Rsnake roadster build thread

[Rsnake]

Hello everyone,
Well, I went and did it! I ordered my roadster on Wednesday with an anticipated delivery of early May.
My son returns from boot camp May 4th and hopefully the car makes it before he heads off to infantry school on May 14th. He was so impressed with the factory five tour we took after Christmas and then again at Barrett Jackson, he will be so excited to see it. I have dreamed about building a factory five for a long time and can't believe it's ordered. So, the details;
Roadster with coyote and Tko 600
Full length headers
Powder coating
IRS
Power steering
Koni double adjustable shocks
Sway bars front and rear
Wildwood brakes
Leather seats
Ffr gauge set
Halibrand wheels
Heater
Probably hydraulic clutch

I have been reading the build threads and learning as much as I can. Tony Zullo was amazing with his knowledge and help with the ordering process. I am impressed.

[SerpantFL]

R, Best of luck with the build, you will have an wealth of information here with the members. Thank your son for his service, and hope he stays safe. Anthony

[Venom61]

Good luck, sounds like a great build. Great info on the forums. Our thanks to your son for his service.

[sbhunter]

Ditto what Venom61 said. Thank you to your son and thank you to you for raising a man willing to serve his country. This build is a fantastic journey. It’s even better shared with your children.

[Rsnake]

Good news. Paid factory five yesterday and the kit should be finished on the 21st and Stewart will be picking it up on the 23rd if all goes well. My son graduates on May 4th so the timing should be good. Getting excited.

[GoDadGo]

Welcome Aboard & Please Thank Your Son For His Service!
I know he is just starting his military career, but he's already a hero in my mind.
I'm sure he is a fine son and one fine American.
Welcome To The Factory Five Family!

Steve

[Rsnake]

Thank you very much. He is a great son and I am proud of him. Cannot wait to see him! On to the build,
has anyone painted the suspensions pieces from factory five? I am thinking about scuffing
all the pieces and painting red to match my future red stripes on dark grey paint scheme. I did this when I built
my 67 fastback and it's a great touch but I haven't seen anyone do it on the forum.

[Dave Howard]

Congratulations on making the jump into the Cobra kit car world. Your build plan sounds text book. Several hundred before you along the same lines. FFR build manual, the FFR Tech Support guys and the collective knowledge in the forums should ensure a successful build. As for changing the color of the suspension parts, you may want to have them pounder coated. I'd be concerned with using paint that road debri would knock the color off.

[Rsnake]

Thank you Dave. It's been 30 years of dreaming about building one. As for the durability of the paint I shoot the same 2 stage used on the body. It held up well on my mustang suspension which was tracked a lot. It did look beautiful if you jacked it up. The front clip of the mustang was another story. Sticky tires kicking up gravel doesn't do well for a paint job, but since I paint cars for a hobby I don't worry about it.

[Mark Eaton]

Rsnake, Painting your suspension parts is a great idea. Post photos please. Also, I'm intrigued that you paint cars for a hobby. I'll be rattling your chain in about six months when I am ready to start painting my MK4.:)

Mark

[Rsnake]

Mark, I have been painting cars on and off for thirty years and enjoy it in small doses. A ton of work and tough on the shoulders with all the block sanding. If I could post photos I would attach a couple. Just finished a tr6 that I was planning on keeping but went to Sema and had to have my dream car so the triumph was sold and the cobra ordered. I am willing to help you out anyway possible. Easier to paint then most people think.

[Rsnake]

I received an email from Stewart yesterday telling me they have trucks on the way to factory five and my kit should be picked up any day, keeping my fingers crossed. Received a photo of the completed kit from Tony on Tuesday so I know it exists. The waiting is killing me.

[GoDadGo]

The fun is about to begin so here are a few tips that will help you get started:

1. Read the manual one more time before you start doing your inventory.
.....(It Makes The Inventory Process Easier!)

2. After you check in each box, make a copy of the packing list place a cope of each sheet on it's corresponding box.
.....(Helps You Find Parts As You Start The Assembly!)

3. Take your time doing the inventory and get familiar with each part, then take you significant other, assuming you have one, out for a nice dinner.
.....(Their Favorite Place!)

4. Then read the manual again and start your build.
.....(It Makes A Diffidence!)

Good Luck & Congratulations Again Because A Grand Adventure Is Truly About To Begin!

[Rsnake]

GoDadgo,

Thanks for the advice. Number 3 is probably the most important since I won't be seeing her as much as usual.
How long does inventory usually take?

[GoDadGo]

It took my wife and I about 8-10 hours.
I dug through each box and found the parts and she checked off each item.
We literally touched every part except for the individual rivets.

