25th MKIV #9772 Build NOR*CAL: new vanity plate [Archive] - Page 3

toadster

10-05-2023, 09:31 AM

waiting for a callback from Ford - we're thinking it's the engine harness that is causing the engine to run improperly, I've been pulling my hair out on this since April - hopefully Ford ships a new harness and this will fix the issue...

while I'm waiting, doing some more to finish up the car before paint

the glovebox door FITS now with the correct parts! I had to get a new hinge and brackets for the CF dash to accept this properly - I guess that's what happens when non-CF dash parts are sent with the original CF dash

https://i.ibb.co/L9Dt7ch/IMG-9454.jpg (https://ibb.co/44wTrXg)

buttoned up the trunk panel and added the bulbseal - Ken said to trim the panel a bit so I'm hoping this will seal things up in back

https://i.ibb.co/JRQQgL7/IMG-9452.jpg (https://ibb.co/pvyy5Dz)

lastly, I got my A/C pedals and extensions (https://fortesparts.com/product/fortes-custom-pedal-extension-kit/) from Mike Forte, the main part was to raise up the brake pedal as it was super low in comparison to the clutch/gas pedals
still not happy with the angle of the Whitby brake pedal, the top of the pedal leans forward quite a bit
https://i.ibb.co/M9JxJFj/IMG-9453.jpg (https://ibb.co/g6cLckX)

other than removing the pedal and heating up to bend it - I'm unsure what to do next with this... removing the pedal in a nearly finished footbox would be a PITA for sure...

egchewy79

10-05-2023, 10:46 AM

could you have a small wedge of aluminum made and get longer hardware to get the pedal to angle up a bit?

toadster

10-05-2023, 10:52 AM

could you have a small wedge of aluminum made and get longer hardware to get the pedal to angle up a bit?

it's possible, but then also drilling 4 concentric holes to align the screws as well - would probably need longer screws for sure on the bottom
maybe I can get my son to print me a spacer on the 3d printer - he was thinking not to use plastic/ABS on the brake pedal, but a solid piece would be pretty 'solid'! :)

toadster

10-06-2023, 08:16 AM

BradC stopped by yesterday, his Tesla Powered 33 Hot Rod (https://thefactoryfiveforum.com/showthread.php?42653-Tesla-Powered-33-Hot-Rod) is stunning in person!!!

https://i.ibb.co/N2XKw5Z/IMG-9461.jpg (https://ibb.co/k2pXYjQ)

He's a whiz at 3D printing and has access to tools to CNC metal as well, will be a 2 part design to angle up the brake pedal so isn't top-forward facing like it is now and makes it more perpendicular like the gas/clutch...

still waiting on Ford to get back to me on the engine harness, the local dealer can order one and get it in 2 days @ $355, would probably be faster than Ford Performance - the last time they shipped my ECU it took a week
I just want to hear this Coyote run properly!!

jamminj

10-06-2023, 08:32 AM

hello Todd
this is James
How r you
My build is coming slow but i work on it weekly, so it doesn't get stale and sit in a corner.
Going to try to get the rear upper and lower a-arms attach to my frame this weekend I don't know if you have been following.
I to have a friend in Gridley he cnc plasma cuts my parts in literally minutes it's amazing how fast they are.

toadster

10-06-2023, 08:45 AM

toadster

10-09-2023, 09:19 AM

after one more final test print for the brake pedal, BradC is a whiz at cad design! We got the right dept now and angle, the last print will be to raise the pedal by about 11mm to have all 3 pedals level.

my son got a new 3D printer (Bambu P1S (https://bambulab.com/en-us/p1)) which is up to 10X faster than his older Creality Ender 3 3D Printer (https://amzn.to/45nzgOv), not a bad printer at all but the Bambu is next level!

He was able to print out the new pedals in about 1.5 hours where on the Ender3 it would have taken about 5-6 hours. Once we fit this pedal, we'll craft the 1/2" spacer out of aluminum and the 3D printed angle part will be carbon fiber embedded.

https://i.ibb.co/1LFT5wx/IMG-9507.jpg (https://ibb.co/1LFT5wx) https://i.ibb.co/NKL73s2/IMG-9493.jpg (https://ibb.co/NKL73s2)

The glovebox door is now attached and I've added the Glove Box Latch from the 1953-1967 Volkswagen Beetle (https://www.partsgeek.com/shqs3j4-volkswagen-beetle-glove-box-latch.html?utm_source=google&utm_medium=ff&utm_content=DN&utm_campaign=PartsGeek+Google+Base&utm_term=1953-1967+Volkswagen+Beetle+Glove+Box+Latch+Volkswagon+ 111857131+53-67+Volkswagen+Glove+Box+Latch+1964+1961&fp=pp&gbm=a&nis=6), like many others, I like the look, and it has a pushbutton versus a scratching key
simply had to create a little longer latch inside the glovebox

https://youtube.com/shorts/Xc6Q1U01V1k

now that we have the shifter placed, we cut the shifter hole and it fits perfectly! We also finished up the wiring behind the dash, added a diode to make the emergency flasher only blink when the button is pushed - I didn't want a red light on the dash all the time that the dash lights were on...

also taped up all the connections where the heatshrink connectors were bare, found a couple of shorts during testing - all better now :)

https://i.ibb.co/rGvD86J/IMG-9500.jpg (https://ibb.co/rGvD86J)

next up today is to take some of the parts to an upholsterer.

Repairing the door cards that haven't held up well from FFR
adding some door pockets
covering the trans tunnel cover
lower dash/radio box wrapped

Here's a pic of the dash, just needs mounted, but leaving loose for a bit more until we get this coyote running right...

https://i.ibb.co/GR5FZL9/IMG-9503.jpg (https://ibb.co/GR5FZL9)

also prepped the cockpit wall to put in the carpet, used gaffers tape on the seams just in case of any mini gaps they won't show through

https://i.ibb.co/hZ1qygk/IMG-9496.jpg (https://ibb.co/hZ1qygk)

today Ford is supposed to let me know their steps. Hoping for a new engine harness...

Ted G

10-09-2023, 11:09 AM

Looking good! I hope Ford comes through for you

Nigel Allen

10-09-2023, 09:10 PM

Here's hoping Ford gets a new loom to you and it solves the problem.

Car is looking great.

Cheers,
Nige

toadster

10-15-2023, 10:08 AM

ford finally came to the conclusion that the engine harness must be the culprit... then they started to look for one to ship to me, ugh - why can't things be done in parallel? we've been working on this since APRIL!

anyhoo... with BradCs excellent knowledge and skills, he and my son Ryan set out to build the perfect brake pedal extension for my Whitby power brake

if you remember where this started, the brake pedal from Whitby's power brake kit was about 3 inches behind the gas and clutch pedals, somewhat a 'pray for brakes' moment would be very scary - so after contacting Whitby, they said there's nothing wrong, others on the forum heated and bent the brake pedal up to a manageable height - neither of which I liked

https://i.ibb.co/pxSzrQj/IMG-7898.jpg (https://ibb.co/pxSzrQj)

so we opted for a pedal extension, starting with Mike Forte's A/C pedal extenders - which helped bring up the spacing, but was at an odd angle...
so BradC designed a 2-piece design, and my son Ryan would do some test prints on the 3D printer until we got a good geometry and spacing

here are the 4 pieces, original to final from left to right
https://i.ibb.co/9sTz44b/IMG-9559.jpg (https://ibb.co/9sTz44b)

each design a bit different from the last, depth, angle, hole alignment, etc.
the final design was CNC'ed from aluminum and the angle pedal was printed with carbon fiber inlay for strength - all with blue loctite socket-head screws and it feels perfect now!

https://youtu.be/ylg4ZdnM80A
https://i.ibb.co/qgVhRCv/71867466075-3-F41-B8-C1-A689-4258-8-BB0-5-B6-B93018-F4-B.jpg (https://ibb.co/qgVhRCv) https://i.ibb.co/nkh4ywx/IMG-4915.jpg (https://ibb.co/nkh4ywx)

what a huge difference when finished!!! The pedals are now flush, and the height is well aligned - SUPER happy how this turned out!

https://i.ibb.co/7VHCvTy/IMG-9567.jpg (https://ibb.co/7VHCvTy) https://i.ibb.co/tzpVxh3/IMG-9572.jpg (https://ibb.co/tzpVxh3) https://i.ibb.co/ZMGYybw/IMG-9573.jpg (https://ibb.co/ZMGYybw)

BradC

10-15-2023, 10:59 AM

So frustrating with Ford huh? Let's hope they get you a new harness soon and that gets it going!

Glad you're happy with how the pedal adapter turned out..

toadster

10-16-2023, 10:40 AM

got a lot done (or at least feels like progress) yesterday with carpeting, seatbelts, some trim and rear speakers
carpeting wasn't nearly as bad as I thought it would be - I did the trunk a while ago and that was 50/50 custom vs FFR stock

I am using a heavier black carpet (20 oz) from BassBoatSeats.com (https://www.bassboatseats.com/products/deckmate-20oz-bass-boat-carpet?variant=540868009), it's $180 for 108 sq/ft (6' x 18') using the FFR pre-cut as a template

layout on the back of the cockpit, as recommended by many is to hang the center piece with some clips to establish location and edges
then spray the bottom portion first, let it dry then the top piece lays in very easily

https://i.ibb.co/xF0M44n/IMG-9574.jpg (https://ibb.co/Sf8KLLk) https://i.ibb.co/Bq67qLR/IMG-9580.jpg (https://ibb.co/ZWgwWdC)

trimming out the speaker and cubby holes is pretty simple once the glue dries, I found that a wide putty scraper was very useful in getting the Breeze cubby trim to not bunch up on the heavier carpet

https://i.ibb.co/85gs0sM/IMG-9581.jpg (https://ibb.co/r620m0k) https://i.ibb.co/cyNZP1X/IMG-9582.jpg (https://ibb.co/QJ6TZfj)

next up, before putting the speakers back in, was to setup the seatbelts - this required putting the seat in the car, measuring from collarbone to the belt adjuster at 10 inches, then mounting and rolling up the excess webbing
this also meant I had to put in Michael Everson's trim rings as the belt hardware won't pass through these so a quick way to level the trim was to use a level and a ruler :)

https://i.ibb.co/xzv79ct/IMG-9584.jpg (https://ibb.co/QYBKSq3) https://i.ibb.co/6rwz1Cy/IMG-9585.jpg (https://ibb.co/n6m9nJw)

toadster

10-16-2023, 10:45 AM

next we could mount the rear speakers, and my son Ryan developed some 3d printed wedges to mount the 4" speakers in the side of the footboxes which gives the clearance and angles the speakers upward a bit more while keeping it all flush

https://i.ibb.co/St6Z9kd/IMG-9586.jpg (https://ibb.co/48F05bY) https://i.ibb.co/yY21WSd/IMG-9587.jpg (https://ibb.co/HxZsndB)

also used the FFR tunnel cover as a template for the sides of the transmission tunnel, I'm having the top of the tunnel upholstered so it will lay over the edges

https://i.ibb.co/SNNPsBL/IMG-9589.jpg (https://ibb.co/0qqcDrw) https://i.ibb.co/tzP7qwS/IMG-9588-1.jpg (https://ibb.co/qCFtNLz)

lastly, before buttoning up the dash, I opted to spray the top bar just to keep things dark and not have the bronze peek through if there's a body gap

https://i.ibb.co/ByC2fn5/IMG-9590.jpg (https://ibb.co/3pCmTR9)

toadster

10-17-2023, 03:05 PM

got a FedEx # from Ford, the new harness should be here tomorrow! YAHOO!!!

also, mounted the rear section of the transmission tunnel carpet -what a strange fit/angle, after about 25 minor trims/cuts - got that installed last night

https://i.ibb.co/kDFwmDh/IMG-9602.jpg (https://ibb.co/X5TKY5z)

test fit the driver carpet footbox carpet, not setup yet, but the Coyote pedal rubs on the carpet, not enough to catch but that's a really tight setup!

