80 Day Build--In time for the London Cobra Show

[Chris @ Forma]

Last week we were contracted to build a Mark IV and our client would like to have it completed by the London Cobra Show (London Ohio--not the UK). The show for those of you who have not attended, typically bring out Cobra enthusiasts from all over the country. In prior years we have seen folks from as far away as Vancouver and WA state. Anyway our build specs are as follows:

Chassis
• Black Powder coated Chassis
• Silver Artery Powder coated sheet metal
• Power steering
• S550 Mustang based IRS
• Electrically actuated parking brake
• FFR 17” Halibrand style wheels, 9” fronts, 10.5” rear
• Performance summer tires 245/45R17 & 315/35R17
• SN95 Mustang GT 11” twin piston front brakes
• S550 Mustang GT 13” single piston rear brakes
• Black powder coated chassis components
• ECUMaster PMU chassis control
• FC wiring harness
Drivetrain
• 2015-2017 low mileage (<18K) 435 HP Mustang 5.0 Coyote engine
• ECUMaster EMU Black ECU
• FC Coil driver module
• Moroso oil pan & pickup
• Energy urethane motor mounts
• FC mount kit
• Ford MT82 G2 6 speed manual transmission
• FC MT82 shifter mechanism
• FC transmission mount
• Stainless full headers & stainless-steel side pipes
• Ceramic Coated Side Pipes
• Header wrap
• FC Driveshaft
• Drive modes
• Mode switching
• Adjustable traction control
• Launch control
• Flat foot shifting
• Custom painted engine cover to match body paint
Interior
• FC Floor heat, defrost & AC
• Seat heaters
• FFR Roadster seats
• Seat adjusters
• leather steering wheel
• Russ Thompson hub & turn signals
• FC full interior in red and black vinyl and silver painted trim
• FC door panels, handles, Speakers & poppers
• FC dash
• FC center console
• FC rear trim
• Silver trim
• FC carpet set in Dark Read/black
• Waterproof Audio system including Clarion Marine Radio and Kenwood amplifier
• 4” door mounted speakers
• Keyless entry and starting
• Thermal/sound insulation
• FC logo gauge package
• FC silver billet bezel for turn & highbeam indicators
• Wilwood pedal box
• Lokar or equivalent accelerator pedal
• 4-point seat belts
• Billet, windshield mounted center mirror
• Billet shifter surround
• LED footwell lighting
• Billet cup holders
• FC CaNbuss controls
• Pushbutton starting
• Pushbutton Head light controls
• Pushbutton High beam controls
• Pushbutton Hazard light controls
• Pushbutton parking brake console
• Turn signals on steering column stalk
• Wipers
• Adjustable Drive modes
• Traction Control
Body
• Silver primary paint color with Black stripes and red accent
• Dodge Viper billet silver
• Venom black
• Adrenalin Red
• Blackout paint package with red accents
• Custom Wheel paint with contrasting spinners
• LED lighting package
• LED headlights
• LED running lights
• LED turn signals
• FC billet fender badges
• Engine compartment and trunk lighting
• Wind wings
• Sun visors
• Aluminum side louvers
• Driver side roll bar
• Roll bar grommets
• Stainless steel quick jacks

We have the FFR complete kit on order +/- and it will be picked up on 5/2/18---52 days prior to delivery. This would probably be and impossible task if we didn't have a little bit of a head start. Last year we purchased a basic Mk IV to use as a development platform for some enhancement products that we have been developing. We are using the body and chassis out of this kit to get a jump on bodywork and paint as well as sheet metal.

Our goal is to post progress reports daily...forcing us to make progress every day.

Hope you enjoy the madness as much as we expect to.

Chris

[Boydster]

Wow... good luck and I'll be watching this one.

[Straversi]

Never understood putting ridiculous deadlines on custom projects but, hey, it's his money and project. I'm sure you guys will do great. Sounds like a great build. Look forward to seeing the updates.
-Steve

[Chris @ Forma]

Steve,
I don't in any way fault the client for the tight deadline. This deadline is self imposed as much as anything else. I've been in manufacturing for nearly 50 years and I don't see a big difference in building a custom car and manufacturing a washing machine. Efficiency is all about establishing and implementing a manufacturing process. We spent about 5 man weeks late last year creating and documenting a build process. This build is our first test to see if we can pull it off. It is understood that nothing will ever go as originally planned, that doesn't mean it is not possible. We intend to make daily posts of our progress and challenges--my way of holding myself accountable to the process.