NOTE: Since we've had many "Life Event Delays" being organized has been extremely valuable.

[Yama-Bro]

Congrats! It'll be in your driveway before you know it.

[Rsnake]

8-10 hours for inventory! Wow, I am scared already.

[initiator]

It's not that bad. I broke my inventory into two or three sessions to keep sharp, but it's a bit like Christmas morning every time you open another box!

I also took a picture of the contents of each box laid out, all internal boxes opened, with the box number clearly in view. Helped me find some parts later. Here's one example:85107

[Rsnake]

Taking photos of the box contents is a great idea, especially if they are tough to get at.Since I don't have storage space the boxes will be in my Sons room since he won't be needing it for a while. I assume everyone writes what's in the box on them.

[edwardb]

Taking photos of the box contents is a great idea, especially if they are tough to get at.Since I don't have storage space the boxes will be in my Sons room since he won't be needing it for a while. I assume everyone writes what's in the box on them.

Congrats on your upcoming kit delivery. You're in for a great adventure. You're getting good advice on the inventory. Don't short circuit the process. Builders get understandably anxious and want to start building immediately. But take the time now and you'll find it's worth it later. Especially as a first time builder. Doing the inventory not only makes sure you have everything, nothing is wrong or damaged, etc., it gives you a chance to see and touch the parts you'll be using. If you did your homework and read the manual (you did, right? :D) you'll recognize things as you go and little by little it will all make sense.

I too highly recommend leaving the parts in the boxes as received. Sounds like you have room. As backordered parts show up, highly recommend to put those in the boxes they were supposed to be in.

Taking pictures and writing on the boxes is a good idea if it helps you. What you may not know is you will receive a full manifest of every box and what's in every box -- line by line -- with your kit delivery. I punch holes in those pages and put in a three ring binder. That becomes my roadmap for finding things as I need them. Some put the pages right on the boxes. That's OK too. But I prefer to have them all together.

Bottom line is to stay organized. You'll understand that even more when you see all the parts. Good luck and enjoy!

[JoeAIII]

I moved the contents of the boxes to black storage bins from hd. They are more resilient and stack better, imo. I put two boxes into each bin with labels on the top and two sides with what boxes are in them and their descriptions. It was a year between inventory and starting the build and we have had no problem finding the parts we need.

[Rsnake]

Thanks for all the ideas. I have read the manual a couple of times and many of the build threads, still digesting all the information.
I have been getting organized over the last few months waiting for the kit and hopefully it stays that way after it arrives.
I think I have a colored picked out, Ford lead foot grey with red stripes. Trying to avoid metallic since I will be spraying it in my garage with poor lighting.

[Rsnake]

It's officially on the truck headed my way, and I even have a photo to prove it. Just cannot post the photo yet.85199

[Rsnake]

Actually it let me post it. My bad.

[shark92651]

Actually it let me post it. My bad.

Awesome, did you get a call from the driver or did you get an update from Factory Five? I still haven't heard if mine was picked up yet. I'm starting to think that Stewart Transport has it out for me since mine has been sitting since 3/24!

[Rsnake]

I emailed both parties this morning to see what was going on as Stewart said they had three trucks on the way.
Tony said the truck was there and it was getting loaded. Hopefully yours is loaded with mine. Jolene did tell me mine was headed to Phoenix where it would be transferred to a truck equipped with the rails to deliver the kit.

[Rsnake]

Wilwood brakes arrived so figured I would safety wire rotors as the wait for the car is killing me.
Have brakes but no car to put them on. 85524

[Rsnake]

Well it finally arrived. The driver was amazing and all went well. Started inventory last night and decided the best method was to write the contents of each box in black sharpie on the outside of the boxes.
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[Mark Eaton]

Right on, let the fun begin! Be meticulous with your inventory...

[Rsnake]

Mark, inventory is done and I am only missing a few things. Will contact Tony tomorrow.
So in 24 hours I have finished the inventory, taken the body off and finished drilling the f panels.
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[John Ibele]

Mark, inventory is done and I am only missing a few things. Will contact Tony tomorrow.
So in 24 hours I have finished the inventory, taken the body off and finished drilling the f panels.
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....and, you're underway! Congratulations!

I followed pretty much all the advice you've been given on inventory process, and it worked well. After that, I went back and took a photo of every inventory sheet, so I had it all in my phone. When I'm away from the car but intend to pick something up or order something, it comes in really handy.