Ted G

10-17-2023, 07:57 PM

Looking good Todd. I hope the Ford harness is the answer. Let me know if you need any help.

Ted

toadster

10-19-2023, 09:02 AM

after 6 months of troubleshooting, different wiring tests, Ford overnighted a new engine harness and we tested last night at 9:30 with open headers
will test more, but the driver side header got up to 160F in 30 seconds, same as the passenger (which worked all along) so we're STOKED!!!!

https://www.youtube.com/watch?v=xU31Ef93QyY

Nigel Allen

10-19-2023, 09:06 AM

Woohoo!

Mike.Bray

10-19-2023, 09:29 AM

Exciting!

Lidodrip

10-19-2023, 10:00 AM

That is awesome, it has been a long time coming!

JohnK

10-19-2023, 10:49 AM

Congratulations!!! That's so exciting. Hopefully that's the end of your coyote headaches and you can wrap up your awesome build.

zarnold

10-19-2023, 09:49 PM

Awesome news!! Congrats!

BradC

10-19-2023, 10:11 PM

Congrats!!! What a huge relief huh?

facultyofmusic

10-20-2023, 11:52 AM

Congrats! What a relief!

ydousurf

10-20-2023, 01:22 PM

Todd, I think we're all so happy for you! Way to stay with it and find the solution. You better get a plate, eh, maybe just a tshirt - PERSEVERANCE! Can't wait to see it all completed.

Doug

toadster

10-23-2023, 12:00 AM

argh, the coyote still only firing on bank #1 and partially on bank #2... hoping Ford ships a new ECU at this point...

we got a data log of the engine running 'normally' on startup then bank #2 shuts down -hopefully Lund can figure something out on what's triggering the shutdown

back to more 'things' on the car... we were waiting to put in the heater hoses till the engine was better, at this point we hope we're past the point of a mechanical issue

this engine bay is way over packed, it's making things pretty tricky to mount any more but I think we've hit the pinnacle :)

Ran the heater hoses to the Thermomotion valve, seems to be working properly, got some heater hose wrap that somewhat dresses up an otherwise bland looking hose

1 inch PET Expandable Braided Sleeving – Black (https://amzn.to/470ob7r)

https://i.ibb.co/cXw8cCB/IMG-9634.jpg (https://ibb.co/h1cdRZ6) https://i.ibb.co/8mvPyPr/IMG-9637.jpg (https://ibb.co/K54VtV2) https://i.ibb.co/hsbcdXy/IMG-9636.jpg (https://ibb.co/VVRxCHt) https://i.ibb.co/q9xYTzK/IMG-9635.jpg (https://ibb.co/82Xg1Jq)

Ryan got to drive Dave's cobra at Cars & Coffee on Saturday, very nice of Dave to do this and Ryan was very excited to have the opportunity!!

https://youtu.be/zfntCxGanHk

toadster

10-25-2023, 05:05 PM

got some more news from Ford today, 99% sure they'll be shipping a new PCM out to me by Friday

also, got the interior parts back from the upholstery shop, they had to re-do the door cards as the FFR ones from the kit were absolute garbage, I'm amazed they charge $199 for those door cards - horrible (see link)
https://thefactoryfiveforum.com/showthread.php?34952-25th-MKIV-9772-Build-NOR*CAL-the-Coyote-bites-back&p=470855&viewfull=1#post470855

here are the rebuilt ones - I would have just done Herb's panels, but I wanted all matching stitching between the seats, etc.
https://i.ibb.co/yVGQy4y/IMG-9732.jpg (https://ibb.co/0Q8GMsM)

the shop redid the suede and matched the diamond stitching and also put in some door pockets

overall pretty stoked with how all the items came out!!

https://i.ibb.co/gPRhM6B/IMG-9731.jpg (https://ibb.co/1dmjfbw)

fingers crossed that Friday results in a good Coyote start and we can finalize this part of the journey!!!

Ted G

10-25-2023, 07:40 PM

Looks great and glad Ford is working with you. Just blame the delay on the "Strike".

facultyofmusic

10-25-2023, 09:37 PM

got some more news from Ford today, 99% sure they'll be shipping a new PCM out to me by Friday

Thank god your PCM is mounted on the passenger footwell and not tucked between the engine and the firewall :P

BradC

10-26-2023, 10:23 AM

Interior looks great! I hope the PCM does the trick!

toadster

10-26-2023, 01:48 PM

while waiting for the new ECU from Ford, I think we've squeezed everything on the firewall that can fit... the last part was the HVAC blower fan, getting those screws in there was a PITA, I think we created some new swear words LOL

https://i.ibb.co/NLP6M4x/IMG-9734.jpg (https://ibb.co/GVLvqh7)

just need to wire the blower motor and I think we're done with all the behind dash wiring :) YAHOO!

hope to get the footbox carpet in next, was waiting on the upholstered parts to arrive to ensure we have good overlap/coverage in that space - I think we're good now :)

also did a re-check on the front alignment, set everything to the FFR manual specs so hopefully good enough for go-karting!

460.465USMC

10-28-2023, 11:35 AM

I was truly bummed to read the wiring harness did not fix the issue. Hoping the ECU is the charm. You're a man of great perseverance. Hang in there!

toadster

10-28-2023, 06:36 PM

I was truly bummed to read the wiring harness did not fix the issue. Hoping the ECU is the charm. You're a man of great perseverance. Hang in there!

sadly the ECU didn't fix this either :(

https://thefactoryfiveforum.com/showthread.php?47524-the-coyote-continues-to-bite

toadster

11-05-2023, 02:49 PM

had some time to redo the ground, just to quell the 'not enough grounds' issue - this one is on the rear of the driver head into the frame, also added another ground on the passenger side head into the frame as well

https://i.ibb.co/HD367MF/image.png (https://ibb.co/bgDT1yW)
https://i.ibb.co/TrJSZSQ/image.png (https://ibb.co/jHq2d2C) https://i.ibb.co/1sHNz8Y/image.png (https://ibb.co/28XrZg0)

also finished up the A/C - Heater blower wiring should be sealed up now and functioning :)
https://i.ibb.co/4MjxRNq/image.png (https://ibb.co/Qn6Gvmg)

travelling this week, Ford and Lund still stumped on the Coyote, may end up taking it to a local Tuner/Coyote Expert (Shaun @ AED)

Nigel Allen

11-06-2023, 05:40 AM

Dumb question regarding engine issue; what is the oil pressure when running? Have you modified the lubrication system in any way?

toadster

11-06-2023, 11:15 AM

Dumb question regarding engine issue; what is the oil pressure when running? Have you modified the lubrication system in any way?

totally normal, 80psi on the gauge
only modification for the engine is removing the CMCV valves

I haven't even been able to test the engine fan, the temps only get up to about 130F, not enough to kick on the radiator fan - the engine in total has run maybe a total of 20-25 minutes from dozens of starts
I don't want it to idle needlessly, with 1/2 the engine firing, so temps never get high enough...

toadster

11-20-2023, 11:41 AM

well, we spent the better part of last week troubleshooting just about everything on the Coyote, from injectors, coils, fusebox, PDU, fuel rail, logging the ECU, continuity, added grounds... still runs weird

I'll be taking the car up to AED which is only 12 miles from here hoping that Shaun can determine what we're missing...

after all that electrical fun, worked on more carpeting in the footbox so I can get the lower dash affixed and be done with that

https://i.ibb.co/VDg9fr7/image.png (https://ibb.co/VDg9fr7) https://i.ibb.co/VV0zdLL/image.png (https://ibb.co/VV0zdLL)

also put the sidepipes back on, the open headers (although catted) were getting pretty tiresome on the ears... used the Kleiner (and others) method of using some stainless bolts and brass coupling nuts, the brass doesn't rust, and won't back off unless you want it to - they look pretty beefy and the 3/8" fits the Coyote headers and Gasn' Pipes very nicely - will still need to determine spacers/angles once painted but for now with hangers, things look pretty solid

here are the parts I ordered

3/8-16 x 2" Socket Head Cap Screws Allen Socket Hex Drive Bolts, 304 Stainless Steel 18-8 A2-70 (https://amzn.to/3MOEJaO) $10 for 10
Brass Hex Nut - 3/8-16 In. (https://amzn.to/49JCoYv) $16 for 25

https://i.ibb.co/yVxhZvL/image.png (https://ibb.co/6NqvT96)

I'd recommend going with a 1.5" bolt
3/8-16 x 1-1/2" Socket Head Cap Screws Allen Socket Hex Drive Bolts, 304 Stainless Steel 18-8 A2-70, Fully Threaded, 10PCS (https://amzn.to/47BigpA) $7

Ted G

11-20-2023, 11:52 AM

toadster

11-20-2023, 12:12 PM

Todd, i love that and when I start my winter projects, I think I'll do this modification as well. Nice and hoping that AED will figure out the issues you are having.