Go ahead....tell me I am nuts. Pretty much everyone I know thinks so. Please chime in with your critiques, criticisms, and suggestions. I have a thick skin and will benefit greatly from the collective wisdom of those who proceeded me.

Chris

[AZPete]

Sounds like fun for all of us here who get to watch! Chris, since you aren't picking up the kit until May 2nd, you'll have plenty of time to join us at Huntington Beach on April 28th.

[Mark Eaton]

This sounds really cool. I will watch with interest. I hope you post photos. I'm not sure what "flat foot shifting" is...

And I'm curious, how many people will work on the project?

Mark

[Chris @ Forma]

Mark,

There are a total of 4 people contributing on the project. No one is working on it full time, as our parent company, whom employs us, has other assignments for each of us. Our build plan adds up to about 220 direct labor hours to complete though I believe we will probably run over budget by about 60 hrs. This does not including paint and body which we currently outsource as we don't have the facilities to paint anything larger than a door panel. Two of us aren't doing to much of the direct labor but are working in the background refining design details, sourcing parts and materials, coordinating inventory, etc.

The plan is to post pictures nearly every day.

Chris

[cgundermann]

Looking forward to the pics...

[Jeff Kleiner]

80 days? Don't let Ron Everett know about this; he'll down a couple of Red Bulls and take it as a personal challenge ;)

Jeff

[Yama-Bro]

Cool, this will be a fun one to watch.

[FFinisher]

80 days? Don't let Ron Everett know about this; he'll down a couple of Red Bulls and take it as a personal challenge ;)

Jeff



I not a red bull guy, But yeah, 80 days.... ? I could do that.


80 days?

Hold my beer.

[Chris @ Forma]

Day 80--

A little progress yesterday...not much picture worthy...mostly spent ordering components, etc. That being said, here is a bit of eye candy.
First, the [icture that inspired our color selection.
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We shot some color plaques to share with the client to get final sign off. The intention is that the car will be silver with traditional width black stripes and the space in between the black stripes will be red.

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[Kyle @ Forma]

I'm not sure what "flat foot shifting" is...



Under heavy throttle, it allows you to shift without letting off the gas pedal. If you try this in a normal vehicle, you'll bounce off the rev-limiter. FFS acts as a temporary lower rev limiter to keep the RPM at the ideal place for the next gear. Multiple parameters ensure that this only happens under heavy throttle and while you're moving, so you don't notice it's there until you use it.

Picture this:
You're sitting in the driver's seat. Turn traction control "off" and drive mode to "sport". When the light turns green, peg the gas pedal to the floor and drop the clutch. Tire smoke ensues. Make lots of noise at 7000 RPM until you finally gain traction, then jab the clutch and quickly engage second gear, all while your right foot stays glued to the floor. Repeat until you are going too fast, then you can finally let your right foot up.

And that, sir, is how you drive a rental.

Oops, I mean a car with Flat Foot Shifting.

[Chris @ Forma]

Made a bit of progress...once again not a lot that is picture worthy. Fitting sheet metal....
All of the sheet metal should be ready to go to powder coat on Monday.
Along with the sheet metal and in conjunction with that work stream we started packaging the air box for the HVAC unit.
We fabricated a laser cut/3D printed panel for the upper trunk area to hold the air box. The triangle in the air box is where we will create all of our ducting/air valves to control Heat (discharges from under the seats), A/C (comes out of the dash), and the defrost (ducted to the windshield).

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More later today

[Chris @ Forma]

Day 63--Progress is painfully slow. We are still two weeks away from picking up our Kit from Factory Five. Though we are still making progress. I've unfortunately had to travel the past two weeks to out of state client meetings and it has impacted my ability to make the progress that we were hoping to make. None the less here is where we stand:
• Doug completed the CAD work on the interior design details.
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• This enabled us to start 3D printing some of the components even before it was completed
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I know that this doesn't look like much, however, by Tuesday these should be finished door panels.
• This week we met with our client and got a sign off on the interior finishes.
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The Red will be the primary color of the dash and the top of the door panels
The Silver gray will be used on the center console extending up the center of the dash under the gauges. We may use this on the door recesses with red stitching .
The Black will be used on the sides of the console and the bottom of the doors.
The silver paint (same as the body) will be used for the painted accents. This is shown yellow/green on the cad screen capture.
• Outside of the interior, parts are showing up every day.
• Moroso Oil pan so we can start building up our engine. Need to get the engine/tranny in the frame so that we can finalize our ducting to the defrost vents. We don't have good CAD data on this so we will have to wait till we can get this dropped in place.
• Also received our A/C unit from RestoMod Air. as well as small but important stuff like Breeze battery box, ECU, PMU (power management unit), CAN input card, security system, etc.
• Kyle wrapped up the new wiring harness design and we should start fabricating this on Monday. Goal is to have the wiring harness installed by the end of next week. Nearly 300 wires in our harness, pretty much has everything. It will even wipe your nose.
• Finally, Tim has been working diligently on the painted parts. All of the sheet metal is out to the powder coater and should be back by the time the wiring harness is installed.
Tim has also been working on getting the body completed. Thursday and Friday we shot paint. Monday we will shoot the clear.
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I'll try to post more as the week progresses,

Chris

[cgundermann]

Looking good! Thanks for the posts, I’m liking the paint scheme...

