I am also doubly impressed by the fact that you have made this progress without a manual. That, or you are just showing off. ;-o)

Thanks for the details, and keep up the great work!

Regards,

Steve

[edwardb]

For those following this thread, Factory Five does have a manual now for the Gen 3 Coupe. Not that Mike needs it... :) I went to see a Gen 3 build a couple hours from me last week (very impressive BTW) and he had just received the manual in the mail from Factory Five. I obtained an electronic version of a draft copy some weeks ago. But the released one is now available.

My Gen 3 Coupe is scheduled to be completed next week. Then wait for Stewart. Trying to be patient.

[michael everson]

Eds right. Manual is now out. For anyone on the fence about building one of these, go for it. You wont regret it.
Mike

[GoDadGo]

Eds right. Manual is now out. For anyone on the fence about building one of these, go for it. You wont regret it.
Mike

I'll ask for one for Christmas, which is what my wife gave me two or three years before we ordered our MK-4.
I must have read that manual 4-6 times, maybe more, since I would read it at Baby Go-Dad's swim meets.
Will likely ask for the new Type-65 manual for my birthday if Santa Wife doesn't put one in my stocking.
Thanks For Sharing The News About The Manual!

[wareaglescott]

Mike I notice you have a tag on the car. When you are building these for customers how does this work? Are the kits in their names? Are you transferring ownership once complete? Any issues with that?
Been talking with this customer of yours on instagram so I know he is on the west coast and the Massachusetts tag had me curious.

[michael everson]

It was just paced there for the picture. Its the front plate off my Z06
Mike

[j65mustang]

On your fuel filler neck hose was the hose just a straight piece or did you have a pre bent hose to get away from the rear of the frame. I just got a straight piece of hose and when mounted on the filler neck seems to have too much of a kink in it. Factory five days I have the right hose but yours seems to fit much better. Thanks for the help. 76794

[michael everson]

If its a GEN 3 there is a 90 degree hose supplied with the kit.
Mike

[Mark Reynolds]

Here is a filler neck modified for the coupe w/o needing to cut the neck and add the straight coupler

http://www.breezeautomotive.com/details.php?prod_id=1131&cat_id=58http://www.breezeautomotive.com/details.php?prod_id=1131&cat_id=58

We offer a $43 credit for your un-cut FFR filler neck.

Sorry to crash your thread Mike!

[nkw8181]

Man you are flying!! I should get my thanksgiving week but you may be done by then :)

[j65mustang]

my gen 3 did not come with the 90 degree bent hose, only a straight hose. sent a picture to what I got to factory five and they said that was correct. thanks for the info I will email them again.

[michael everson]

This one came with the same one they use on the Hotrod. They even show it in the instruction manual. In fact I don't think I even got the hard straight one.

Mike

[michael everson]

Its been a couple of weeks since I updated this post. Been very busy with other projects as well as getting some work done on the Daytona.

For starters, I have the complete air conditioning system installed. I will do a separate post on this later but for now here are some photos of what I did.


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[michael everson]

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I have the complete cooling system installed including the cooling tubes from Boig Motorsports. They fit perfect.

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This is the radiator shroud from Breeze Automotive. Its the same one as the Cobra. Fits perfect. Probably not needed but looks nicer than the straps.

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[michael everson]

I started fitting the hatch glass yesterday. Everything went well except the hinges were a little too short. I was able to fix it, but FFR said it has already been updated in later kits.

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And finally I have the spoiler fitted. No issues there either. The body is now ready for the paint shop.

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In this pic you can see the FFR supplied power steering pump and bracket. Fit pretty good with no interference.

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[edwardb]

Looking great Mike! Will be very interested in your thread about the A/C installation. I saw where FF posted Gen 3 A/C instructions so I've reviewed those. Is that the setup you used? Also, what did you end up with on the Coyote to drive both the A/C and the power steering? One last question (sorry) the Boig Motorsports cooling tubes you mention, that's the upper and lower radiator hoses pictured? Instead of the FF provided corrugated hoses?

