CDobbs MK4 base kit build by wallace18

[wallace18]

I just ordered a base kit MK4 for my painter guy, Chris. We are swapping out work. I will build his MK4 and he will do the paint and body work on my Hot Rod 35 P/U. Works well for me. We will go get both kits in early April. We will use a 1992 donor mustang he has for the base kit. I always wanted to build a base kit car, now I get to do it. Here is what we ordered.
Base Kit
Powder coat chassis
Body cut outs for 2 roll bars
Tubular lower FCA
FFR vintage gauge set
wind wings and sun visors
passenger roll bar with grommets
heat/defrost
Electrical system completion components
vinyl seats
J-pipes

The game plan is for everything to be black. I am very excited as is Chris. I will be getting all the donor stuff ready till the kit is ready. :cool:

[Yama-Bro]

That's a good trade. It sounds like both of you are going to win. Good luck!

[CVOBill]

That's a great deal for both of you!!!

[SelectivePC]

Sweet, I have re-ordered so many misshipped parts in the last month. I'm surprised the kit went so long without even being checked, 2/2014 delivery, I checked parts boxes last year... 12/2017. Hah. This is a sweet deal though. Cant wait to see the progress..

[wallace18]

After getting some measurements from Tony at FFR and RoadRacer I am 100% sure both kits will fit in my 20' FFR enclosed trailer. The 35 is 14' long but the frame is only about 19" wide at the very front. This allows me to put the 35 way into my v-nose on the floor up front. The distance from the frame front to the rear of the cab is 8'. This allows me 13'6" from the rear of the cab to the rear door. The MK4 is 13' long. I will build a platform above the 35 bed for the MK4 and stack them staggered. There will be plenty of room on the sides for boxes as well as my F-150 bed and rear seat area. We will have to attach the MK4 floor to 4"x6" side rails after the 35 is in place and tied down. Should be an adventure for sure, but will save me another trip and money. Thanks again to everyone who gave me measurements to make this happen.

[wallace18]

Chris brought by his 1992 donor mustang last night. Turns out it already has the A/C delete for the front serpent system. Nice donor and has really nice wheels and tires to go on the MK4. Engine has GT40 intake and GT40P heads. I will start to get all the donor stuff off of it on Friday afternoon.

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[wallace18]

Had time after lunch to remove engine, trans. and drive shaft. Hope to get rest of donor stuff out of car tomorrow.

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[wallace18]

Today I was able to remove all the donor parts from the 92 Mustang. I loaded it up on my trailer for Chris to get it out of my yard, LOL. Taking Sunday off for good behavior.
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[wallace18]

Took apart the motor yesterday. Chris told me that he thought he hurt the motor doing a burn out. It turns out it wiped out the crank and bearings but everything else is OK. I will replace lots of wear items anyway. Chris is coming by tomorrow to take a look and get my parts list so he can get the needed stuff for the repair of needed items.

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[wallace18]

Been working on donor stuff. I cleaned and painted the heads, accessories brackets, steering rack, rear end and power brake unit. Lots of blasting and wire brushing before paint.

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[WIS89]

Tom-

That's a pretty unusual clothes line you have going there... HA

You are making solid progress as always! Is Chris pretty stoked about seeing the work you are doing?

As always, I enjoy following along!

Regards,

Steve

[wallace18]

Chris is excited for sure. It turns out after I honed the cylinders #1 has a big scratch in it. Chris is either going to sleeve that #1 cylinder or find a good std. block.

[wallace18]

Today I cleaned up fuel tank, transmission. Cleaned and painted front calipers, water pump, intakes, bell housing and front spindles. Should have most everything cleaned and painted by Monday. Chris is working on parts list for me.

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[FLPBFoot]

Great pics. You do nice work!!

[wallace18]

Today i reconditioned the pedal box, gas pedal, wrinkle painted valve covers, replaced injector seals and reassembled intake. taking a few days off till parts come in and block comes back from fixing #1 cylinder.

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[wallace18]

Chris and I have been going back and forth on what to do with his block and crank. We ended up using a good 0.40 over block and pistons I had with a rebuilt 10/10 crank kit. I am waiting on a gasket set and then should be able to put the motor and trans stuff together. Chris came down with the flu. Hope he is better by April. Short block assembled today.