Chris

[Chris @ Forma]

Finished the clear and wet sanding. Part way through the buffing and polishing.
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Color really pops with the addition of the clear.

Minor set back...the manufacturer of our CAN BUSS boards just announced a new version. We have been designing around the older board and don't want to tie us into a corner for future builds. Need to make sure that the current product will continue to be supported and available. Otherwise, our design needs to accommodate both. It is never easy.

Chris

[Jeff Kleiner]

Plastic scoop molded to 'glass hood?

Jeff

[Doug @ Forma]

Plastic scoop molded to 'glass hood?

Jeff

Yes, just like we did with our first Mark IV. Some more info in our build thread here (https://thefactoryfiveforum.com/showthread.php?23720-FormaCars-MKIV-9004-Build&p=279148&viewfull=1#post279148).

[cgundermann]

Sweeeeeeeet!

Chris

[Chris @ Forma]

That is correct. This is the second one that we have done this way and so far, no issues. I didn't personally do this bonding work, but I can check with my body guy to get the details of the process and the products that he used, if you are interested. I realize that many want to pay homage to the original/authentic Cobras, however, our aesthetic goals are to build to current production car fits and finishes. I'm not claiming that we achieve this objective, but that is still where our aspirations lie,

Chris

[Jeff Kleiner]

That is correct. This is the second one that we have done this way and so far, no issues. I didn't personally do this bonding work, but I can check with my body guy to get the details of the process and the products that he used, if you are interested...

Chris

Thanks Chris. I was just curious and will only mold in the 'glass scoops. I've done some trading among customers to wind up with fiberglass ones to bond and plastic ones to bolt on. If your guy is having long term success with his method of bonding the dissimilar materials my hat is off to him!

Jeff

[Hacksaw84]

I am building my car for London too! I just don't know what year... is that the same?

[Chris @ Forma]

Ours needs to be done by June 22, 2018. 56 Days from today. FYI, I'm picking up our kit next Wednesday.

[Chris @ Forma]

We have been making quite a bit of progress, though there is still much to do.
Our wiring harness is complete and installed in the chassis
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We completed the door panels. Assembly in the picture is missing a painted part that trims out the door panel after installation that goes directly below the red component.
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We have completed the dash assembly except for the glove box and glove box door. These will be completed tomorrow.
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The instrument cluster is also assemble and ready for installation.
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Finally, we completed the engine wiring harness and installed the engine and tranny.
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Hope to be ready to drop the body on by Monday or Tuesday.

Chris@Forma

[DavidW]

Lets see some more pictures, two days to go!!!!!!!

[Chris @ Forma]

Well we were disappointed not to get the car done before the show, though we did take it to the show. It looks spectacular...but there is still quite of bit of work to do under the skin.

My team did an absolutely fantastic job pulling off the nearly impossible task of getting it to the show. At 3:00 PM on Friday we moved the body to the Chassis for the first time since they were separated just prior to paint. My guy, got it to the show by 9:30 on Saturday. Including mounting the doors, windshield, hood, trunk lid, installing our proprietary door latches, inner door panels, etc. For a static display...it looks fantastic.

We were so exhausted and busy at the show nearly everyone forgot to take any pictures. Doug did get a few.
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Our customer for this car is the Ohio Cobra Club and this is their 2019 Raffle car to benefit the Cystic Fibrosis Society. This year they sold about 10,000 Raffle tickets and for next year (with our build) we are hoping for 15-20,000. You can win this car by simply buying a raffle ticket on line once we make final delivery.

We still have a number of tasks to wrap up...

Photo shoot for the Club...unfortunately delayed till Friday due to rain on Tuesday and Wednesday.
Remove the body to wrap up the wiring to HVAC which is located in the trunk.
Install new glove box as the initial one has a clearance issue.
Correct a wiring issue with the CAN-Buss controls in the center console
Paint the spinners Red
Install inner fender sheet metal
Install spray on liner on inside of fenders
Fire up the engine and tune
Road test for setting the traction control parameters
Road test balance brakes
Rework the front wiring harness to get rid of our signature green sleeving in the engine bay (clashes with the paint scheme).