Btw, did you try to run it with side pipes on? Just wondering if that may affect the AFR sensors

this is my forever winter project LOL

we've done sidepipes throughout the process, same issue... didn't affect AFR since the O2 is in front of the cats

toadster

11-23-2023, 01:03 AM

update on the Coyote https://thefactoryfiveforum.com/showthread.php?47524-the-coyote-continues-to-bite-4-bad-injectors-!&p=542851&viewfull=1#post542851
needless to say, spent more money to get 4 new fuel injectors for Bank2

spend a few minutes tonight putting the Stage 8 locking washers (https://amzn.to/3sKVU6g) on the passenger headers, that side has always been hot and had several cycles

will most likely finish up carpet this weekend now that the engine will most likely not be coming out of the car :)

Alan_C

11-23-2023, 03:25 AM

update on the Coyote https://thefactoryfiveforum.com/showthread.php?47524-the-coyote-continues-to-bite-4-bad-injectors-!&p=542851&viewfull=1#post542851
spent a few minutes tonight putting the Stage 8 locking washers (https://amzn.to/3sKVU6g) on the passenger headers, that side has always been hot and had several cycles

How did the substitution of the locking fasteners for the studs go? I have my Stage 8 locking fasteners on the bench waiting for install. I have headers from Ultimate Headers as my Coyote is going into a Mustang. The header design blocks direct access to some of the bolts on each side. I have the copper anti-seize planned as a precaution. Any recommendations you have I would like to hear.

toadster

11-23-2023, 11:20 AM

How did the substitution of the locking fasteners for the studs go? I have my Stage 8 locking fasteners on the bench waiting for install. I have headers from Ultimate Headers as my Coyote is going into a Mustang. The header design blocks direct access to some of the bolts on each side. I have the copper anti-seize planned as a precaution. Any recommendations you have I would like to hear.

removing the coyote studs was simple enough, Stage 8 recommends anti-seize on the bolts

https://youtu.be/U15OxrX_NBc?si=X9GPU0dU4v7upjvG

the equal length headers are similar to what you describe, the headers block access with most sockets, so I used a mix of wrenches

Klein Tools 65200 Ratchet Set (https://amzn.to/3GgmozP)
https://i.ibb.co/HKgfbNV/image.png (https://ibb.co/HKgfbNV)

GEARWRENCH 1/4 Inch Drive Gimbal Ratchet (https://amzn.to/40RWGuU)
https://i.ibb.co/xmkJjB0/image.png (https://ibb.co/xmkJjB0)

WORKPRO 1/4" Drive Flex Head Ratchet (https://amzn.to/3sFqDBU)

https://i.ibb.co/vj1MwPt/image.png (https://ibb.co/vj1MwPt)

7/16 Inch TIGHTSPOT Ratchet Wrench (https://amzn.to/40YRzt2)
https://i.ibb.co/MnSz66D/image.png (https://ibb.co/MnSz66D)

the passenger side is relatively easy, the driver side will require some contortions and jacking up the front end for sure to get to the 3 rearmost bolts

toadster

11-25-2023, 01:37 AM

https://media.giphy.com/media/vmv47p4zksWDC/giphy-downsized-large.gif

https://youtu.be/REo-gU2gq30?si=deR8apmlD-gfts9B

John Ibele

11-25-2023, 10:08 AM

Really, really happy for you, Todd. What a great feeling. Your persistence was commendable through the whole saga, and I wish you steady forward progress as you finish off your build.

Its Bruce

11-25-2023, 10:37 AM

All injectors on one bank... I wouldn't believe it if I didn't see it in your posts. Congrats on seeing this through and your now operational go kart.

Did his tool isolate the injectors from the Ford harness during testing? It's almost as if they're wired to fail an entire bank if one goes out.

460.465USMC

11-25-2023, 11:45 AM

Congrats, Todd! What a great feeling to get to the root cause. You persevered and conquered. So impressive. I look forward to seeing you go-kart. Well done!

Jeff Kleiner

11-25-2023, 01:05 PM

toadster

11-26-2023, 10:39 AM

Todd,
Happy to hear that you've made progress but as someone who spent a decade and a half in the engineering test labs at GM doing both destructive and durability testing I have to say you really can't stick a fork in it until you can answer the question of "why?" As I said earlier, the likelihood of all 4 injectors just randomly being bad is a statistical impossibility. Something caused it, either electrically or mechanically (i.e. clogged, perhaps with debris left in the line when the hoses were made up). I'd sure want to do the forensic investigation to determine what that was.

Good luck!

Jeff

Hey Jeff - totally agree with you on this! All the lines were cleaned out prior to closing them up, at least with compressed air. Even if there was gunk in the lines, why would it only choose the driver side?
Electrically, I believe all the injectors share the same 12V wire, but each injector (maybe bank of injectors?) has a driver that opens/closes the circuit to ground, Ford can maybe dig into this when I return the old ECU.

since we determined the issue on Wednesday afternoon, Ford Performance was already closed when I sent the email - so I will follow up this week with them
hoping they'll somehow recoup my cost for the (4) injectors ~$133, and I'll have them pay for shipping of the old ECU and 2 harnesses

Ted G

11-26-2023, 07:28 PM

Congrats Todd! Sounds great and can't wait to escort you to Cars and Coffee in go-kart stage.

Hoooper

12-04-2023, 12:42 PM

Since you have a new harness and a new ECU I wouldnt worry too much about it. My guess would be all 4 injectors share the same ground path after the ECU drivers and there was an issue in the harness with the ground that led to the failure of those injectors. Possible the drivers themselves were bad and friend the injectors but I think that seems kind of unlikely to happen to have 4 bad drivers at the same time.

BradC

12-04-2023, 12:59 PM

Ok, I told you I was holding off on saying congrats again this time but I think we're in the clear. Congrats!!

Add me to the go-kart convoy to CnC with Ted!!

Ted G

12-04-2023, 07:13 PM

toadster

12-05-2023, 02:30 AM

Todd, I'm doing this modification and ordering these parts. Did you use any lock washers or thread locker? What about just flat washers?

nope just nuts and bolts, the brass acts as a lock since it's softer than the stainless and won't rust either :)

Mike.Bray

12-05-2023, 08:38 AM

nope just nuts and bolts, the brass acts as a lock since it's softer than the stainless and won't rust either :)

And "lock" washers don't actually lock anything, they're just a false sense of security.

toadster

12-08-2023, 11:06 AM

after a week of travel for work - a little more time back in the build

as many of you know, my a/c installation is customized from the Gen3 coupe kit
in hindsight knowing what I know now, I'd custom build from scratch to minimize waste

now that the engine is running properly (getting it dyno tuned next week) I wanted to see if the A/C lines will hold pressure...

I got a vacuum pump and A/C kit on amazon
Kozyvacu AUTO AC Repair Complete Tool Kit with 1-Stage 3.5 CFM Vacuum Pump, Manifold Gauge Set, Hoses and its Accessories (KZTA350F+) (https://amzn.to/3RhT8NY) ~$140

I am able to pull a good vacuum ~30 in/hg but when turning off the pump, it would return to non-vacuum within a few minutes
in another thread, it was suggested that I pull it all apart and redo the o-rings and use a better sealant

Refrigeration Technologies RT201B Nylog Gasket/Thread Sealant (https://amzn.to/3GB55d2)~$12 and super goopy compared to the stuff in the kit!

Car Air Conditioning Compressor Seals O-Ring Kit (https://amzn.to/3TyDEIz) ~$9 and way more o-rings than I'll ever need!

I pulled all connections apart, and redid all the rings/seals and tightened them down
https://i.ibb.co/c6p78ys/IMG-0309.jpg (https://ibb.co/c6p78ys) https://i.ibb.co/JF9Hm5j/IMG-0310.jpg (https://ibb.co/JF9Hm5j) https://i.ibb.co/R0V5XV6/IMG-0311.jpg (https://ibb.co/R0V5XV6) https://i.ibb.co/d2YzhDX/IMG-0312.jpg (https://ibb.co/d2YzhDX) https://i.ibb.co/2KXMt6Z/IMG-0313.jpg (https://ibb.co/2KXMt6Z) https://i.ibb.co/jzBvwGn/IMG-0314.jpg (https://ibb.co/jzBvwGn) https://i.ibb.co/1mFhkF7/IMG-0315.jpg (https://ibb.co/1mFhkF7)

This time, the vacuum holds better but will leak down over 30 minutes...

in the essence of time, I found a shop that does custom A/C work so we trailered it down yesterday... IMHO a few of the fittings I had to bend to fit the curvature I needed and maybe aren't seating well
it stinks to have all the tools and still take it to a shop, but it's a learning process and I don't want to fight in the engine bay for A/C leaks in the future... hopefully buttoned up today!

fingers crossed!

Next friday I'll take the car to AED in Cameron Park, CA to have the car dyno tuned by Shaun - he's the coyote expert that found my dead injectors and I wanted to support his shop

I'll be selling the HP Tuner programmer and ditching the LUND tune over email... sadly no refund, but I'm just frustrated with their process

k-roy

12-08-2023, 02:25 PM

toadster

12-08-2023, 03:47 PM

When I put my AC lines on vacuum, I lost pressure through the pump. Are you closing the system off (two knobs under the gauges) to shut out the vacuum pump? (Leaving the two access port knobs open to read the pressure)

the shop verified that my one adapter that went into the compressor got x-threaded, this was my concern as I had to bend the adapter to meet the curvature of the hose - but must have over-corrected

I ordered a new adapter and a new adapter for the compressor as well - major bummer! everything else was good though!

toadster

12-09-2023, 07:28 PM

while waiting for my a/c parts to come in, figured I'd finish up more interior work

carpeted the forward floor of the driver and some of the passenger footbox, will do the sides of the cockpit before I do the biggest floor pieces to keep the seams to a minimum... always love the smell of Super 77 in the morning ;)

https://i.ibb.co/n7xsH9R/IMG-0341.jpg (https://ibb.co/n7xsH9R) https://i.ibb.co/L6Znk4q/IMG-0342.jpg (https://ibb.co/L6Znk4q)

also attached the transmission tunnel cover, using some HD velcro - will see if it holds enough, may have to revert to screws after some test drives :)

https://i.ibb.co/H4vKsYG/IMG-0344.jpg (https://ibb.co/H4vKsYG)

lastly, we modified the lower dash to get mounted for (hopefully) the last time...

we tightened down the billet button rings and my son 3D printed a spacer for behind the start button to keep it secure
we also had to bore out the leather for the mounting screws and adapt the subwoofer dial on the driver side - thankfully all our quick disconnect adapters worked great - all electricals passed!

We really had to fight this as we didn't fully account for the extra space required for the leather and foam wrap but things lined up after some coercion

I think the lower dash turned out AMAZING!
https://i.ibb.co/2KbWGk9/IMG-0343.jpg (https://ibb.co/2KbWGk9) https://i.ibb.co/VCfWj0w/IMG-0346.jpg (https://ibb.co/VCfWj0w)

next up will be to situate the shifter boot and attach the trim ring and finish up the carpeting...

last items will be to run the vent hoses, my son is 3d printing some adapters so we get 1 vent in the dash, and 1 vent into the footbox per side

460.465USMC

12-13-2023, 10:43 AM

I agree your lower dash, AND dash, AND transmission cover look AMAZING. Kudos to you and your son.

One more congratulatory WHOOP your Coyote is running solid!

toadster

12-13-2023, 04:38 PM

I agree your lower dash, AND dash, AND transmission cover look AMAZING. Kudos to you and your son. One more congratulatory WHOOP your Coyote is running solid!

thank YOU! its starting to feel 'real' again! :)

Last night, I did a bit more carpet while my son printed out some custom 3D tubes for the dash A/C vents - it's going to be epically hidden behind the dash, but I'm SO impressed with his 3D printing skills!!!
https://i.ibb.co/6wHYpRX/IMG-0371.jpg (https://ibb.co/6wHYpRX) https://i.ibb.co/fMPtJry/IMG-0370.jpg (https://ibb.co/fMPtJry) https://i.ibb.co/NT3zSSC/IMG-0376.jpg (https://ibb.co/NT3zSSC) https://i.ibb.co/v4GWZDm/IMG-0377.jpg (https://ibb.co/v4GWZDm)

also, wanted to test my flasher for the 3rd brake light (CHMSL) - dumb video (https://youtube.com/shorts/diGh2FX4830?si=ZfRQbU2sZCRqgUIX), but it works ;)

toadster

12-13-2023, 04:39 PM

I've been eyeballing the sidepipes and what spacers may be needed, I know it's all estimates until the body is on - any recommendations?