[Rsnake]

So after work today I figured I would get the pedal assembly mounted up as I am waiting for parts. I don't think it will interfere with anything down the road, will it? I don't want to remove something because it's in the way. Hopefully I didn't waste my time.
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[Rsnake]

My friend put a tesla sticker on the nose of the body last night. I think I will keep it for a while, should generate some interesting discussions.
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[Yama-Bro]

So after work today I figured I would get the pedal assembly mounted up as I am waiting for parts. I don't think it will interfere with anything down the road, will it? I don't want to remove something because it's in the way. Hopefully I didn't waste my time.
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Shouldn't interfere with anything. The pedal box goes in pretty early on. The only thing that's close to it is the firewall and I think you have room.

[Rsnake]

First issue appeared tonight. My son wanted to install the steering rack and I figured why not, I don't think it will interfere with anything down the road. We pressed out the bushings that came with the rack and installed the poly ones with no drama. The drivers side of the rack dropped into place and we inserted the 1/2" bolt, as the passenger side was lowered I realized the rack mounting hole is 1/4" too wide! I thought about drilling the holes on the chassis to 5/8" which will give me the width but wanted to check with the professionals before doing so. Thanks in advance for the help.

[edwardb]

You list power steering in your first post. So the power steering rack from Factory Five? Just curious and making sure nothing unusual. Also you mention installing the poly bushings. Also the metal sleeves that go inside those? Just want to confirm. I personally haven't had the issue, but I've seen mention by several builders that they had to enlarge the frame mounting holes. First make sure the powder coat is removed from the holes and the bolt will go in and out freely (same can be said for all the suspension mounting holes). Whatever additional clearance is required I would slot the holes the required direction rather than drilling them larger. I would also make sure that whatever adjustment you make the rack stays centered.

Another option is the bushings from Breeze. https://www.breezeautomotive.com/details.php?prod_id=720. These replace the FF poly bushings and sleeves and allow adjustment to get everything aligned.

[Rsnake]

Edward, it's a factory five power steering rack straight from them. I have the poly bushings with the metal sleeves and the bolts do go through the frame with no issues. I can try and snap a photo. And things were going so smooth, oh well, all in the fun.
I will call fcatory five tomorrow and see what they say. Thanks

[edwardb]

Edward, it's a factory five power steering rack straight from them. I have the poly bushings with the metal sleeves and the bolts do go through the frame with no issues. I can try and snap a photo. And things were going so smooth, oh well, all in the fun.
I will call fcatory five tomorrow and see what they say. Thanks

Pretty normal to have "adjustments" like this. 99.9% sure they'll tell you to enlarge the holes.

[Rsnake]

Factory Five informed me the drivers side hole in the chassis should be slotted and mine is not. They want me to send photos which I will do when I get home tonight.
I will report back.

[Rsnake]

This afternoon I slotted the driver side hole and the rack dropped right in. All is good. Not sure what happened but it's all part of the fun.

[Rsnake]

Today started painting some of the suspension pieces. Painted both sway bars, upper control arms, driveshaft, trunk hinge arms and front body mount brackets. Glad I painted the driveshaft as the black that was painted on came right off with a scotch bright pad and never would have lasted. Still waiting on parts so figured I would get some of the painting done.
I have most of the aluminum drilled and in place with clecko's.85996
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[Rsnake]

Here is a photo of the painted upper control arm.
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[Rsnake]

Installed the upper control arms this afternoon but I was curious if anyone else had to take them apart as the factory had them assembled wrong or maybe I messed up and should have left them alone. The ball joints went in easy so I guess that's a good thing.
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[Mark Eaton]

I had to reassemble mine as they had been put together incorrectly from the factory

[Rsnake]

Mark, that's good to hear, thought I might be taking a step back.

[JoeAIII]

I have not heard of anyone who did not have to flip them.
They are re -purposes from another application that uses them "upside down"

[edwardb]

Installed the upper control arms this afternoon but I was curious if anyone else had to take them apart as the factory had them assembled wrong or maybe I messed up and should have left them alone. The ball joints went in easy so I guess that's a good thing.


I had to reassemble mine as they had been put together incorrectly from the factory


I have not heard of anyone who did not have to flip them. They are re-purposes from another application that uses them "upside down"

Factory Five has used different vendors for the upper control arms just in the years I've been kicking around here. As supplied by the current vendor they are "upside down" for this application but I'm not sure I'd call them assembled incorrectly. They're stock parts and that's apparently how they supply them. The proper configuration is shown in the instruction manual and easy enough to change. But unfortunately many do miss it and it's been flagged on multiple builds. Glad you got it right the first time. No fun taking things apart. Especially the ball joints when installed with Loctite as they should be.