There are other smaller items...but these are the big ones.

Our biggest challenge right now is that the car needs to be a another show in a little over a week and we don't have much time to get the body off, make the changes, and get the body back on for the Arthritis Foundation show on the 6th. Goal is to deliver the car and get paid on Friday the 13th....Maybe we'll wait till the following Monday.

I did shoot a couple of pics in the final week...just ran out of time to get things posted.
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Under seat duct for heat
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Defrost ducting
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CAN-Buss board for launch control, traction control, drive mode, control of parking brake, headlights, wipers, etc. Mounted in a temp 3D printed bezel
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Top of temp bezel
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Test fit of center console.

I'll post some more shots after our photo shoot tomorrow.

Chris

[wareaglescott]

great looking build!

[Chris @ Forma]

Opps....Meant to say my Guys did a great job....it was a team effort

[cgundermann]

Very, very nice styling!

[Yama-Bro]

I love how you guys use 3D prints to use as final parts. I always think of 3D prints as prototypes, just because that's how I've used them for the years at the places I've worked. I need to dream up something to use them for on my car. Cool stuff! Keep up the good work.

[cv2065]

Looks great. I'd like to see some detail and pics on that console and dash! :)

[Chris @ Forma]

This past week was a bit challenging to make progress.
We need to take the body off to address some wiring issues, however, we needed to get the car photographed as this was built for the Ohio Cobra club for their annual Raffle car. Rained Tuesday and Wednesday, our photographer was not available on Thursday, so we were stuck waiting until Friday evening. We shot a couple of hundred high res pics, and on Saturday selected one of PhotoShop for color correction that the Club will print on the Raffle ticket. Our goal for the coming year is to sell out all of the tickets and we are partnering with the Ohio Cobra club to do just that. I haven't heard from the board as to how many tickets they are planning on printing, but I am pushing for either 15K or 20k. Regardless, I encourage the community to get behind this effort. It is your chance to own a nearly $100K build with the purchase of a $20 ticket. The raffle benefits the Cystic Fibrosis Foundation. Raffle tickets will be available on the Ohio Cobra's web site by the end of the week. I encourage everyone in the community to participate.

I would also like to acknowledge Aesthetic Finishers, GP Headers, and Factory Five Racing for the discounts that they provided us in achieving this spectacular build.

Here is the raffle ticket pic that we selected for the raffle ticket.

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[Chris @ Forma]

Regarding our center console and dash assemblies, they consist of quite a large number of parts. Here is a CAD screen capture of our interior design.

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The material selected for each of the components is based on the job that we are asking the component to do. Although we have a number of custom sheet metal parts in the assembly, these parts are relegated to structural rectilinear components:
Dash Structure
top of tunnel (bottom of center console assembly)
glove box door (inner, outer, hinges)
attachment clip retainers (hold Volkswagen interior assembly clips to 3D printed parts)
Dash structure attachment brackets

Some of these parts, such as the dash structure are moderately complex parts
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Other structural parts include custom aluminum extrusions. These are also appearance parts and are green/yellow and straight in the first image image.
The curved yellow/green parts in the first image are 3D printed and painted.

The back side of the dash looks like this:
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The gauge cluster/climate control assembly snaps into place on the dash and the back side of it is shown here:
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This assembly consists of 3D printed parts, laser cut ABS sheet, a hand full of small sheet metal parts etc.

Here is the dash assembly with the gauge assembly removed.

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The rear console assembly is all 3D printed then upholstered or painted. It is worthy of noting that our HVAC system is located in the trunk space between the roll bars and the AC ducts run through our console assembly. Attachments for this duct is located at the back of the rear console assembly.

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The center console consists of sheet metal, extrusions, laser cut ABS sheet, and of course 3D printed parts.

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Underneath it all there are a few relatively complex 3D printed parts. At the fire wall, we have our Wiring Hub. This houses the fuse box which is accessible from the engine compartment, interior lighting controls, system busses (power, ground, and ignition power) and the security system. Below this part is a duct transition that takes defrost air from the tunnel to behind the dash. Finally, we have another duct for getting the defrost air from below the trunk and into the tunnel shaped to package around the IRS/drive shaft attachment flange (We are using the 205-2018 Mustang rear end).

I could write all day and not capture everything, but these hare the major elements.

[Chris @ Forma]

Late last Friday we photographed this build. Here are a few of the pics.
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