[michael everson]

Ed. I got he complete power steering kit from FFR. Very nice install and does not interfere with the A/C at all. The Boig Motorsport cooling tubes take place of the corrugated hoses that FFR supplies. Looks much nice in my opinion. Tell him I sent you.
As for e A/C install, I followed FFR instructions but did deviate a little bit on running the A/C hoses. The only real issue I ran into is the short hoses from the under dash unit to the front of the foot box. If you don't get the length exactly right, you wont be able to screw them into the bulkhead. One of mine ended up being about 1/4 inch too long. My fix was to space out the fitting on the bulk head. You can see that in this picture.


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Also I did not cut an access hole like FFR shows in the instructions. Instead I cut that panel at the 90 degree bend so that the front part stays in place while giving access to everything inside.

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I just cut it alone the long left edge shown in this picture. I plan to rivet it back together using a piece of aluminum angle from the inside.

[Vette1972]

Mike,

Incredible detail and nice clean finish on everything. It's a pleasure to see such craftsmanship on these cars.

Thanks for the update,
Len

[David Williamson]

wow you are quick building it. Hope the AC can be fit with only the top of the foot box open !! mine has been closed up for months and still waiting on the AC system.
David W

[michael everson]

David. I don't see any way. FFR does show in there instructions to cut an access panel into that panel. I thought my way was just neater.
Mike

[michael everson]

So I am about 140 hours into this build and making great progress. It will be leaving for the paint shop probably tomorrow. Here are a few things I got done this week.
Most of the body fitting went pretty well. I really could not get the hood and the cowl gap to look right. The weight of the hood was forcing the cowl down a bit. I came up with a brace which fixed this problem. The cowl is now solid and the hood fits perfect. Here are a few pics of the brace. Its kind of hard to see it mounted in the car.

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I also found when the car was on the ground at ride height the rear wheels were too far into the wheel wells. I bought 1.25 spacers and they look much better. The pic on the right has the spacers and the left does not.

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[michael everson]

Once I was satisfied with the body, I moved on to the interior. The customer and I discussed padding the dash. I used a self adhesive foam to cover the whole dash then wrapped it in vinyl. I powder coated the gauge hood semi flat black to match.

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[Dave Howard]

Whew... Great build thread. To the point. Not over the top elaborate. Great builders shine through naturally. With lots of chatter in the interweb on the Gen3 coupe, its nice to see you take a lead with showing it go together. Hats off Mike. Coyote on!!!

[Paul G]

Plan on making more of the Cowl braces for sale? What kind of space is there between the back of the Coyote and xbrace in the center? I haven't seen any pics of the control pack, I assume you are waiting for it? I'm waiting on my A/C to finish the wiring, then the Coyotes and T-56 will go in.

[michael everson]

I have the control pack. I plan to mount the ECU through the firewall on the passenger side. Most of it will be inside. I don't see this brace interfering with much. Plenty of room back there. No sure I really want to try and make these. I'm afraid there may be too much variation from car to car. we will see.
Mike

[Bobby Doug]

After reading this thread I just might sell my cobra and build one of these. Nahhh! Excellent information for someone thinking about building one. Thanks for sharing.

[D K]

What kind of headers are those?
Nice collectors..!

[Erik W. Treves]

they are FFR pieces

[michael everson]

So the Coupe is off to the body shop for the first round of body work. My guy will get all the door gaps perfect and then remove the body. I will get back to work on the chassis as soon as I get it back. In the meantime its back to a gen 1 Coupe build. Wish me luck....

[nkw8181]

Looking good!

[michael everson]

I got the Daytona back from the body shop. It was there for them to finish gap the doors and nose. No I am going to fit the exhaust and at some point the side windows. Then I will remove the body and give it back to them to finish and paint.
Here are a few pics of the exhaust install. Both pipes fit pretty decent but did need a little help. Both side pipes got a Breeze shim to move the end of the pipe closer to the body by 1 inch. also i needed to use 5/16 bolts to bolt them up so I could rotate the side pipe up a bit to make it parallel with the body. The end result is a perfect fitting pipe.

Here are a couple of pics before the shim and smaller bolts.

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and here is a pic after the shim and smaller bolts.


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and a pic of the hanger at the back of the pipes.

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I have read a lot of complaints about the side pipe fitment, but i didn't find them too bad. Certainly not any worse than the Cobra.