Driver Side has about 1" of clearance to the frame
https://i.ibb.co/LdJ5psq/IMG-0366.jpg (https://ibb.co/LdJ5psq) https://i.ibb.co/LnqXKyz/IMG-0369.jpg (https://ibb.co/LnqXKyz)

Passenger Side has about 3.5" of clearance to the frame
https://i.ibb.co/nwpqRB2/IMG-0367.jpg (https://ibb.co/nwpqRB2) https://i.ibb.co/2d2h5K8/IMG-0368.jpg (https://ibb.co/2d2h5K8)

too early to worry about it? I sent these pics to Mark at Breeze as well for ideas...

Lidodrip

12-13-2023, 05:05 PM

toadster

12-13-2023, 05:35 PM

You might want to wait until you have the body fitted in its final location before fitting the side pipes. How the pipes fit in relation to the body (not the rails) is what matters and there is some adjusting of the body (pushing in/pulling out) to get the door fit right. I have a Gen 2 Coyote with the FFR catalytic converter headers and GasN Touring pipes and ended up using 1 small wedge on the passenger side and 1 large wedge on the driver side (from Breeze). Pipe alignment was perfect.

Your transmission cover looks great - where did you get the diamond stitch fabric?

James

awesome thanks!

I had the center cover stitching matched by a local upholstery company and they had a bazillion colors of everything, from the suede to the stitching...
they took my rudimentary drawing and made my thoughts into reality!! not cheap, but as you can see, it's worth it!

https://www.finelinetrim.com/automotive

Nigel Allen

12-13-2023, 07:47 PM

toadster

12-14-2023, 12:11 AM

G'day Todd,

I really like that third brake light flasher. Third brake lights are mandatory here in Oz, but not flashing ones. I wouldn't mind fitting a flash module, hopefully to wake up some of the clowns that insist on tailgating. Could you share which module you used.

Cheers,

Nigel

exactly my thoughts on safety - here’s the one I got - they’re $20

Brake light blinker, four flashes then solid. Safety Flash Light Alert. Universal (https://amzn.to/3GHBLkZ)

toadster

12-18-2023, 06:20 PM

it's been a wild and wacky weekend!

I took off work Friday to get my car dyno tuned at AED in Cameron Park, CA - famous for being a small town with it's own airport where pilots actually have their airplanes parked in airplane sized garages that adjoin to the runway - one of, I believe, three in the whole US - pretty cool... oh, and Shaun Perry who owns AED also has his shop there! It's about 12 miles from our house, so we trailered the car up to him. What a fun afternoon! and of course, more changes...
a few snaps of the shop, and dyno setup - Shauns' dog Duke is awesome and super friendly as well :)

https://i.ibb.co/vsPBjZj/IMG-0387.jpg (https://ibb.co/vsPBjZj)

what we found during the tuning session is that the Coyote was struggling to breathe.. at least exhaust wise, the intake was doing well and adding air, but the restriction of the catalytic converters and the GASN touring pipes was really pulling the power down and creating excessive backpressure... the catalytic smelled funky, and I had been assuming this all along that jet-hot damaged them during their curing process - so I pulled the trigger and Shaun handed me a hammer and pick, and I quickly eviscerated the catalytics... money down the drain, or in this case, in the vacuum...

https://i.ibb.co/pj6NzBw/IMG-0392.jpg (https://ibb.co/pj6NzBw) https://i.ibb.co/9bLJ2pX/IMG-0393.jpg (https://ibb.co/9bLJ2pX) https://i.ibb.co/jwn4gDf/IMG-0391.jpg (https://ibb.co/jwn4gDf)

once we gutted these out, the coyote was happy again and put down 413HP and 370 lb-ft at the wheels
not winning top HP prizes, but I'm happy with the 400+ club numbers :)

https://youtu.be/a0yedDbFMgM

https://i.ibb.co/sR0yp0Q/Screenshot-2023-12-18-082727.png (https://ibb.co/Pj7ws74)

toadster

12-18-2023, 06:46 PM

on Saturday, since I still have FMan's trailer, and with his permission, I helped Ken Pike move some cars from his Yuba City shop to his new place in Marysville, CA

https://i.ibb.co/dPVVq64/IMG-0409.jpg (https://ibb.co/dPVVq64) https://i.ibb.co/nqySTZt/IMG-0408.jpg (https://ibb.co/nqySTZt) https://i.ibb.co/4SMkg8t/IMG-0407.jpg (https://ibb.co/4SMkg8t) https://i.ibb.co/ZxJ2C6s/IMG-0411.jpg (https://ibb.co/ZxJ2C6s)

it's a long way from being all done, but at least was able to move 3 rollers and two bodies during the morning time, felt good with the local Sacramento guys to contribute some time to help Ken with his move :o

lastly, today I had my new parts for the A/C setup and I took to a local custom builder... funny enough, Darryl who owns the custom service in Rancho Cordova, CA has used Ken Pike as his painter in the past - the world get smaller everyday!

anyhoo, I had one bad connection on my A/C setup the Coyote compressor connection got cross-threaded
I ordered up 2 new parts, a #10 inverted o-ring adapter, and the two custom Coyote compressor fittings.

I opted to have the custom shop dial this in for good... a new hose was created to go between the condenser and the compressor and we used 2 cans of R134 and they topped off with about 6 oz more
blows nice and cold now, and is finished! 1 out of 8 ports on a custom A/C setup going bad, isn't that bad IMHO - pretty lucky on my end, but learned A LOT during the process!

https://i.ibb.co/XC6tRD2/IMG-0424.jpg (https://ibb.co/XC6tRD2)

even though it was about 55 degrees outside, the A/C was blowing REALLY cold :) very happy that this is working!!!!

Justin

12-19-2023, 08:28 PM

As someone that lives in AZ the AC mod is in my future. I’m glad it’s working for you!

toadster

12-20-2023, 12:13 AM

As someone that lives in AZ the AC mod is in my future. I’m glad it’s working for you!

was really happy that only 1 fitting was messed up, these guys do custom A/C all the time and were impressed with the customization that we did to get it all to fit, and performed really well!

here are a couple 3D prints that my son is testing out to make our 4 port HVAC ports...

https://i.ibb.co/25M1938/passenger-side-AC-ports.png (https://ibb.co/25M1938) https://i.ibb.co/p32FNzW/driver-side-AC-ports.png (https://ibb.co/p32FNzW)

they probably don't make much sense like this, but since the space behind the dash is at a premium, he modeled these ports - one fitting per side

one of the ports will blow out the front of the dash and the other will blow into the footbox...

the front ports (yellow arrows) and the bottom ports (orange arrows)

https://i.ibb.co/Nx0R3nT/image.png (https://ibb.co/cJWqvXY)

Justin

12-20-2023, 03:36 PM

Makes sense to me. I have a 3D printer and basic modeling skills so I might follow your lead.

I might put the blower and evap in the trunk too. I have a weird plan that works on boats. But I need to sleep on it a few more times.

toadster

12-21-2023, 02:23 AM

Found some toggle switch labels for the wipers and A/C switches on Etsy, turned out pretty nice IMHO

193530

cv2065

12-21-2023, 06:02 PM

toadster

12-22-2023, 12:05 AM

Sounds and looks great. Love the dash. I'll be coming up behind you in a couple of months and will need some tips on cutting that CF. You are getting close! By the way, I can't get any of your pics to come up from imgbb. Just goes blank?

thank you! cutting the CF is nerve wracking for sure, but I have a bunch of hole saws now that are the right size... it's all about high speed, light pressure, keep centered and wear a mask at a minimum
we also kept our vacuum running while drilling to pull all the CF powder away...

strange about the imgbb links - anyone else having issues?

zarnold

12-24-2023, 12:11 PM

strange about the imgbb links - anyone else having issues?

Working OK for me, maybe just a momentary issue.

toadster

12-28-2023, 03:00 AM

had a crazy idea to hack up my new shifter that I got from f-line, I know everyone has issues with them, but I've never had one problem stuff ships and arrives within a day or two - anyways...

I reached out to BradC who built the Tesla Rod (https://thefactoryfiveforum.com/showthread.php?42653-Tesla-Powered-33-Hot-Rod) :)
he lives about a mile away and had the most awesome garage tool setup known to man

the issue is that I have a shifter ball from Breeze (a few years ago) that isn't made anymore, it's a 3/8-24 thread pitch, and the f-line shifter is 1/2-20

I got the crazy idea of chopping off the 1/2-20 thread and pulling out the fake reverse lockout (not a fan if it's not real)
drilled out the obligatory 3/8" holes in the shifter handle, and I got a 3 inch grade5 bolt and lopped off the head, just needed a way to merge the two parts

https://i.ibb.co/s2f7gfb/IMG-0494.jpg (https://ibb.co/s2f7gfb) https://i.ibb.co/hLx6DsZ/IMG-0497.jpg (https://ibb.co/hLx6DsZ) https://i.ibb.co/nwFV6Kw/IMG-0506.jpg (https://ibb.co/nwFV6Kw)

enter BradC with his CNC machine and he milled down the 75 cent bolt and then tack welded it in place and ground down the excess

https://i.ibb.co/V2b7xP9/IMG-0502.jpg (https://ibb.co/V2b7xP9) https://i.ibb.co/2FyGsQ2/IMG-0507.jpg (https://ibb.co/2FyGsQ2) https://i.ibb.co/njxM6Jb/IMG-0516.jpg (https://ibb.co/njxM6Jb)

all I need now is to get a chrome 2" tube with 1/2" ID and 5/8" OD to finish it off

super happy with this setup and it mitigates the 'pinch' on the shifter boot, of which I also inverted, and will be putting on a leather boot to hide things soon

toadster

12-30-2023, 01:36 PM

did more alignment on the front end yesterday, and the ball joint boots, like many, were just thrashed... I ordered the Energy Suspension 5.13102G Ball Joint Dust Boot for Chrysler (https://amzn.to/49XteHY) which are ~$8 for top and bottom

disassembling the front knuckles can be a PITA, especially the bottom ball joint, a ball joint spreader doesn't extent tall enough for the bottom ball joint, and the C-clamp style won't work because the knuckle placement, so it was pickle fork time!
the lowers did have a compression spring O-ring around them, the new ones do not have this... hoping this isn't an issue

uppers came apart pretty easily with a few whacks of a hammer
the bottom ones needed the pickle fork... you can see the boot discoloration and there are tears (not visible in these pics)
lastly you can see the new lower boot installed
https://i.ibb.co/7Gwdb36/IMG-0519.jpg (https://ibb.co/7Gwdb36) https://i.ibb.co/HpdKWcz/IMG-0532.jpg (https://ibb.co/HpdKWcz) https://i.ibb.co/BKq3Mn2/IMG-0535.jpg (https://ibb.co/BKq3Mn2)

passenger side and driver side done, these new boot seem to be 10x better than the ones that come with the kit
https://i.ibb.co/ftV9B05/IMG-0538.jpg (https://ibb.co/ftV9B05) https://i.ibb.co/ngpKqQf/IMG-0537.jpg (https://ibb.co/ngpKqQf)

need to grease them up and do some go-karting :)

toadster

01-11-2024, 01:49 PM

in prepping for the HVAC ports, the fun part here was that the angle of the dashboard shifted a bit over time and I had to re-mount the grab handle support along with the changed HVAC ports

here are some pics, the grab handle supports ended up being about 1.4" longer than previously done - but worked out great! (ones shown below are just mocked up wooden strips, used 1/8" steel bar)

https://i.ibb.co/6ZGLk6q/IMG-0608.jpg (https://ibb.co/6ZGLk6q) https://i.ibb.co/Ns1SnxH/IMG-0613.jpg (https://ibb.co/Ns1SnxH)

toadster

01-11-2024, 01:54 PM

now that the dash is pretty much solidified, had to mount the Russ Thompson turn signal for the last time (I hope!)

