View Full Version : Scotts 289 Build Thread
June 6, 2018, I received the 289 USRRC complete kit with IRS, power steering, sway bars, heater, windshield wipers, Wilwoods, and 15" Halibrand replica rims....so it is about time I start a build thread.
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ALUMINUM
I like the look of aluminum so all engine compartment aluminum was brushed using a straight edge, sanding block, and ultra-fine gray ScotchBrite. Then sealed with SharkHide. I am very pleased with the result; however, the first few pieces on the passenger side foot box were treated with SharkHide prior to installation. That was not a good plan. I choose to use the Bostik 1100FS (from Breeze) so cleaning the goop that oozed out compromised the SharkHide. The remaining pieces will be installed, cleanded, then sealed with SharkHide. I really like the Bostik adhesive/sealant.
Here are a few shots of the brushed aluminum in the engine compartment.
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HEATER AND FRESH AIR
I did not like the heater blower sucking in engine compartment air, so I turned the blower upside down, attached a 3" adapter and 3" hi-temp brake duct hose. It leaves room for the windshield wiper motor. Now I can get fresh air to the heater and also fresh air to the foot boxes when heat is not needed.
I also did not like the way the blower attached to the heater box by just screwing into plastic, so I cut some aluminum strips for inside the heater box, drilled and tapped them 10/24 so now the blower is bolted to the heater box. This also allows the wiring to be neatly routed through the existing engine harness.
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IRS and BRAKES FOR 15" WHEELS
I wanted IRS and 15" rims. I really wanted the 289 FIA 15" knock-offs...but I had to settle. Thanks to Levy Racing, his Wilwood 15" brake solution worked beautifully. As you can see in the photos, the rims fit without any clearance issues. I will be installing Levy's manual emergency brake solution, which fits a disc between the driveshaft and the IRS along with a mounting plate, which holds the manually operated caliper.
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FRONT:
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REAR:
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WILWOOD PEDALS
I machined the Wilwood pedal arm attachment area so that I could attach my AC foot pedals:
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RADIATOR
I installed the Breeze radiator mount and the Breeze fan shroud. Great products.
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DASHBOARD
I received the pre-cut dashboard from FFR. The only issue was that once the speedometer and tackometer were installed, the inside mounting rings hit the cowl bar keeping the dashboard from mounting as high up as planned. That is why the top vinyl has not been glued back. I am awaiting final fitment to trim it. I also bought a new high-beam indicator light since the one I received did not have the chrome bezel that the green and red ones have. Yes, I know, the tach and speedo are reversed. I figured on the street I would need the speedo rather than tack in my direct eye line. I also opted not to utilize the built in idiot lights in the speedo.
I also installed the Russ Thompson turn signal...very nice!
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cnutting
10-08-2018, 01:19 PM
Looking good! Is that the breeze upper radiator mount? If so, you may run into some interference with the body. I ended up mounting mine to the top of the 3/4" tube. The radiator angle is more shallow than the MKIV.
Vspeeds
10-08-2018, 07:01 PM
Looking good. Youre really moving along on your project. Nice to see another 289 project.
Jimtmich
10-08-2018, 09:07 PM
Congratulations! Your plan and progress look great.
wltrmtty
10-09-2018, 07:36 AM
Looking good! Have you posted the Build details (e.g., engine, transmission, rear end, color, options, etc.,)?
I am going to continue this build until around mid-December - when hopefully FFR will have another 50% off sale and I will order the type 65 Coupe...in which case, I will be selling this to make room.
Jimtmich
10-12-2018, 12:39 PM
Well keep me in you perspective list of people to talk to regarding your 289 when the time comes.
Sales sure help a lot for a coupe build.
FUEL LINES
Installed the fuel lines - both supply and return lines. I intend to go carb with an in-tank pump. Perhaps the Spectra SP1138 low pressure pump, which would not require the return line...but I will have the return line if needed later.