[Rsnake]

It has been a little while since my last update, about a week. Still waiting on parts so I just keep painting.
I actually received the differential on Thursday and figured I would get it painted. What is everyone doing with the aluminum cover? I was going to clear it but it's got some marks on it and clear would make it look worse.
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Also assembled the freshly painted irs control arms but cannot install as I am waiting for bolts and bushings for the differential.
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The diff was leaking gear oil and made a huge mess in the FedEx truck, I felt sorry for the driver.

[Rsnake]

Coyote control pack arrived today and figured I would install the upper and lower clutch switches.
The one which goes under the peddle box is easy as it doesn't matter if it's a cable or hydraulic clutch.
The other one is another issue. I fabricated a bracket and bolted it on the top of the wilwood peddle box.
My question for the evening, if you ever need to service the clutch area of the wilwood box is it near impossible to access?
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[boat737]

According to Wilwood, those master cylinders are pretty much fail proof. That being said, I've had two (clutch) masters leak. I've put about 400 miles on the car in gelcoat. After the body was removed for painting a few months ago, I noticed some very minor "wetness" around the rubber boot on the clutch master. Peeling it back it was very wet inside the boot, and obviously leaking around the piston. As much as I hated to open up the clutch plumbing ( I HATE working with brake fluid, nasty messy stuff) I figured I needed to replace the master. Ordered a new one from Wilwood and installed it. As I was bleeding in in the car, paying attention to the slave and not the master, I ended up with brake fluid pouring out of the master around the piston/boot again, this time a lot. I sent both units back to Wildwood, and both were bad according to them, so they sent me two replacements. Installed one of the replacements (this being the third unit on the car) and got it going. So far no leaking around piston, not sure about the fitting on top from the reservoir though. I'm keeping an eye on it. I'm going to have to really hold my breath when I close up that foot box area, and get the body back on. And yes, to answer your question, I don't see any way to do any maintenance or work on those master cylinders with the body on and footboy panels installed. It's going to kill me not being able to at least see what's going on with those masters, let alone not able to work on them.

[edwardb]

You guys do have the removable cover on the DS footbox don't you? Seen in the picture below. Not exactly the same as the current sheet metal, but that's the idea. Wouldn't be fun, but between this cover and reaching from underneath, could do some work in the footbox. Might have to swing the fuse panel out of the way as well if using the recommended location. None of which would be easy, but nothing compared to removing the body. I hope to not find out (so far so good...) but it would be possible to change one of the MC's that way.

Nice fab work on that clutch switch Rsnake. But to be honest, that's not going to make reaching in there for maintenance any easier. The FF provided mounting bracket, and what several of us did before the FF one was available, mounts on the pedal box mounting screws right next to the MC. Much more compact and out of the way. FWIW.

http://i867.photobucket.com/albums/ab234/edwardb123/Factory%20Five%2020th%20Anniversary%20Mark%204%20R oadster/Aluminum%20Panels/th_IMG_3919_zps76jsekkn.jpg (http://s867.photobucket.com/user/edwardb123/media/Factory%20Five%2020th%20Anniversary%20Mark%204%20R oadster/Aluminum%20Panels/IMG_3919_zps76jsekkn.jpg.html)

[Rsnake]

Thanks Edwardb on the tip about the clutch switch. I think I need to follow the manual instead of just jumping into different jobs. A friend came over tonight and wondered how you would ever change out a master cylinder with the small access, I told him it wouldn't be fun and I hope to never find out.

[Rsnake]

Rear diff bushings arrived so this weekend I installed it.
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Installed rear brakes and hoping I can still install cv shafts as I have left the knuckle to control arm bolts loose.
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[Rsnake]

I haven't posted anything for two weeks and I have been busy on the build. The coyote has been installed for some test fitting and making sure I have this where they need to go. Hopefully the next time it gets installed it will be the last time.
I also received the front spindles so I finished the fron suspension and brakes. Did a really rough alignment assuming the control arms are near level when at ride height. The fuel tank finally showed up so finishing up the fuel system once all the 3/8" lines arrive from Summit Racing.
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I also bleed the brakes and the clutch. The brakes feel good but the clutch is heavier than a modern car that's for sure, not too bad but stiff.

[Rsnake]

It's been a while since I have posted anything, family and work leave little time to be on the Internet.
So today the coyote came to life! First push of the button and it fired right up, damn that thing is loud without mufflers.
I don't think the neighbors appreciated it. Three months after it came home it came to life, hoping for a go cart drive tomorrow.

[Higgybulin]

WOW, your killing it!!
Higgy

[Rsnake]

Thanks Higgy. It has been fun and keeps me out of trouble. I would post some photos of the completed dash and center console but it says I don't have permission even though I have posted photos in the past. Weird.