in the forums I saw this thread (https://thefactoryfiveforum.com/showthread.php?48060-Russ-Thompson-Turn-Signal-Clicking) about greasing up the turn signal, so I used some Synthetic grease
once greased up it's a bit of a bugger to re-assemble and get the clamp ring back on, but it's doable :)

https://i.ibb.co/qNFF4ZY/image.png (https://ibb.co/qNFF4ZY)

toadster

01-11-2024, 02:00 PM

ok - now finally, to the HVAC ports, my son finally dialed in the 3d printed HVAC ports for our custom setup, the provided Y's from the kit are just too big/bulky for a 4-port setup

you can see his 3D designs in this post (https://thefactoryfiveforum.com/showthread.php?34952-25th-MKIV-9772-Build-NOR*CAL-dyno-tuned-and-A-C-blowing-cold!&p=544744&viewfull=1#post544744)

with the angles and 3d printed parts, it took several tries -but dang he's talented! We cut down the screw on ports for the back of the vents, and he 3d printed threads inside the bottom port so the cover will screw right in

here's all the parts
https://i.ibb.co/p1skSd0/IMG-0623.jpg (https://ibb.co/p1skSd0)

one big customization is on the passenger side, where we cut the hole it's on the curve of the dash, so he had to print front/rear spacers to match the slope and also add an extension to the back of the HVAC port so the threads would extend deep enough!

https://i.ibb.co/58c09xw/IMG-0624.jpg (https://ibb.co/58c09xw)

here's the passenger side mounted and attached
https://i.ibb.co/WgD65wZ/IMG-0650.jpg (https://ibb.co/WgD65wZ) https://i.ibb.co/nbHmnXF/IMG-0648.jpg (https://ibb.co/nbHmnXF)

and the driver side (easier setup)
https://i.ibb.co/vxfM2sq/IMG-0661.jpg (https://ibb.co/vxfM2sq) https://i.ibb.co/nrvg6Cp/IMG-0660.jpg (https://ibb.co/nrvg6Cp)

I also got the North Racecar plenum for the defroster but will modify the pipe once the chassis/body are in the same room :)

toadster

01-11-2024, 02:01 PM

lastly, I finished modifying the shifter handle, again Ryan 3d printed an extension to mitigate the gap where the 'Tee' used to be on the 427 handle, fits perfectly but wasn't chrome

https://i.ibb.co/jJNVbtw/IMG-0568.jpg (https://ibb.co/jJNVbtw)

opted for some chrome tape from Amazon, worked perfectly and looks great IMHO

https://i.ibb.co/hg4tQCX/IMG-0651.jpg (https://ibb.co/hg4tQCX) https://i.ibb.co/4TtdydP/IMG-0652.jpg (https://ibb.co/4TtdydP)

dbo_texas

01-11-2024, 02:50 PM

and the driver side (easier setup)
https://i.ibb.co/vxfM2sq/IMG-0661.jpg (https://ibb.co/vxfM2sq) https://i.ibb.co/nrvg6Cp/IMG-0660.jpg (https://ibb.co/nrvg6Cp)

Did you remove the center 3/4 dash support from the FFR frame? I was trying to figure out how to sneak my heater vent hose around that - looks like you just cut out out?

toadster

01-11-2024, 05:06 PM

Did you remove the center 3/4 dash support from the FFR frame? I was trying to figure out how to sneak my heater vent hose around that - looks like you just cut out out?

yep, we got to the point where it was just in the way with the evaporator there, the A/C created all kinds of fun challenges ;)

toadster

01-18-2024, 04:06 PM

a few more basics completed last night, carpet is finished and got the footbox blower hoses attached - they work VERY well!

also impressed with the volume of air from the HVAC setup as well, all 4 ports blow very strong! won't have to worry about the cold, and the A/C should REALLY help when it's hot out :)

https://i.ibb.co/h75nyk4/IMG-0752.jpg (https://ibb.co/h75nyk4) https://i.ibb.co/zFQR2x4/IMG-0756.jpg (https://ibb.co/zFQR2x4) https://i.ibb.co/gPPCGSg/IMG-0755.jpg (https://ibb.co/gPPCGSg) https://i.ibb.co/jbVyrR0/IMG-0754.jpg (https://ibb.co/jbVyrR0) https://i.ibb.co/gPD7qWn/IMG-0753.jpg (https://ibb.co/gPD7qWn)

next up, seatbelts, temp seat attachments, need to review a bit more but almost ready for paint!

Nigel Allen

01-18-2024, 08:57 PM

Stunning work! Thanks for documenting so well.

Cheers,

Nige

facultyofmusic

01-18-2024, 11:47 PM

Wow! The way the seats match the trans tunnel is freaking cool. Very nicely done! Will you be making a diamond-stitched door-flap for the storage cubby?

toadster

01-19-2024, 05:46 PM

Stunning work! Thanks for documenting so well.

Cheers,

Nige

Wow! The way the seats match the trans tunnel is freaking cool. Very nicely done! Will you be making a diamond-stitched door-flap for the storage cubby?

thanks guys! yes the door cards match the rest as well, the shop redid the FFR ones and added pockets :)

toadster

01-25-2024, 01:48 PM

seatbelts installed, haven't done the submarine one yet - probably not till I fully mount the seats

I did some prefit for the ReplicaParts radiator shroud (different thread (https://thefactoryfiveforum.com/showthread.php?48174-design-ideas-replicaparts-mike-everson-radiator-panel))

I will have to modify the shroud to mate up with the A/C condenser on top of the radiator, plus the angle is a bit different (51-deg vs suggested 58-deg)

https://i.ibb.co/f8ggLK5/image.png (https://ibb.co/f8ggLK5) https://i.ibb.co/9WTPQ1S/image.png (https://ibb.co/9WTPQ1S)

mocked up a template with thick paper, and got the general idea of the cuts but will wait until the body is painted and mounted to finalize

https://i.ibb.co/f8nxg2b/IMG-0813.jpg (https://ibb.co/f8nxg2b) https://i.ibb.co/jffR4nb/IMG-0814.jpg (https://ibb.co/jffR4nb) https://i.ibb.co/MMvzfDb/IMG-0820.jpg (https://ibb.co/MMvzfDb)

just need to finalize ride height and do some more go-karting, then I believe the car is ready for paint!

using the race car checklist in the manual to verify everything :)

both rear brakes look like this, I know the fronts take the majority of the braking and I have about 1/4 mile on the car, assuming with more normal driving this will show more even wear in the back?

https://i.ibb.co/nrHw1C3/image.png (https://ibb.co/1ZD0X6s)

Windsor

01-25-2024, 06:42 PM

Don't worry about the black on the rotors.

By the time you get the pads properly seated, they'll be all shine.

Ted G

01-25-2024, 08:35 PM

Looks great! My brakes looked the same until I started putting miles on the car. Let's Go Kart you to C&C soon!!

Ted

Fman

01-25-2024, 11:59 PM

Your car is really looking awesome, so many nice details. You have really done one amazing job, can't wait to see it all painted up!!!

toadster

02-19-2024, 01:59 PM

it's go-kart season! ;)

https://youtu.be/XK8sh4RjCj8

Ted G

02-19-2024, 02:20 PM

Nice!!! I'm sure it feels great after all!

BradC

02-19-2024, 06:11 PM

Too cool Todd - congrats!! Using those sun breaks wisely I see...

toadster

02-22-2024, 08:34 PM

today was one of those checkmark days! I started the SB100 registration process in CA

I now have a temp driving permit to get DMV inspection and brake/light inspection before I get the next step - although the state has no issue taking my money at this point...

195929

hopefully Ken will have power and the paint booths setup in March and we can get the rest of the body/paint done! woohoo!

this whole thing started 4 years ago... almost done!

toadster

04-18-2024, 11:09 PM

I nearly forgot to do this, but I did the Wade's Door Latch Repair (https://www.linger.com/cobra/DoorLatchRepair.htm) (before it breaks)

Simple enough tweak and it's super sturdy now!

Parts needed:
(2) 5/16" X 3/4" carriage bolt (https://a.co/d/fSWVArP) - I inadvertently got 1" bolts but that's an easy fix :)
(2) washers and
(2) lock nuts

First, get a file to knock off the edges in the pivot
https://i.ibb.co/PFq4zFz/image.png (https://ibb.co/k5N0656)

Then I persuaded the carriage bolt into the square hole, added the washer and locknut - realized I had an extra 1/4" sticking out so I trimmed with a hacksaw
https://i.ibb.co/6RtV92f/image.png (https://ibb.co/FbYNZ9j) https://i.ibb.co/pWd9S0D/image.png (https://ibb.co/GsRbqxw) https://i.ibb.co/n3vbWjC/image.png (https://ibb.co/7g5X9K4)

https://i.ibb.co/9w1qrkw/image.png (https://ibb.co/dbVQ5wb)

now I just need to grind down the head of the carriage bolt so it sits flat against the door
https://i.ibb.co/Sfxs5Nj/image.png (https://ibb.co/7kzYjvf)

I think the whole mod for both latches was about 20 minutes total - definitely recommended!!

toadster

04-18-2024, 11:10 PM

here's the body waiting for me to bring up the chassis tomorrow!!

https://i.ibb.co/ysyV5cg/image.png (https://ibb.co/s3wtQds)

Ken is still trying to get power into his booths, but more body fitting can be done prior to paint - getting much closer now!!! Yahoo!

Barwickad

04-18-2024, 11:21 PM

Looking good. Cant wait for Ken to get the new booths online and to see your car painted! I’m in line behind you.