I also started getting the Coyote wiring and computer in place. I found that with a very minor mod to the engine harness i could get the computer mounted into the firewall.
Seems like a good spot for it and its out of the way. No interference behind the dash either.

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https://farm5.staticflickr.com/4674/39108434824_19bed223f7_z.jpg

The fuse box for the engine will also be mounted inside the car.

[michael everson]

And finally here is a pic of where I mounted the power steering reservoir. That system is now completed.

https://farm5.staticflickr.com/4719/28039530959_e34d2b4f92_z.jpg

[wallace18]

Very nice work Mike.

[David Williamson]

Looking good and coming together quickly.
It seems the side pipe fit is good with the Coyote but those of us going old school with the 302 based engines are having issues. My driver side is OK but the passenger side is off by about 2 inches. FFR is working with me to fix it and I know I will "win" in the end
David W

[michael everson]

Started working on some of the interior wiring. I already modified and ran the front and rear harnesses. This is a heavily modified RF harness. I decided to mount the fuse box to the right of the steering column up under the dash. Its the only place that made sense to me and still be able to get to the fuses.

https://farm5.staticflickr.com/4748/24992796967_fb72535718_z.jpg

https://farm5.staticflickr.com/4698/39153770984_fb4d33afb5_z.jpg


Also have the Russ Thompson turn signal installed and wired in. Hope to have the rest of the wiring done tomorrow then onto the Coyote wiring.


https://farm5.staticflickr.com/4608/39153771504_fc6329181c_z.jpg

https://farm5.staticflickr.com/4714/24992797597_0beb3cffc0_z.jpg

[nkw8181]

Looking good. I won't catch you but I will try ;)

[michael everson]

Been a while since I have updated. The body is being worked on at the body shop. I have been finishing up a ton of little things to get it ready to go. One of the big things was wiring the A/C unit.
I wired up the face plate with a plug so it could be removed for service if ever needed. Makes the wiring a little neater too.

https://farm5.staticflickr.com/4603/25193178297_e324400f22_z.jpg

https://farm5.staticflickr.com/4611/40032669542_87e2327559_z.jpg

I now have all of the wiring done and tested. Also have most of the interior insulated and carpeted Waiting on some high back seats and a shifter to finish off the interior.


https://farm5.staticflickr.com/4612/40032635712_d5ba35410c_z.jpg

https://farm5.staticflickr.com/4755/40032636722_f7c671f8bf_z.jpg

In this picture you can see where the fuse box and computer are mounted. Makes for a clean wiring job.

https://farm5.staticflickr.com/4711/28285787329_a75e2a049e_z.jpg

I opted to mount the Coyote fuse block on top of the driver foot box. there is not enough room to remove the cover once the body is on. I decided to mount it to a bracket that will allow me to remove one screw and slide it forward.

https://farm5.staticflickr.com/4697/39354519074_e025a97757_z.jpg

[Vette1972]

Mike,

Amazing detail and very neat. Enjoy following each update. Just great work.

Thanks,
Len

[nkw8181]

Looking great. It is amazing how the cars ca be "the same" but how we all do a little of this and a little of that different. I might copy you with the two switches above the stock ones. I find I have ALOT of switches.

[bil1024]

Looks great Mike, any advice on the a/c install ? Getting ready to do the passenger side foot box and would like to see what hints you have for the install

[edwardb]

Looks great Mike, any advice on the a/c install ? Getting ready to do the passenger side foot box and would like to see what hints you have for the install

Don't recall Mike had a lot of detail in his build thread about the A/C. He tends to spend his time building instead of in front of the keyboard like some of us. :rolleyes: Assume you're talking about the Factory Five heat/AC kit for the Gen 3 Coupe? Talked about it quite a bit in my build thread with lots of pictures. Link in my sig line below.

[bil1024]

Don't recall Mike had a lot of detail in his build thread about the A/C. He tends to spend his time building instead of in front of the keyboard like some of us. :rolleyes: Assume you're talking about the Factory Five heat/AC kit for the Gen 3 Coupe? Talked about it quite a bit in my build thread with lots of pictures. Link in my sig line below.

Cool , will check it out thanks