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[wallace18]

Waiting on gasket set had me doing what you have to do with a 26 year old donor. Clean, wire brush, paint bolts and brackets. Not my idea of fun but needed work anyway.

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[wallace18]

Finished up the basic engine. All black as per Chris. Taking the weekend off to do a car show.

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[glastron351]

Thanks for the detailed pics and updates....nice to see

[WIS89]

Tom-

Looking good, as always! It's nice to follow along on a donor build.

Good luck at the car show. Which car are you taking? Let us know how it goes if you get the chance!

Regards,

Steve

[wallace18]

I do not have a car right now, waiting on my35 kit. Just helping out.

[wallace18]

After catching a bad cold for the 3rd time in 4 months I am finally feeling well enough to do some donor work. I installed the BBK clutch kit on the pedal cluster. Way better IMO than the stock plastic stuff. Also painted the fuel tank and quad shocks. Chris should have rest of the stuff to finish up donor prep by Wednesday.

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[videodude]

Tom,

I'm impressed with the speed in which you have progressed on this project. What did you do, hire a bunch of garden gnomes to pull that donor apart? My planned build echoes this one very closely, and my donor is a '93. I'll be watching your build thread with great interest. Are you doing PS as well as PB?

Video

[wallace18]

Tom,

I'm impressed with the speed in which you have progressed on this project. What did you do, hire a bunch of garden gnomes to pull that donor apart? My planned build echoes this one very closely, and my donor is a '93. I'll be watching your build thread with great interest. Are you doing PS as well as PB?

Video

Yes we are doing both. I am fortunate to be retired and have a excellent workshop and tools. It makes the whole deal go easy. Thanks for the kind words.

[wallace18]

Picked up the rest of the parts we needed yesterday. I pulled off the rear end cover , drained fluid and checked it out. Nice 4:10 Ford ring gear set. Chris found a aluminum cover to replace rusty old one. Filled up and ready to go!

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[wallace18]

Installed the control arms, shocks, sway bar and new brake hose. I also installed & packed new front wheel bearings, rotors, pads on the front spindles. All ready to bolt in. Installed new S/S headers and oil filter on new adapter.

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[wallace18]

Just got email from Tony at FFR. We will pickup MK4 and 35 on April 9th. Chris is stoked!

[Higgybulin]

With all the pre-assembly these should be about a 3 month build!!!!! No pressure!
Higgy

[wallace18]

Well we are all ready to hit the road tomorrow morning to get the MK4 and 35 P/U. We have stops in NC and PA for the first few days. Should be at FFR Monday morning to load everything up.

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[wallace18]

Made it to FFR on Monday safe and sound. Met with all our great FFR folks. Dave gave Chris the 50 cent tour and Chris was blown away with FFR. We loaded the 35 first them his MK4. Made it home safe on Tuesday about 10:45PM. Thanks to all the FFR gang for their help and friendship.

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[wallace18]

Yesterday morning I got all the boxes out of the trailer. I put all the MK4 boxes on the LS and my 35 on the RS of my bay. I was able to inventory all of the MK4 by noon, Yea! Besides the POL list (backordered parts) only 2 bolts were missing . Great job, Paul at FFR! I will finish up getting some bare steel parts painted for assembly on the MK4 today as well as finish up the 35 inventory.

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[wallace18]

Lots of folks have been wondering how we were going to get the MK4 out of the second deck in my trailer. It was very easy. I lifted the front of the frame and Chris put a furniture dolly under it. We backed my trailer as far back to my shop opening as we could and put another dolly under the ramp door. Chris and I lifted the rear of the MK4 and rolled it out enough to strap it to the beam over the shop door. Then I pulled the trailer forward till the dolly was at the rear of the deck. Then my neighbor Dave came by with his JD loader and lifted the MK4 up and I drove the trailer away. Then we set the MK4 on 2 dolly's and rolled it up on the lift. My hotrod buddies came over and we put the body on the body buck. Now I can get going on the build. Woo Hoo!

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[wallace18]

I had time this afternoon to paint the spring perches, brake hose brackets, spindle adapters and front bumper/T/S brackets. Also used truck bed coating on the front aluminum panels. Did some clecko work too.