460.465USMC

04-20-2024, 01:32 PM

I nearly forgot to do this, but I did the Wade's Door Latch Repair (https://www.linger.com/cobra/DoorLatchRepair.htm) (before it breaks)

Simple enough tweak and it's super sturdy now!

Nice work, Todd. I did the same, and so far so good after 1,600+ miles. I also filed a bit of material off the leading edge of the post that stops the latch arm movement. Otherwise, the bolt sat proud of the face plate, which can prevent it from opening as there's just enough of the bolt protruding to catch.

I'm not very good at explaining with words, so it's letter "B" in the photo below.

https://thefactoryfiveforum.com/attachment.php?attachmentid=180861&d=1677453867

toadster

04-22-2024, 12:41 AM

Thanks for the explanation and the pic helps!!!

Fman

04-22-2024, 08:36 AM

Nice progress Todd! Also keep an eye on your ball on the handle, had one fall off and had to purchase a couple threaded balls from McMaster. Never a good day when you loose one of your balls ;)

https://thefactoryfiveforum.com/showthread.php?35778-Fmans-Dart-427-build-9818-14-quot-Leather-steering-wheel&p=471538&viewfull=1#post471538

toadster

04-22-2024, 01:56 PM

toadster

04-28-2024, 09:17 PM

Got an update :)

198763

Jeff Kleiner

04-29-2024, 08:09 AM

Got an update :)

Unfortunately my friend Ken is beyond frustrated. He has a whole building full of gray (primered) cars at his new shop and PG&E has him swinging in the wind because they say they can't do the power upgrade necessary so that he can use his paint booths until the end of May...at the earliest :mad: :mad: :mad:

Jeff

Nigel Allen

04-29-2024, 06:10 PM

Unfortunately my friend Ken is beyond frustrated. He has a whole building full of gray (primered) cars at his new shop and PG&E has him swinging in the wind because they say they can't do the power upgrade necessary so that he can use his paint booths until the end of May...at the earliest :mad: :mad: :mad:

Jeff

Get in a rental generator and bulk tank. It will hurt a bit, but cheaper than having a body shop crew standing around with little to do.
If the supply upgrade work was adequately scheduled with the power company and they failed to meet the date, send them the rental bill.
Thats has worked for me.

Best of luck

Nige

Jeff Kleiner

04-30-2024, 07:58 AM

Get in a rental generator and bulk tank. It will hurt a bit, but cheaper than having a body shop crew standing around with little to do.
If the supply upgrade work was adequately scheduled with the power company and they failed to meet the date, send them the rental bill.
Thats has worked for me.

Best of luck

Nige

Ken and I chatted yesterday and that's exactly what he's had to resort to doing Nigel. Big generator and electrician are coming today. The service upgrade order was put in with the utility months ago but I'd say that it's still not likely that he'll be able to strongarm PG&E to cover any part of the costs.

Jeff

toadster

05-01-2024, 10:18 AM

I hear you guys, Ken is really frustrated but he's been really good to me storing the body for so long, and moving it between his old site and new one.
I can't say enough, Ken is awesome and really glad he's really close by - we even ran into him and his wife a few weekends ago doing some wine tasting :)

fortunately we found a few more projects to do prior to him spraying the car - bonus points if you see one of them in my update pic above :D

Thanks guys for tracking with me - it's been a journey, can't wait to get this thing done!!

toadster

05-08-2024, 10:31 AM

one more thing to finalize and take up to Ken - he has a generator now and has been spraying some panels, etc to dial in the booth - very exciting!

The defrosters are something I was on the fence about, but as usual - someone on the forums convinced me to pry open the wallet again, it's almost silly now - but I got the NorthRaceCars plenum for the defrosters since there's no space to mount the regular defrosters.

from their website: https://northracecars.com/heat_ac.html

One of the problems with FFR cars and the heater on the passenger side is getting defrost while getting heat to both sides of the passenger compartment. So, if you are tired of all the hoses behind your dash why not run only one hose for your defrost. With this set up run one hose from the defroster to the plenum to get both vents with one hose, then run the other defrost duct to the driver and if the passenger gets cold turn on the heat and have all three. Bond on or use the demist vent screws to hold in place. No holes pre cut, put the tubing where you want it and install one defrost duct. Custom curved to fit the FFR car and fit between the dash and the firewall. Plenum is great for Air Conditioned cars with too much tubing already behind the dash

here's the 2" hole for the defroster feed, of course I went off center :rolleyes:
https://i.ibb.co/3zSHVsJ/image.png (https://ibb.co/KwVHBG1)

two more custom 3D parts needed to be printed, we will be setting the 2" hole in the center of the plenum and feed with a 2.5" tee
I wasn't able to find any 90 degree tees with a reducer, at least not under $130, so these $2 3D printed PETG parts will have to do

tee that will go on the main feed line to the driver side vents
https://i.ibb.co/gjbpgZG/image.png (https://ibb.co/vwCGz4b)

hard to see on this test print but my son made up for the off-center with the flush edge on the plenum
https://i.ibb.co/RNmPgp9/image.png (https://ibb.co/42GMFZ7)

final print for the plenum part - now to epoxy in place and find some time to get it up to Ken
https://i.ibb.co/2YBKyCm/image.png (https://ibb.co/Pz8CNP3)

This is how it will all go together - pretty sure it will all fit once we trim the hoses to size
https://i.ibb.co/Q6hgwfv/image.png (https://ibb.co/Wc7hJ6v)

of course with this setup, and laminar air flow, we will be dependent a bit on back-pressure in the system to blow up to those vents, I can close off the 4 cockpit vents to force air up to the defrosters, but IMHO there will be VERY rare cases where this will be needed - I just wanted a more complete system because it will be near impossible to do this later on

so close now!

Jeff Kleiner

05-08-2024, 12:34 PM

toadster

05-08-2024, 01:50 PM

I've used that plenum before...well actually parts of it because the passenger side conflicted with the heater box and wouldn't let the body sit down fully so I had to cut it up and reshape the RH side. It should be test fitted with the body and chassis together before bonding it onto the body otherwise you're kind of playing Russian Roulette.

Jeff

yep, Ken is going to do another fit with the plenum before bonding it together - I may have to move some bits on top of the A/C evaporator but hopefully will squeeze in there :)

toadster

05-10-2024, 01:01 PM

taking the plenum up to Ken this afternoon, just to show the finished setup epoxied into place - all hoses fit great! just needs ziptied to secure on the barbs

https://i.ibb.co/7bpgPhb/IMG-2514.jpg (https://ibb.co/7bpgPhb) https://i.ibb.co/4P4BPz8/IMG-2518.jpg (https://ibb.co/4P4BPz8) https://i.ibb.co/tptdx0s/IMG-2517.jpg (https://ibb.co/tptdx0s)

(https://ibb.co/7bpgPhb)

toadster

05-23-2024, 01:30 PM

it's been a magical week! here come the pics!

to give some background - here's the details of the paint :)

main color: San Marino Blau (B51) - BMW cars (and some Porsche)
stripe color: Crystal Laurite Silver (977) - related car: Mercedes-Benz SLR McLaren
pinstripe color: GM Cashmere (15U) - not so sexy a related car, but matches the bronze frame

https://i.ibb.co/LxSh8pY/B51-San-Marino-Blau.jpg (https://ibb.co/LxSh8pY) https://i.ibb.co/g9SS3mL/IMG-2681.jpg (https://ibb.co/g9SS3mL)

toadster

05-23-2024, 01:49 PM

next up the silver gets laid down... yes, single broad stripe, not the usual double stripe look...

https://i.ibb.co/vJk9xfw/IMG-2647.jpg (https://ibb.co/vJk9xfw) https://i.ibb.co/CM3gPNk/IMG-2646.jpg (https://ibb.co/CM3gPNk) https://i.ibb.co/9gSk5fn/IMG-2645.jpg (https://ibb.co/9gSk5fn)

toadster

05-23-2024, 01:52 PM

this next part threw me a bit, Ken sprayed the bronze for pinstripes - and I wondered how they'd turn out, I shared these pics with several folks and they were like - I thought you said the car was going to be blue!?

https://i.ibb.co/m0Y3q3w/IMG-2684.jpg (https://ibb.co/m0Y3q3w) https://i.ibb.co/2SrHSP8/IMG-2683.jpg (https://ibb.co/2SrHSP8) https://i.ibb.co/JdLLmsN/IMG-2682.jpg (https://ibb.co/JdLLmsN) https://i.ibb.co/17QpXDv/IMG-2678.jpg (https://ibb.co/17QpXDv)

toadster

05-23-2024, 01:55 PM

ok now the fun part, masking the stripes... I started to 'get it' on how he was doing this now! oh the mind of a painter!

https://i.ibb.co/cw4LB98/IMG-2710.jpg (https://ibb.co/cw4LB98) https://i.ibb.co/yFL6qMx/IMG-2709.jpg (https://ibb.co/yFL6qMx) https://i.ibb.co/XtPgtky/IMG-2708.jpg (https://ibb.co/XtPgtky)

toadster

05-23-2024, 02:07 PM

Ken in action - love that he sent this over!!

https://youtube.com/shorts/Ca2oEFtrDkM?si=Kx-ezTpM_DwPKiTS

toadster

05-23-2024, 02:09 PM

here's a shot of the blue, and how the pins came out! (before clear)

https://i.ibb.co/qBF4Nj0/IMG-2716.jpg (https://ibb.co/SN71tyQ)

toadster

05-23-2024, 02:13 PM

now the awesome clear over it all... I'm still in awe :)

https://i.ibb.co/GMH5GL5/IMG-2718.jpg (https://ibb.co/GMH5GL5) https://i.ibb.co/vsbsQPS/IMG-2730.jpg (https://ibb.co/vsbsQPS) https://i.ibb.co/YdbvNDs/IMG-2725.jpg (https://ibb.co/YdbvNDs) https://i.ibb.co/dGdFLGz/IMG-2726.jpg (https://ibb.co/dGdFLGz) https://i.ibb.co/ZTnbksL/IMG-2727.jpg (https://ibb.co/ZTnbksL) https://i.ibb.co/ZcGn4br/IMG-2729.jpg (https://ibb.co/ZcGn4br)

toadster

05-23-2024, 02:15 PM

a few pics sent to me today from one of the local guys who was visiting Ken...

https://i.ibb.co/MNhHYCq/IMG-6537.jpg (https://ibb.co/MNhHYCq) https://i.ibb.co/xM7ZW4M/IMG-0504.jpg (https://ibb.co/xM7ZW4M)

Fman

05-23-2024, 02:25 PM

WOW! that turned out amazing, looking forward to seeing it soon! Ken Pike really does one fantastic job on these cars... a true master at his craft.

BradC

05-23-2024, 02:54 PM

Congrats Todd! You've had quite the ride with the build. Can't wait to see it all together.

egchewy79

05-23-2024, 04:04 PM

Awesome combo!

JohnK

05-23-2024, 06:07 PM

Congratulations Todd! That looks amazing!

