Making progress in Missouri!

[Randy's]

My threads on this forum, up to this point, have been me seeking help. Without exception, those on this forum have answered every question. For that, I am grateful. This post however is a "thank you" for all the support and, perhaps, to help those trying to decide if they have what it takes to build a Factory Five roadster. Doing this has been on my bucket list for years. I was fortunate enough to order my complete kit in the spring of 2018, attend the build school in June 2018 and take delivery of my kit in August 2018. I know how to turn a wrench but I'm no mechanic so I had some concern that I might not pull this off. It didn't help that I had friends that thought I was nuts. Funny story, but one guy at the build school joked that he had not purchased his kit because he was going to buy mine from me at a bargain price once I gave up! Fast forward 14 months. Last week I drove the car to the Missouri State Trooper Inspection Station and passed with no issues! I'm just waiting on the state issued VIN and Title to come in the mail so I can get my tag and be street legal. Don't get me wrong, it has not always been easy. I can't count how many times I had to undo and redo, how many trips I made to the hardware and auto parts stores and the frustration of not having the proper tool. Plus, not everything just easily goes together like in the instructional videos and manual. And don't get me started in the after market modifications that I just had to have! Despite all that, this may be the most rewarding thing I have ever done. It is true that you get addicted to "the build". Maybe I'll sell this car to that guy I met at the build school (at a premium price!) and build another one. So, if you are undecided, go for it! If you are frustrated with your build, don't give up! The great people on this forum are glad to help. One final thank you to my wife. Without her support, understanding and "permission" to spend almost every weekend in the garage, this would not have happened.

If interested, I have attached a few pictures. I still have the body work, which I have never done before, but I look forward to the challenge!

[BadAsp427]

Very well done from what you show... I've got mine completed to the same point basically and have 9000 exciting miles on it. I started on it at the same time as you and completed to this point in December 18... Started driving in Feb 19 (waited for the tags... ) I may be in the St Charles area at Turkey day. Where are you at?
Carl

[CraigS]

Good thread Randy. I retired from being a dealer tech so have plenty of back round to make working on these fairly easy. But over the 12 years I have been here there have been quite a few builders like your self. They had almost no experience and yet they end up w/ a car. I really enjoy their threads. Keep on going and posting!

[Gizmosrcool]

Way to go. It looks like you may have AC? Was that hard?

[initiator]

Your story is very similar to my story, just further along. Congrats and thanks for the encouragement. Plus, I'm stealing your rear cupholder/USB charger idea. Zoink!

[Randy's]

I am in Sikeston (near Cape Girardeau).

Yes, I do have AC. It was my intent to order the kit from Whitby but they kept saying it was not available. So I designed my own system using Vintage Air components. I started by ordering their Gen II Mini mock up kit. It is just the plastic shell of the evaporator, no internals. It cost about $50. With that as a template, I figured where to cut the firewall. I used the firewall forward mod but it is still tight. No glove box either, no room. I also had to fabricate an aluminum "box" to cover part of the evaporator blower motor that protrudes into the engine bay through the firewall, figure out how to mount the condenser in front of the radiator and design the hose routing and lengths needed. I had the hoses crimped at my local NAPA store. Because not very many builders do AC, I had a little trouble finding details on how to integrate the Vintage Air wiring into the Holley Sniper EFI system. The Sniper system will shut down the compressor if the engine reaches a specific temp and at wide open throttle. It will also compensate for when the compressor kicks on and off. I should note that I purchased a Blueprint 347 Engine with AC so I did not have to deal with mounting the compressor. It was a little challenging but I am very happy with the results. It works great and makes a huge difference, even with no top. It gets hot and humid in SE Missouri!

I'm glad you like my cup holder layout. Please copy it. I can honesty say that almost every mod on my car is the result of looking at what others have done. On the front of that console are the seat heater switches, a USB charging port and the USB/Aux port for the stereo.

[Lancaster Lad]

Randy
Very nice looking machine. I too purchased a gen 2 mini mockup unit. I cannot figure out how to mount
without major chassis modification. It appears that the top clearance leaves no room for the hose with the
cowl. Please tell your secret. I just thought now if your evaporator is angled instead of being straight up and down.
I have been on this problem off and on for over 6 months while I work on other things.
Thank you for your time.

Cecil

[2FAST4U]

Gorgeous work.

[GTBradley]

Nice work. I like what you did with the RT Droptrunk cover, I may try to replicate that. Keep bringing the good ideas!