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[wallace18]

Mounted front aluminum panels and front suspension minus POL front shocks. Mounted front rack with extensions. Thanks to Mike Everson for help with that. Drilled and fabbed up R/S foot-box, drilled most of L/S foot-box. I removed R/S and pt together with some technical screws. I will coat outside with Lizard Skin and inside with get Eastwood Therm-sound insulation. This is great time to layout insulation. Beats trying to do it in the car laying on your back, LOL. Dave Smith talked Chris into some 17" staggered Roadster wheels. Wink, Wink! We will be converting to 5-lug next week so Chris can use those instead of the 4 lug ones from the donor. Sweet!

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[wallace18]

It was a drilling kind of day today. I drilled and mocked up the rest of the foot-boxes, floors, rear interior panels and 6 pieces of trunk panels. I will now coat all of them so they can be installed when it is time. To save time if 2 panels are mirror images I drill on and use it as a template for the other. Makes it look the same and saves time. I also make a center brace for the firewall. Still have 8 more interior/trunk aluminum panels to drill and mock up.

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[wallace18]

Today I finished up the rest of the interior aluminum drilling. I then coated the foot-boxes, floors, tunnel cover and firewall with Lizard Skin coatings. All the rest that is exposed to the outside I coated with black HF truck bed liner. The Florida sun made it quick drying for sure.

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[wallace18]

Today I siliconed and riveted 90% of the interior aluminum, firewall, Passenger foot-box and front of drivers foot-box. Also installed Battery, hold down and negative cable. Installed steering shaft minus POL top shaft. Installed pedal box, P/B booster and Master Cylinder. I used a left over complete kit gas pedal instead of modified stock one. Waiting on Jeff at Whitby to send P/B brace for frame. Should have been here a week ago. Hopefully soon. Staying busy working around missing parts till they come in. Hope to have 5-lug conversion parts by tomorrow. Taking Thursday off to drive church bus for the day.

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[Yama-Bro]

Today I siliconed and riveted 90% of the interior aluminum, firewall, Passenger foot-box and front of drivers foot-box. Also installed Battery, hold down and negative cable. Installed steering shaft minus POL top shaft. Installed pedal box, P/B booster and Master Cylinder. I used a left over complete kit gas pedal instead of modified stock one. Waiting on Jeff at Whitby to send P/B brace for frame. Should have been here a week ago. Hopefully soon. Staying busy working around missing parts till they come in. Hope to have 5-lug conversion parts by tomorrow. Taking Thursday off to drive church bus for the day.


Today?! Dang, that's more than I can get done in a month. ;) Keep it up!

[wallace18]

Today I spent most of the time converting the front and back to 5-lug from the 4-lug Fox body stuff. Started to install the 4-link rear end. Still have to do the spring perches, springs and axle straps. 3-link is much easier , IMO.

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[wallace18]

Worked just a few hours this morning. Finished up rear end , Installed E-Brake handle and hooked up to cables, mounted gas tank and fuel filter.

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[KenWilkinson]

Did you apply Lizard Skin to the bottom and top sides? IE, ceramic for insulation and the other for sound insulation?

I'm interested in this approach rather than a Dynamat solution if it makes sense.

Any feed back folks?

[wallace18]

With Lizard skin you must first apply the sound deader coating, then the ceramic heat coating. I do this on the outside of the footboxes and trans tunnel area. I then install Eastwood X-mat on the entire interior cockpit inside. I have done this on multiple builds with great success as far as heat and noise.

[wallace18]

Today I finished up fuel tank area hoses, wires and lines. I made a charcoal canister. I made all the brake lines and bled brakes. Found out I forgot Chris wants to install line lock. I will have to redo front brake lines tomorrow, :(. Installed rest of trunk aluminum.

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[wallace18]

I siliconed passenger foot-box and installed X-Mat inside as well. I installed inside drivers foot-box and top inside aluminum panels. I made up my own brake light switch bracket. Installed heater/defroster, wiring harness's, ECU computer and clutch cable. Chris came by after lunch and installed his ignition wires, nice job by the way. Hope to install engine/trans tomorrow.

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[wallace18]

While waiting on some part answers, I mocked up the dash so it can be removed with the body on. You never know when you may need to get at some wiring down the road. I use aluminum angle and tap it for 1/4-20 S/S button heads to mount dash later. Chris decided to postpone line lock till down the road after car is done.:o After lunch I installed engine/trans and started running wires and such.