460.465USMC

05-24-2024, 09:30 AM

Woohoo! That’s a sharp dressed Cobra! Congrats! Looking forward to seeing it all together. Thanks for posting the pics.

toadster

06-03-2024, 03:16 PM

more progress being made, hope to see it in person within a week or two
ABSOLUTELY LOVE how the engine cover is turning out

https://i.ibb.co/GWD3JGB/IMG-2819.jpg (https://ibb.co/GWD3JGB) https://i.ibb.co/qRxH8T4/IMG-2833.jpg (https://ibb.co/qRxH8T4)
https://i.ibb.co/2d2htjn/IMG-2818.jpg (https://ibb.co/2d2htjn) https://i.ibb.co/ZJdFrMB/IMG-2832.jpg (https://ibb.co/ZJdFrMB)
https://i.ibb.co/W0JrcLj/IMG-2820.jpg (https://ibb.co/W0JrcLj) https://i.ibb.co/BGVy1vJ/IMG-2872.jpg (https://ibb.co/BGVy1vJ)

toadster

06-03-2024, 03:17 PM

also - Ken sprays the underbody, did an awesome job!

https://i.ibb.co/YX6K7pT/IMG-2838.jpg (https://ibb.co/YX6K7pT) https://i.ibb.co/pJzRWsh/IMG-2837.jpg (https://ibb.co/pJzRWsh) https://i.ibb.co/7KYcp25/IMG-2836.jpg (https://ibb.co/7KYcp25)

ydousurf

06-03-2024, 03:38 PM

Paint looks awesome, Todd! I dig the single stripe and bronze pinstripe highlight. That should compliment the wheels perfectly. I can’t wait to see it all back together and you being able to enjoy the driving aspect going forward. Enjoy the final assembly of your build.

Doug

Ted G

06-03-2024, 05:14 PM

Looking amazing.... can't wait till you get her home so I can come see in realtime!

toadster

06-04-2024, 09:05 PM

https://i.ibb.co/Lr7QjWD/444765445-448456684496888-4038319876593686791-n.png (https://ibb.co/1MWsy5Y)

toadster

06-06-2024, 01:06 PM

another tickler photo from Ken :)

some sanding and polishing going on, and the engine cover painted and placed on the coyote!

https://i.ibb.co/D49DjmV/IMG-2925.jpg (https://ibb.co/MncDJK2) https://i.ibb.co/4PRY1qs/IMG-2922.jpg (https://ibb.co/WgvPVhD)

pickup is scheduled for next Wednesday!!!!

Its Bruce

06-06-2024, 09:16 PM

I happened to be in town last week visiting family and drove by the Garden Hwy location to sneak a peak of your car and anything else in Ken's shop but I couldn't find the shop. Did they relocate?

Traveller

06-06-2024, 09:31 PM

I happened to be in town last week visiting family and drove by the Garden Hwy location to sneak a peak of your car and anything else in Ken's shop but I couldn't find the shop. Did they relocate?

Yes. Shop is now in Marysville.

Jeff Kleiner

06-06-2024, 09:43 PM

toadster

06-08-2024, 03:13 PM

yep - Ken has a new website too
https://streetrodpainter.net/

new address is:
520 3rd Street
Marysville, CA 95901

https://maps.app.goo.gl/kkydZeasL9RKB9Rc8

it's only about 3 miles from his old spot in Yuba City, but just over the border into Marysville ;)

https://i.ibb.co/nRGf4g0/image.png (https://ibb.co/R7FPtvS)

toadster

06-12-2024, 10:42 AM

yet another teaser, had a windshield issue with the passenger side arm, FFR is remedying the issue, but won't pick up until next friday now...

btw - the headlights are JW Speaker 8700 EVO 2 Classic (https://www.jwspeaker.com/products/model-8700-evo2-classic-led-light/) - wasn't sure how they'd turn out, but so far liking the pic, need to see it in person
I wanted the bright LED output without the glare so these are focused lights, and wanted something different from the tri-bar look...

https://i.ibb.co/nCpWVzR/image.png (https://ibb.co/m8pxY6S)

toadster

06-20-2024, 09:36 PM

windshield goes on in the morning, picking it up tomorrow!!

https://i.ibb.co/0YhfMpz/image.png (https://ibb.co/2cgjt0p)

https://i.ibb.co/g7R4y6Y/image.png (https://ibb.co/xs7Fh3Z)

https://i.ibb.co/DbTDx1g/image.png (https://ibb.co/9vS9Fp3)

Barwickad

06-21-2024, 12:27 AM

Like a little kid on the night before Christmas. Congrats.

toadster

06-21-2024, 10:23 PM

what an awesome day!!! still lots to do, but HOLY COW this paint really POPS!!!

https://youtu.be/_aFPx-f122w

ydousurf

06-21-2024, 11:24 PM

Looks killer Todd! Awesome job! And here I thought the sirens were going to be a joke pulling you over already for the first time. ;) Glad to see you are approaching the end of your dream build. Enjoy your new ride and never wipe that smile off your face. :D All the best and be safe out there too!

Doug

toadster

06-22-2024, 12:12 AM

Thanks Doug! It's been a journey for sure!! going to sneak over to C&C tomorrow morning :)

Daddy O

06-25-2024, 04:27 PM

Excellent Todd! Thanks for sharing your journey. Sent you a PM about build. Thanks!

toadster

06-25-2024, 07:47 PM

The cobra is home! Everyone is asking what the car's name is... LOL, I have no clue! Give me some ideas!

Also, I took the car to our local Cars & Coffee - got a LOT of eyeballs on it!

https://i.imgur.com/ax08IuV.jpeg

https://i.imgur.com/a9yDQLt.jpeg

toadster

07-03-2024, 07:57 PM

adjusted the ride height in the rear, the front is perfect at 4" and the rear was also 4" - we raised the rear to 4.5" because over bumps the 315s out back would rub the body a bit

201353

took the car for alignment - to a place I've never used, but was recommended
unfortunately they didn't feel they could adjust the camber properly without disassembling the front upper arms and placing shims to bring the camber up

For a car using power steering car use the following specifications:
Caster: 7
Camber: -0.5°
Total Toe: 1/16”

2015 IRS only
Camber: -0.5°to -0.75°
Total Toe: 1/8” Toe in

201354 201355

they wanted $800 to do this... needless to say I paid them $35 for a diagnostic fee and drove home... will hit up another local spot that i KNOW has worked on FFRs before

Jeff Kleiner

07-03-2024, 08:06 PM

They clearly don’t know what they’re doing.

Jeff

BradC

07-03-2024, 08:20 PM

Owning two of the eyeballs that were on your car that day I will confirm the collective oversized thumbs up there was on it! Nice job!!

Pretty sure Eddie at Tire Pros will do it. They did my 33 and it's a PIA. And they only charged me like $180 I think for 4 wheel.

toadster

07-04-2024, 08:38 PM

Some small adders today - did the rear view mirror, side mirrors and the wind wings
https://i.ibb.co/j4RjXC2/IMG-3452.jpg (https://ibb.co/2KNp4zQ)
https://thefactoryfiveforum.com/blob:https://thefactoryfiveforum.com/19ccbae4-5865-4152-85fa-b0cbb4ccb4ea

also installed the Breeze radiator cowl cover, this was a tricky 1 man job
Thankfully I pre drilled everything prior to the body going on, I really like how this part buttons up the front of the engine bay and will keep the air flowing through the radiator and not up and over the engine
https://thefactoryfiveforum.com/blob:https://thefactoryfiveforum.com/90945697-03c3-4da0-963f-66d1a6cfd958
https://i.ibb.co/6wrw4Kp/IMG-3453.jpg (https://ibb.co/kB5BhLr) https://i.ibb.co/C2VZc8s/IMG-3455.jpg (https://ibb.co/4d4Gqtg)

also added the side badges
https://i.ibb.co/2cbqThL/IMG-3457.jpg (https://ibb.co/XFwXqLd)
https://thefactoryfiveforum.com/blob:https://thefactoryfiveforum.com/6993ee5f-6301-4763-b5df-63a6126ee624

toadster

07-08-2024, 10:36 AM

simple stuff since it's 112 outside, garage is barely keeping up around 86-89 with the A/C running...

visors and rear view mirror - with square nuts this time :)
a LOT of sanding/grinding to get the 8-32 nuts to fit into the windshield channel (for the mirror) - but much easier than trying to hold a hex nut with a screwdriver (because they spin)

https://i.ibb.co/c6cBNQQ/IMG-3480-1.jpg (https://ibb.co/c6cBNQQ) https://i.ibb.co/W5cmHmy/IMG-3479.jpg (https://ibb.co/W5cmHmy) https://i.ibb.co/5T53xDV/IMG-3478.jpg (https://ibb.co/5T53xDV) https://i.ibb.co/sPFJTFN/IMG-3485-1.jpg (https://ibb.co/sPFJTFN) https://i.ibb.co/Gnxf06M/IMG-3484-1.jpg (https://ibb.co/Gnxf06M) https://i.ibb.co/b5hmJLn/IMG-3483-2.jpg (https://ibb.co/b5hmJLn)

also hooked up the fuel filler hose and ground strap - now I can actually get some gas in the tank, will probably do 1/3rd of a tank to get it aligned this friday

also working on the license plate light wiring, and adding an LED light bar to the filler plate to light up the trunk a bit more when the interior lights are on (pics to come!)

also, the rear view camera/backup light setup with my license plate frame won't work in the current setup, either the camera on top blocks the license plate lights, or with the camera on the bottom, the trunk won't open
more planning needed !!

Mike.Bray

07-08-2024, 11:23 AM

visors and rear view mirror - with square nuts this time :)
a LOT of sanding/grinding to get the 8-32 nuts to fit into the windshield channel - but much easier than trying to hold a hex nut with a screwdriver (because they spin)

You're not going to like this but if you use 6-32 square nuts they slip right in. Got that from Mr. Kleiner.

toadster

07-08-2024, 11:55 AM

You're not going to like this but if you use 6-32 square nuts they slip right in. Got that from Mr. Kleiner.

yes I used 6-32 on the visors, but couldn't get them to work on the rear view mirror... had to go with 8-32 :(

toadster

07-15-2024, 12:34 PM

got my new appointment to get aligned, the guys at BigO didn't disappoint! only $129 and 1.5 hours - dialed in!

201876

Jeff Kleiner

07-15-2024, 12:55 PM

Those are good numbers Todd. Set your tires to 22-23psi and the car ought to drive great!

Jeff

toadster

07-15-2024, 02:18 PM

Those are good numbers Todd. Set your tires to 22-23psi and the car ought to drive great!

Jeff

Thanks Jeff! I've been wondering about the tire pressure... I believe they're at 35psi right now, but tracks EXTREMELY well compared to previously!