[CraigS]

I did a similar trunk cover also. Be sure to orient the hinge in the center correctly. That way even if other stuff is in the trunk you can lift just the rear half to get small things in and out.

[magicmarto]

Hi Randy
So So Awesome! Great job
I will call you soon to catch up
Martin

[Randy's]

Cecil,

I've looked back through my photos and have attached the ones that I think might help you with the AC. It was a challenge and took some time to figure out. I'm sure there are better ways so take what I have done and improve upon it. I could not fit the evaporator inside the cockpit on the firewall. Just not enough room. I had to cut a hole in the firewall, mount the evaporator at an angle, and build a "box" to cover the blower motor on the outside of the firewall. I insulated the inside of that box with Xmat from Eastwood (similar to Dynamat). All the hose connections are on the outside of the firewall as well as the drain for condensation. As you can see, it is extremely tight. You also have to remove (cut out) the small 1" by 1" bar on the frame that supports the middle of the dash hoop. I read quite a bit on the forum where several have done this so no issues with weakening the structure. You also do not use (remove) the plastic cover over the blower motor that Vintage Air provides. It is held on with two small screws so easy to take off. I used the mounting brackets provided by Vintage Air but modified them. As you can see, there are two mounting points on the outside of the firewall above the evaporator and one on the inside of the firewall at the bottom of the evaporator. The picture of the cut out in the firewall for the evaporator is a rough cut. I had to tweak it some but could not find a picture of the final cut. I got it close and used the 3M brand strip caulk to seal around the unit and the firewall as well as around the blower motor "box" I created. Installing the AC also required that I cut holes in the firewall for the front electrical harness, etc. in different locations from what the FFR manual says to do. I also attached pictures of where I placed my inside vents. There are two in the dash and two in the console that I created that fits under the dash. You can direct the air flow in to each foot box which is nice. That console is also where I mounted the controls for the AC. There are also two defrost vents.

I'm not sure why the attached pictures rotate when I attached them but I think you can still see them. That is everything I can think of but I will be glad to answer any questions.

[Lancaster Lad]

Sir Randy

Thank you for the reply. I know what they say about assume but can I assume the floor vents are not used.
Using the mockup unit I could not find a way to fit it and use the floor vents. One solution I thought about, was
to weld a 2 x 2 below the existing 2 x 2 and cutting the top off about 1 1/2 in to fit the evap unit. Another solution
was to do what Zots over on the 289 forum did. That one appears to be similar to the one Northracecars sells.
I guess I need to just buy the actual Vintage Air Evaporator and see what can be modified like you did. The photos
are a big help along with your descriptions.
I already purchased the upgraded controls to place in the console similar to yours. Also have Saab cupholders similar
to DANW. As anyone who goes off the reservation knows there is not a lot of room in these cars.
A semi off topic but where does the air to heat or cool enter the evaporator? Does the air just recirculate through
the interior.
Again thank you for the help. After the actual evaporator arrives I will see what it looks like and maybe then I will
have some more questions.

Cecil

[Randy's]

Cecil,

The air is pulled into the evaporator from the interior of the car. With the way I've installed it, air is mostly pulled in from the passenger foot box area. I have used dash support brackets but most of the bottom of the dash is open which allows the air to flow easily. The bottom of the evaporator is not flat, it has a moderate "v" shape. So, even though it sits directly above the 2" x 2", the floor vents do work. However, the air does not blow straight down, it is deflected out as it hits the 2" by 2" but the floor vents still push out air. I have attached another picture that shows the blower, the "box" used to enclose the portion that extends through the firewall and how the bottom of my dash is open to allow air to be pulled in by the blower.

[Duster]

Hi Randy

We are semo neighbors, we are in Dexter. I am about a year behind you as I went to the build school this June and my Roadster was delivered in August. I use the powder coating guy north of town too often. Your build is really looking good. I would love to come by some time for tips and pointers if you would like to show your car off in person.

Thanks

Dave

[PaulProe]

Have you guys registered on the Gateway Cobra Club site? We occasionally cruise down your way. In addition to the website articles, check out the forums

Gateway Cobra Club (http://gatewaycobraclub.com)

Paul

[Randy's]

Dave,

You are welcome to come by. I have my car "broken down" and am doing the body work now so you can see the go-cart which is probably how you would prefer to see it. PM me and we can firm things up.

Paul,

Once I am done I will certainly consider joining. Looks like a great club!