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[wallace18]

Spent all day on wiring harness for engine and fuel lines. I covered fuel lines with 2 different heat sleeves. I may header wrap #3 and #4 pipes out of head to help with heat near fuel lines as well. I have 90% of EFI/Engine harness done. Throttle cable and clutch cable routed as well. I have P/S lines on rack, ran out of time to finish up to pump.

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[wallace18]

Not much to take photos of today. Finishing up wire harness for engine, installed coil and made up coil wire, installed O/P and W/T sensors and wiring. Hooked up P/S hoses and filled pump. Installed drive shaft and filled trans with fluid. Plumbed up P/B booster. Worked on getting all the pedals and cables just right and installed stops. Taking weekend off for good behavior, LOL.

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[wallace18]

Installed 95% of cooling system. Rubber mounted radiator. heater hoses all run. Installed J-pipes and O2 sensors. Finished up air intake and MAF sensor. Waiting on some stuff from Summit so I can start engine.

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[wallace18]

Scored a nice 5.0 intake bolt plate on E-Bay. Installed the Whitby frame brace around booster. Started wiring the FI relay/fuse panels.Installed heater valve and temp sensor in lower radiator hose. 5.0 intake does not support 3 water temp ports like aftermarket intakes do. Filled engine with 50/50 coolant mix. Hope to start it tomorrow sometime in the afternoon.

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[wallace18]

Milestone today, started engine! Seems to run great. Waiting on POL parts so I can go-cart. Good oil pressure and fans come on when they should. Got lucky I guess, LOL. :cool:


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

[JoeAIII]

Woo hoo!

[wallace18]

As good as it has been going I guess I was due a bad day. It started out good as I swapped out the fan sensor and temp gauge sensors. I liked the temp sensor in the head vs in the lower radiator hose. I refilled engine with coolant and started working on interior wiring. I came back from lunch to see water dripping from the bell housing area. I looked at the drip and it was coming from the oil pan in the passenger rear area. Well I looked everywhere I could and could only see water dripping from the oil pan. So I drained the oil, no water. It wass still dripping under car by the oil pan. I pulled the pan to find it was the thermostat housing all the time. I ordered the parts to fix and called it a day. Hope tomorrow is better. :(

[wallace18]

Still waiting on a thermostat housing. So I mocked up the center console, under dash panels and made spots for radio, speakers and heat vents. Speakers and vent will be hidden when you are seated in cafe and from above. I will cover dash with FFR supplied cover and rest with marine grade black vinyl.

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[wallace18]

Normally I do not work on Saturday but, this week has been weird. I reinstalled the oil pan and went to install the T-Stat. housing and low and behold the lower stud pulled out of the intake when I went to tighten the housing down. Most likely the reason for the leak in the first place. I ended up installing a heli-coil. I went and covered the dash so it felt like I got something done. Oh the joys of Kit car building, LOL.

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[wallace18]

I have been chasing a coolant leak around the Thermostat housing for several days. It turns out the lower intake is bad. Chris is going to get another. Today I worked on covering the under dash panels and finished wiring all the dash, radio and electronic antenna. Tunes are coming out of speakers, Yea! I have to recover the radio console. I am not happy with the first result.

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[wallace18]

Today I finished up radio console. I also started to replace lower intake. Hopefully this will fix coolant leak.

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[wallace18]

Yesterday I was able to finish up intake, no coolant leaks-Yea! I installed seats for holes to be drilled and installed slider on drivers seat. Marsha and I tried to bleed brakes but could not get any pressure out of rear circuit. I ordered another master cylinder and now have pressure but a soft pedal. May still have some air in it. At least now all 4 brakes grab. I removed seats and installed X-Mat. POL front shocks and trans bracket came Fed Ex so I finished up front suspension and trans mounts. I also drilled and mounted roll bars.

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[wallace18]

Running out of stuff to do. Waiting on upper steering shaft so I can go-cart. Also wheels and tires should be here by end of the week. Today I mocked up the rear lights, front lights, fuel filler and hood scoop. I do not like to use front T/S lights to hold body brace. So I mount the light 90 degrees from the holes that come from FFR and will countersink some screws for the brace when mounting the body. That way if you ever need to remove the light it won't mess with body position, JM2CW. Going to put the MK4 under cover till parts arrive. I may do a little work on my 35 stuff.:cool:

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[KenWilkinson]

Wallace18,

I'm about three hours away. Found out my 35 is going on the truck this Friday (fingers crossed). I"d like to visit you if possible and maybe be of assistance for a few hours. Let me know if possible.