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E-BRAKE
After test fitting the emergency brake handle, I did not like the way the huge lock nuts scraped the tunnel aluminum. I can imagine how it would affect the rug once installed. I could reverse them but then the unsightly nut would be exposed to view. To solve the problem, I utilized 1/4 x20 cabinet bolts....a nice finished look.
To make them fit properly I had to cut about 1/4" off the nutsert side...but before I cut it, I tapped it so that the threads continued through the entire length of the nutsert so that there would be sufficient threads to hold. I then drilled out the hole in the handle to accept the larger diameter cabinet bolt. A little blue locker and I tightened them down and cut off the remaining length of the bolt.
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Mark TX
10-16-2018, 09:55 AM
Wow. They should sell them like that. Very clean.
There are so many "improvements" that I have not even begun to contemplate!
BUILD Thoughts
If anyone is wondering about the difficulty in building a Factory Five Cobra...I have to say that FFR has developed an excellent, straight forward build with a tremendous build manual. In fact, it is almost too easy! Of course, I purchased the complete kit so everything is new - no donor stuff to worry about. I say this because my last project was an RCR40 - a GT40 replica from Race Car Replicas. Their's is a great car. The all-aluminum monocoque chassis is a true work of art. The engineering is top notch. With it you get endless opportunities to scratch your head, figure it out, and fabricate what you need...and redo it! In fact, it took me almost a year of staring at it in the garage to get the courage to start! Fitting the spider and doors alone was quite a challenge since every slight change affects each X, Y, and Z axis. I thoroughly enjoyed the build. Unfortunately, someone came along and offered me the right price and I sold it before completion (regret it now!). I would do it again....but not until I build a Type 65 coupe.
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David Hodgkins
10-16-2018, 12:51 PM
Scott,
You are off to a great start! Quick question for you; does the current chassis still have an interference problem between the clutch arm and the frame?
https://thefactoryfiveforum.com/showthread.php?13397-15th-Anniversary-MKIV-build-thread-Showing-off-at-Barrett-Jackson!&p=200905&viewfull=1#post200905
I had to notch the frame to get full travel of the arm. I'm not sure if FFR had addressed that issue yet or not...
https://thefactoryfiveforum.com/attachment.php?attachmentid=42532&d=1433776514
https://thefactoryfiveforum.com/attachment.php?attachmentid=42533&d=1433776516
:)
Yes, my driver's side frame looks just like yours in the picture - so FFR must have addressed the issue. I do have full clutch pedal travel. How do you like your BOSS 302? I am contemplating that route with their new X2302E that has the new X2 head package.
David Hodgkins
10-16-2018, 04:22 PM
Yes, my driver's side frame looks just like yours in the picture - so FFR must have addressed the issue. I do have full clutch pedal travel. How do you like your BOSS 302? I am contemplating that route with their new X2302E that has the new X2 head package.
I was under the impression that Ford had discontinued the Windsor BOSS 302. Do you have a link to a new package?
:)
Summit Racing has the new M-6007-X2302E listed as well as Gary Yeomans Performance Parts in Daytona Beach, FL (I spoke with them, they said they were available with the X2 heads for a more compatible exhaust setup).
https://www.summitracing.com/parts/fms-m6007x2302e
E-BRAKE
With the IRS and 15" rims, the normal emergency brake system would not fit inside the rim. Levy Racing to the rescue. They have a mechanical Pinion-Mount emergency brake system which I just installed. The photos below show the e-brake mounting plate attached to the crossbar just in front/underneath the IRS center section. The second photo shows the disc test-fitted to the pinion with the mechanical caliper below (mounted to the adapter plate.) Yes, there is clearance between the caliper and the U-Joint mounting plate. I will finish it with the Lokar EC-8000TP Emergency Brake Cable.
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It is now a roller!
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...getting ready to buy a coupe....so I am willing to let this one go for the right price.
Jimtmich
12-16-2018, 08:40 PM
I sent you a PM. Let me know what you want for it.