[Rsnake]

So hopefully this works and I can post some more photos. Here is the dash.
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[Rsnake]

The completed dash and center console. It will be covered in dark grey leather.
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[Rsnake]

The body work has officially begun.
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[Rsnake]

More body work. I am actually impressed with how straight the body is. Not a lot of filler needed. Maybe go through 1 Qt when it's all said and done.
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[Rsnake]

It's in primer. Hopefully the body goes on this week and start assembly.
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[Rsnake]

It's been another month and the car is in primer and the dmv adventure starts Monday at 2:30!
About two weeks ago I had a run in with the law. My daughters boy friend wanted a ride in the go kart stage and I said lets go. We kept it mellow and in the neighborhood until I realized we were low on fuel so I decided to swing down to the main road and put some gas in it. As I was fueling up a San Mateo county sheriff drove past and hung a u turn. He pulled up and rolled down the window and said"really". He then started naming all the infractions, I told him I live up the street and just built it and needed fuel. He went and parked and walked over. It turned into a lot of questions and a " you had better not be here when I get out of the store". Lucky me. So hopefully Tuesday I can legally drive it on the road.
It's been 6 months and 1 week since delivery. Can wait to get it out on the road.

[cv2065]

LOL...Good story! You know he wanted to take a drive.

[Rsnake]

All I can say is WOW!!
Went to dmv today to begin my sb100 registration and it went pretty smooth considering it's the dmv.
Made me get a brake and light inspection and then return to get a 90 day temporary operating permit.
But they gave me a couple of 1 day permits to get the brake and light inspection. So, what did I do, went straight home and took it out on the road for the first time. What a car! At 60 mph in fifth gear it's a docile beast and could have a conversation with my daughter. Not a lot of wind compared to my topless CJ, but once you get on it which was only part throttle and it's like hell broke loose. I am actually afraid of what full throttle must be like. I am so impressed with the factory five product after actually driving it. Put 26 miles on the odometer and smiled the entire time. Photos will be coming.

[Pat427]

I'm enjoying following your build. Keep it up!

[Yama-Bro]

It's been another month and the car is in primer and the dmv adventure starts Monday at 2:30!
About two weeks ago I had a run in with the law. My daughters boy friend wanted a ride in the go kart stage and I said lets go. We kept it mellow and in the neighborhood until I realized we were low on fuel so I decided to swing down to the main road and put some gas in it. As I was fueling up a San Mateo county sheriff drove past and hung a u turn. He pulled up and rolled down the window and said"really". He then started naming all the infractions, I told him I live up the street and just built it and needed fuel. He went and parked and walked over. It turned into a lot of questions and a " you had better not be here when I get out of the store". Lucky me. So hopefully Tuesday I can legally drive it on the road.
It's been 6 months and 1 week since delivery. Can wait to get it out on the road.

Haha, this could've went a lot worse. Good story, and a cool officer. :D

[PeteMeindl]

Congrats, Rsnake! That's great news - looking forward to seeing the pictures! I can just imagine you cruising up highway 1 there in go-cart mode...

[Rsnake]

Follow up to the sheriff episode. Called a friend today to let him know the car is on the road and to come over and look at it. First thing he says after answering is" heard the police have their eyes out for you on the coast". He then proceeds to tell me the local sheriffs are talking about the interaction. His best friend is a sheriff on the coast and had heard about the encounter. Funny how things get around.
Went to DMV yesterday and now have my 30 day temporary operating permit. Trying to get a chp appt now.

[Rsnake]

Now a little over 100 miles on the car and everything works perfect. I am getting some brake peddle pulsation at higher speeds and I am assuming it's the rears since it's not felt through the steering wheel. I took my wife out yesterday for her first drive and she actually enjoyed it, she wants to drive it which is a good thing. Here are some photos.
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[Rsnake]

Some more photos
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[PeteMeindl]

Looks fantastic, Rsnake!! Nice going!

[Rsnake]

So noticed my first issue today and hoping someone can help out. The coyote has always fired quickly until yesterday. It cranks for a couple of seconds and then fires, especially when cold. Starts up quick when turned off and restarted immediately. If I look at the fuel pressure gauge it climbs when the ignition is on but drops back to zero almost immediately when shut off. I am using the FFR supplied fuel system with the Walbro intake pump and assuming the check valve is bad?

[Rsnake]

Its been a long road but it's time to graduate 9338. I haven't posted on here much but I figure it was time. Just finished paint last weekend, cut/buff and body back on this week. Nice drive down the California coast with my wife today.
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Hopefully these photos load. Thanks to everyone on this forum, couldn't have done it with out you.