[wallace18]

Wallace18,

I'm about three hours away. Found out my 35 is going on the truck this Friday (fingers crossed). I"d like to visit you if possible and maybe be of assistance for a few hours. Let me know if possible.

Sure thing. PM sent.

[wallace18]

Made some panels to hide roll bars and seat belts in trunk area. Also Powder coated quick-jacks and painted trunk hinges. Chris came by to check out build. First time he heard it run in the flesh. He is a happy guy, LOL.

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[wallace18]

Still waiting on some parts. ***Just a note to those who are thinking of doing a base kit build. The base kit does not come with hood hinges and gas struts. It comes with hood pins and you will have to lift off the hood. Spend the extra money and get the hood hinge kit. I just ordered it for Chris. IMO the complete kit is a better way to go. I am glad to be doing this base kit build so I could see the differences myself. I am going to have some minor surgery next Wednesday and will be out of service for 2 weeks, so parts waiting is not so bad. LOL.

[wallace18]

For the last week I have been going crazy not working on a car. Since I am allowed to lift 20lbs, I went and painted the hood hinges. I then installed the kit on Chris's hood. Hopefully on Wednesday I get the go ahead to start back on the cars without restriction.

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[wallace18]

Wednesday the doctor gave me the OK to get back to full work load. Yea! Thursday the steering shaft came and Chris dropped off the painted wheels with tires. Today I installed everything. Shimmed up the pillow block near the steering wheel for clearance on the frame. Then I did a front alignment. Then Go- carted it. Storm was in area so no video yet. I barely made it back to the shop before the storm hit. I had to modify the tie rod ends. As they were off the 1992 donor they would not allow for toe in with lock nuts installed. I removed lock nuts and drilled and tapped for set screws and lock nuts. Now everything is cool. Chris is coming over on Sunday to drive go cart and help me put body on.

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[WIS89]

Tom-

It's about time you got back to work! HA ;)

Very pleased to hear the doctor cleared you for everything, and I know it must feel good to be back in the garage!

Chris has to be pretty stoked to be able to go-kart. I look forward to reading about how that goes.

I look forward to your regular updates on your myriad projects!

Regards,

Steve

[wallace18]

Chris came by after church. He got to go-cart it. Nothing but smiles from him. We then dropped the body on the chassis. Here is some pics and a video.

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https://youtu.be/YTpdeBKtjdQ

[CVOBill]

Looks like Chris enjoyed the go-cart lol. Looking good Tom.

[wallace18]

Today I centered and bolted down the body. One thing I do a little bit differently is I countersink 2 S/S screws to mount the body to the front body braces instead of using the turn signals. I then drill 2 holes for the turn signal 90 degrees from the FFR holes. I also installed the hood. I still need to trim it for the 3/16" gap. Car is coming along very nice.

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[wallace18]

Got a lot done today. I gapped the hood, trunk and doors. Then mounted all of them. Installed the windshield, hood latches & door latches as well. Make sure you mount windshield 27" from rear door opening in case you ever want to install soft top.

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[wallace18]

Wired up all the tail lights and front lights. I use weather-site connectors from Summit. I also mocked up all the splash shield and radiator aluminum.

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[wallace18]

Finished up all I can do til I get side pipes back from ceramic coating. I clearance the roll bar holes, mocked up the rest of the aluminum, rear view mirror and located defrost vents. Chris cannot take car for bodywork/paint for 3 weeks. So on the 4-post the MK4 goes and the 35 on my 2-post.

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[wallace18]

Chris brought by the ceramic coated side pipes late yesterday. I mounted them today. I do the brackets a little bit different. I install thread inserts in frame for rubber mounts and clearance the brackets around the frame some. Boy they sound great! First set of FFR side pipes I have installed. Usually install quiet pipes. Now car will go to Chris on the 23rd for body work and paint.

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[wallace18]

Delivered the MK4 to Huegenics this morning. We also went down the street and had it weighed. 2160 lbs without driver. Chris will do bodywork and paint now.