Thanks
Jim
Just picked up my engine - new Ford Racing 347. I got the Holley setup as well as the Weber setup. I am comfortable tuning DCOE's...now to tackle IDF's. Now for the TKO600 and clutch and I am ready to install!
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Engine in!
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Oops...be sure to remove the radiator before installing the engine....ugh....
Vspeeds
03-07-2019, 11:27 AM
Nice!
KDubU
03-07-2019, 04:26 PM
That is awesome! Beautiful engine and am totally jealous as Weber’s or Stacks are in my next build plan.
OK...I live in Houston. It gets hot. I don't really need a heater but it would be nice to have some air conditioning. I had a Cobra a while back with A/C...it did not do much good but it was nice to have. I decided I could build a better version...and since my engine already had the compressor I might as well install the rest.
I took the FFR heater:
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and an evaporator unit:
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and performed some surgery to make it all fit behind the dash. The only sacrifice was I had to remove the speedometer (289 FIA dash layout). I have not decided where to put it yet. I first hacked the heater unit.
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then hacked the A/C unit. Come to find out, the evaporator had a 45 degree angle built in to it so I could tuck it up against the heater core, which allowed it to fit behind the dash and not hang below it without any mods. I was able to utilize the original A/C enclosure after some modifications.
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I built a plenum out of sheet metal to move the air to the center console vents. Glue sure gets everywhere...but I will be covering with dash material.
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I added some vents on each end for future use. I also created a 2" butterfly valve out of PVC and old SU HS4 carb parts and installed it on top for the defrost.
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test fit it with the A/C hoses in place.
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Now to attach the vent front to the plenum.
Test fit without dash
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Here it is with the dash fit. You can see the hole where the speedo was. Maybe I will put a glove box door there.
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And a view from the top to see how it all fit.
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It is a large evaporator unit so it should produce some cold air!
I had a Cobra with under-car exhaust and one with side pipes. My kids still have leg scars. I like the clean look of no side pipes - especially on the 289 version...so here goes.
I purchased custum short headers from GP Headers in stainless. I then purchased 2.5" oval pipes and Series 7000 thin-line muflers from SpinTech and began the process of fabbing the system. Here is the product.
Headers with 2.5" round to oval transition:
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Exhaust system with Muffler Armor attached:
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Here is the muffler hanger:
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Side view:
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I will finish the side out once the body is in place. I am still evaluating rear-exit - but with the IRS, it probably won't happen.
I have about 3/8" clearance between foot box bottom and the Muffler Armor. I also placed Thermo-Tec heat barrier on the underside of the car above the exhaust. The muffler tucks up a bit under the additional height that is available under the seats. The whole thing hangs down less than 2.25" from the bottom of the side 2x2 frame rail.
Jimtmich
05-12-2019, 08:18 PM
Great job
Looking good Scott!!
Walt
It's Alive!
This is actual FIRST effort to start the engine. I primed the oil pump - installed the distributor - aproximated the advance - primed the fuel pump - attached the positive cable to the battery - and turned the ignition switch!
https://www.youtube.com/watch?v=_eJ0Lxr-KLo
Jimtmich
06-20-2019, 10:33 AM
Congratulations!
Vspeeds
06-20-2019, 11:21 AM
Thats awesome. Congratulations!
First drive!
https://www.youtube.com/watch?v=UzKHWdkZWTk
Vspeeds
07-18-2019, 09:49 PM
Nice! Congratulations on your first drive!
KDubU
07-19-2019, 06:37 AM
Congrats! Great milestone to hit.
Great, your coming right along Scott!
Just ordered a/c setup and a top for mine.