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[wallace18]

Went to Huegenics today to help Chris remove body for paint. He modified the doors for more room as well as a neat deal around the side pipes. Should be getting paint over the next few weeks. I took chassis home for clean up and interior work when I get back from Vacation.

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[wallace18]

Got back from vacation and drove my 35 out and into my home garage. I pressure washed MK4 frame to get dust off from bodywork. I cleaned everything up and started to install carpet. Hope to have chassis ready for painted body by Saturday. Chris is holding me up, LOL. Guess I will light a fire under him, NOT!

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[wallace18]

I finished up interior and trunk area. Just a few more things to knock out and it will be ready for that gloss black body!

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[wltrmtty]

With Lizard skin you must first apply the sound deader coating, then the ceramic heat coating. I do this on the outside of the footboys and trans tunnel area. I then install Eastwood X-mat on the entire interior cockpit inside. I have done this on multiple builds with great success as far a s heat and noise.

I'm admittedly ignorant regarding these cars, but with the wind noise of an 'open cockpit' roadster having side pipes that blast just below your ears, I'm curious as to how effective or necessary a sound deadener of any type would be. The heat shield, I get.

[wallace18]

It helps with the aluminum not vibrating and makes the interior more comfortable in my opinion. If you thud the floor without the sound deadener and then with, you will see a huge difference. When the car is not not noisy. IMO it is well worth doing.

[wallace18]

Well I am done with everything I can do till body is done painted. All loaded up in trailer . Maybe by 2nd week of OCT???

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[wallace18]

Took the chassis to Huegenics to mount body, doors, hood and trunk. Mounted a few other stuff. Brought it home to work on my lift to finish it up. Possible hurricane Michael on the way also.

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[wallace18]

Finished up the MK4 today. Made a trunk prop from leftover 33 hood parts. Chris will do final detail and remove my finger prints on Friday, LOL. Big car show debut on Saturday. Thanks again to FFR, Replica Parts, Herb's door panels for the great parts and service.

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[wallace18]

Finished up the MK4 today. Made a trunk prop from leftover 33 hood parts. Chris will do final detail and remove my finger prints on Friday, LOL. Big car show debut on Saturday. Thanks again to FFR, Replica Parts, Herb's door panels for the great parts and service.

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[CVOBill]

Nice job Tom. Now get back to work on the 35 lol

[wallace18]

The MK4 is loaded up and going to Huegenics today for final detailing. Big car show Saturday. A couple of things I would like to point out about the base kit vs complete kit. First if you use aftermarket 5-lug conversion kit be wary of front dust caps. The FFR supplied ones in the complete kit do not interfere with the spinners but I had to grind clearance to make them work with the NPD kit. See attached photos. The base kit does not come with hood hinges, you must lift it off the car. Pay the extra for the hinge kit. We really did not save much vs the complete kit. Our donor had a bad radiator, master cylinder, rotors, etc. We would have been ahead going the complete kit, IMO. The quick jacks are a shin killer, IMO. Buy the bumper kit. They look better and not as hard on your shins, LOL. I was glad to build a base kit so I could see the difference. I will post final pictures on Saturday. I start another MK4 on the 20th for a new customer. I do get to work on my 35 a few days though.

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[JoeAIII]

Regarding the quick jacks, I saw the 289 beauty shots they are mounted "backwards" which would save the shins, especially if it winds up parked in a tight garage...

[wallace18]

Here it is all shined up. Chris the owner standing by. Another car, 33Hot Rod I built for Richey was at the show as well.

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[wallace18]

MK4 Won best paint in its first car show. Proud owner Chris standing by. :cool:

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[wallace18]

Here is a better picture of the finished mk4.

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[cv2065]

Congrats man. That’s awesome! I’m only an hour or two south from you. Should be ready for paint in a couple of months. Is Chris taking orders? :cool:

[wallace18]

Congrats man. That’s awesome! I’m only an hour or two south from you. Should be ready for paint in a couple of months. Is Chris taking orders? :cool:

You can contact Huegenics. Here is their website.

http://www.huegenics.com

[Rleon]

Tom,
Congats! That car looks great. Chris must be so proud!

[cv2065]

You can contact Huegenics. Here is their website.

http://www.huegenics.com

Thanks. Left Chris a message through the website.