Walt
When I installed the A/C I had to relocate the speedometer, which left a hole in the dash...what to do? I tried a faux glovebox door but I did not like the location it had to be to cover the hole. So...I ordered a bezel from SpeedHut and mounted the FFR badge recessed into a piece of the dash material. I thought about inserting the AC steeering wheel emblem but I like the Factory Five emblem...and after all, it is a Factory Five and I am proud to have built every bit of it. I still might swap it out with the AC emblem...an easy swap. Or maybe use it as a picture frame!
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Body on today!
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Yes, I know, the steering wheel is upside down!
chuckster
11-08-2019, 07:57 PM
Lookin’ good.
Jimtmich
11-08-2019, 09:42 PM
Exciting
Why doesn't FFR incorporate the gas cap well into their 289 body mold?
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My first Cobra...circa 1993...with my daughter.
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Second Cobra....circa 2005...looked like this...
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My new Cobra...circa 2020...expect to start the Texas registration process this week.
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2FAST4U
01-28-2020, 06:53 PM
Bee-u-tee-full! Great build
KDubU
01-29-2020, 07:38 AM
Very nice! Congrats.
Vspeeds
01-30-2020, 09:09 AM
Looking good Zots
Street Legal!
I drove it home yesterday after the ASE Master Mechanic went over everything and gave it his blessing...mentioning the top-quality build. I now have a Texas 30-day tag so I can drive it to all the places that I need to get through the Texas Registration process.
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That is an electric power steering pump you see...from the MR2 Spyder....an all-in-one unit with pump/resevroir, and controller.
Jimtmich
02-29-2020, 10:28 PM
Nice job sits!
Vspeeds
03-01-2020, 12:59 PM
Street legal...Awesome!
Wind Wings, Visors, Light bezels installed and roll bar in place! Ready to drive.
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Great, hopefully see you at the club meet for lunch next Saturday at Sharkys!
Walt
Oil cooler installed - with a 180 degree thermostatic switch. Most carpet installed...now on to body work while I enjoy driving it!
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Just went through Texas DMV and easily registered it as a Custom Vehicle, which required a lot of forms and an ASE Master Mechanic inspection. As a Custom Vehicle it does not require the yearly inspection...just pay registration and show proof of insurance! In Texas, it is titled as 2020 ASVE Replica: 1965 Cobra
ChopperJustin
05-17-2020, 03:48 PM
I had a Cobra with under-car exhaust and one with side pipes. My kids still have leg scars. I like the clean look of no side pipes - especially on the 289 version...so here goes.
I purchased custum short headers from GP Headers in stainless. I then purchased 2.5" oval pipes and Series 7000 thin-line muflers from SpinTech and began the process of fabbing the system. Here is the product.
Headers with 2.5" round to oval transition:
106906
Exhaust system with Muffler Armor attached:
106907
Here is the muffler hanger:
106908
Side view:
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I will finish the side out once the body is in place. I am still evaluating rear-exit - but with the IRS, it probably won't happen.
I have about 3/8" clearance between foot box bottom and the Muffler Armor. I also placed Thermo-Tec heat barrier on the underside of the car above the exhaust. The muffler tucks up a bit under the additional height that is available under the seats. The whole thing hangs down less than 2.25" from the bottom of the side 2x2 frame rail.
Scott - would you mind providing an update/ photos from your exhaust build? Did you decide on the side-outs? I'm going to run a solid axle, but I'm still concerned the linkage is too low to have a rear exit exhaust - which is my preferance. Thank you!
I took the Cobra to Harris Hill Raceway, San Marcos, TX, for an afternoon of track time. It was a blast to drive. I had added the swaybar to the rear IRS for track time and the handling was exceptional. Street Cooper Cobra tiress are not the tire for the track (as compared to Hoosier race tires) and the tires let loose a few times for some spirited drifting around some corners!
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Grubester
08-13-2024, 12:13 AM
Is the firewall in the stock location? I'm going for a heater, too, but will offset the firewall about two inches so there is still room for a shallow glove box.
I was curious about "air intake". What about drawing from the cockpit, just not directly from where it dumps into the footwells?
Are you using the F5 htr/def?