If I check the Yokohama site it says this:

The optimum 'working' tyre temperature of the Yokohama Advan A052 is around 40 degrees Celsius, with a temperature spread of 10-15 degrees across the tyre tread area.
Yokohama recommend the following technical set up: Optimum hot pressure dry use 2.0 - 2.2 bar or 29-32lbs. Minimum cold air pressure is 1.4 bar or 20lbs

Jeff Kleiner

07-15-2024, 02:41 PM

Trust me, the car isn't heavy enough to create full tread contact when they are run that high. With that much pressure the tire will be overinflated for the load and only running on the center of the tread.

Jeff

toadster

07-18-2024, 03:53 PM

tidying up some items before the inspections... one item was a VERY touchy brake light - we thought this was resolved prior to the body going on, BUT it stayed...

crawling into the driver footbox is a contortionists dream! fortunately the seats aren't attached yet, so that simplified things a bit

the problem is that with the Whitby power brake pedal and the Wilwood pedal setup is that the mount point for the brake switch is about 1/8th of an inch too short with both hex nuts attached
this would cause the brake lights to stay on, and would actually 'flutter' when driving because the switch was right on that edge on open/closed when driving and the pedal riding on the switch

we need the switch to move closer to the brake pedal by about 1/8" of an inch that nut is just a bit too thick!
https://i.ibb.co/ysk3PNc/image.png (https://ibb.co/7yp9CSd)

getting into the footbox took sheer will, and some stretched neck muscles for sure!

this is my son Ryan (who is 6'3") and barely can get in the footbox, I'm sure I filled in the space a bit more LOL
https://i.ibb.co/Syn9J1c/image.png (https://ibb.co/g9TB6Xd)

the goal was to use a crescent wrench to loosen the top nut while keeping the switch intact to allow us to remove the switch and the nut behind the switch and replace it with a simple washer, not sure if this will hold over time but need to get this fixed or it won't pass brake and light inspection

with a thin washer in place of the nut, and hopefully tightened down enough the brake pedal switch is now kept open at rest, and works as expected - need to go-kart a bit more to test it out
you can see the much thinner washer and it moved the switch ever closer to the pedal bar

(https://ibb.co/kDBjD39)https://i.ibb.co/6rDVLD0/image.png (https://ibb.co/q7mXVmY)

toadster

08-03-2024, 02:00 PM

doing more post-paint checklist items:

1. shortened the seatbelts a bit more, I tell that that's fun with the body on! it helps to have the speakers removed though to get a few hands in there! Now they're pretty snug, and I feel better to attach the seats and submarine belt.
2. figured out my turn signal/dash flashing issue - was a bad LED bulb, I put the incandescents in for now in the front - a replacement LED is on it's way and I'll test again
3. buttoned up my dash and re-installed the speedometer (which was removed to ease access behind the dash when we were chasing the weird electrical issue in #2)
4. fixed a bad ground in the rear of the car, essentially the ground to all the trunk lighting was dead, installed a new ground in the trunk and all good
5. installing an LED in the trunk cover (from DWC) to give more light from the top/inside of the trunk
https://i.ibb.co/mtXKrnQ/image.png (https://ibb.co/hHZNxGp)

6. was fidgeting with the license plate lights, how we found the bad ground, and I snapped off the screw :(
https://i.ibb.co/JHp7vtT/image.png (https://ibb.co/0r9MC2L)

7. #6 forced me into my backup camera install, got things drilled, now I just need to mount it
https://i.ibb.co/SVxbPtK/image.png (https://ibb.co/p4Pcxf3)

https://i.ibb.co/9p4ncq8/image.png (https://ibb.co/grWymDj)

toadster

08-10-2024, 06:43 PM

had more fun finishing up the rear view camera setup... not for the light of heart for sure

from my last post, since the screw post snapped on my license plate light, this is the time to get this mod done - was going to wait for after registration, but - without the light cover attached, I figured it would fail inspection

now - in order for the camera to fit into the light fixture, the grounding bar is in the way where the camera will sit - the nice part is that the ground bar is a bit higher than the actual camera spot I located, just a hair below the screw post
I used the 18.5mm hole saw and cut a raw hole

https://i.ibb.co/WvN3bpd/IMG-3765.jpg (https://ibb.co/zVW5yHL)

notice that the bar still is connected, so there's ground continuity to both lights for the license plate

next up, I needed a little more width for the screws I was going to use , the ground bar isn't wide enough, so two 1/8" holes were drilled and I added a small aluminum bar to overhang the grounding bar a bit

https://i.ibb.co/rtRJ5G3/IMG-3774.jpg (https://ibb.co/vB68Lxh)

using some small rivets, I was able to place the two the extension bar just between the ground and positive bars, without touching - there's plenty of clearance
https://i.ibb.co/m6Lb2mV/IMG-3776.jpg (https://ibb.co/NZ8tJXd)

top view of the result - the new #25 holes with #10-24 tap will be used next
https://i.ibb.co/zbk3Bm4/IMG-3777.jpg (https://ibb.co/L6GTc0Z)

toadster

08-10-2024, 11:36 PM

next up, spacing out the exterior screws, I used #10-24 since I have a boatload of them :)

measured equal distances from center and use a 7/16 bit for the bolt holes
https://i.ibb.co/92pvJDX/IMG-3778.jpg (https://ibb.co/7VSzHfc)

once the exterior holes were drilled, then I could use a #25 drill bit and then tap (https://amzn.to/4dGVj7F) the holes for 10-24 screws
also note, I had to use the 18.5mm hole saw (https://amzn.to/4fI4dmS) on the added aluminum bar as well

https://i.ibb.co/yPgtF3q/IMG-3780.jpg (https://ibb.co/tKYgpdD)

hopefully you can see the tolerances between the lights, screws and positive/negative bars
https://i.ibb.co/0VpxF3H/IMG-3781.jpg (https://ibb.co/dJsRLy8)

toadster

08-10-2024, 11:38 PM

here's the camera I used - 1080P Backup Camera (https://amzn.to/4dEEv16)

we had to clock the camera a bit to get it aligned, pretty simple after all the installation

https://i.ibb.co/RHktCKc/IMG-3785.jpg (https://ibb.co/PCvJ5yg)

and the finished result :)
https://i.ibb.co/BN40Hwf/IMG-3786.jpg (https://ibb.co/m8vfrSR)

Fman

08-11-2024, 08:09 AM

Nice work Todd, how is your A/C working for you? Can you drive the car on a 90+ degree day and not turn into a baked potato?

Mike.Bray

08-11-2024, 10:17 AM

That backup camera is neat, it would be handy to have on all the time as the rearview mirrors I have don't give the best view. I doubt if I have the energy to add it to a finished car though.

toadster

08-11-2024, 10:44 AM

That backup camera is neat, it would be handy to have on all the time as the rearview mirrors I have don't give the best view. I doubt if I have the energy to add it to a finished car though.

to be honest, on a finished car it would be a bit of a chore with the wiring, neat idea for always on, but then I'd never see the radio screen :)

Nice work Todd, how is your A/C working for you? Can you drive the car on a 90+ degree day and not turn into a baked potato?

it does rather well! keeps the footbox nice and cool, got sunburnt yesterday not realizing how much sun was on us! LOL

460.465USMC

08-13-2024, 09:24 PM

A backup camera in the license plate light housing...who would have thought? Pretty cool! Things are coming together very nicely, Todd. Looking great!

toadster

08-14-2024, 10:28 AM

did my first fillup last night, I even got .10c off per gallon, stupid CA gas prices

https://i.ibb.co/Vq1sKD9/image.png (https://ibb.co/5R0P7v4)

and before you ask, this is the Boyds gas tank :)
https://i.ibb.co/hgMZtyv/image.png (https://ibb.co/8mBdS0V)

toadster

09-03-2024, 11:48 AM

a few more things to get the build a few more steps along...

installed an LED into the DWC filler panel, this adds a TON of light into the trunk - as you can imagine, stuffing your trunk full of stuff can block the trunk lights - this gives you a nice overhead light to see :)

https://i.ibb.co/C0hP8zm/IMG-3468.jpg (https://ibb.co/cTDY31k) https://i.ibb.co/XyzJy6S/IMG-3938.jpg (https://ibb.co/WDcKD7g)

added my exhaust hangers, and used rivnuts like many have so I didn't have to bolt through the 2" square tubes
I'm using the Gas'N hardware and may change over time to a different exhaust hanger setup, but these Coyote 4-in-1 headers mount pretty well to the Gas'N side pipes
note: pics below are basic setup, not fully tightened down

https://i.ibb.co/WyCFg6Y/IMG-3940.jpg (https://ibb.co/cFqtD17) https://i.ibb.co/mHYGw4B/IMG-3941.jpg (https://ibb.co/cNp1HQv)

lastly, also mounted my Drummer Mike Side Pipe Shields - these are REALLY nice quality!
I tweaked my install a little bit... added some high-temp gasket material to the exhaust wrap that sits inside the bands between the exhaust pipe and the shield - REALLY simplified installation by holding the gasket in place!

https://i.ibb.co/59gcXms/IMG-4003.jpg (https://ibb.co/vB6zCpL) https://i.ibb.co/kH2z17t/IMG-3943.jpg (https://ibb.co/1vGB6gk)

toadster

09-03-2024, 11:52 AM

I also used some leftover zero-clearance shielding from Breeze Automotive to add another layer of insulation to really reduce temps

https://i.ibb.co/NTStzt9/IMG-3951.jpg (https://ibb.co/dmgjyjP) https://i.ibb.co/dLkQdrx/IMG-3949.jpg (https://ibb.co/nnQDHbt)
https://i.ibb.co/Pjzk5jf/IMG-4004.jpg (https://ibb.co/QQj06Q1)

will do some temp comparisons soon to show the heat difference...

CHP inspection tomorrow!
pre-drilled my plate mount :)

https://i.ibb.co/bbQ71Lp/IMG-4007.jpg (https://ibb.co/LNYvS64)

getting closer to being fully registered!!

Fman

09-03-2024, 10:38 PM

toadster

09-03-2024, 11:15 PM

FWIW If your pipes start to sag you can toss out that rubber grommet and go with thicker exhaust straps which won't stretch out and will hold the pipes level. Those drummer mike shields look great, it's too bad he stopped making them... top notch quality!

thanks Travis - I have those straps on my Amazon wishlist (https://amzn.to/3MvFhld) :) will see how they go - these 4-into-1 header flange mounts are pretty sturdy - the pipes seem dead on after 195 miles so far but now at least they're supported a bit more now

agree, the drummer mike shields are excellent quality - I got them just as prices doubled! ouch!

Mike.Bray

09-04-2024, 07:57 AM

I wrapped one of these (https://www.amazon.com/dp/B09GFT3HJD?ref=ppx_yo2ov_dt_b_fed_asin_title) around the rubber grommet to give it some extra support without taking out all of the flex.

toadster

09-04-2024, 02:49 PM

I wrapped one of these (https://www.amazon.com/dp/B09GFT3HJD?ref=ppx_yo2ov_dt_b_fed_asin_title) around the rubber grommet to give it some extra support without taking out all of the flex.

cool idea! I could probably even use a 4" metal bands and tighten down, may come loose over time though...

also, here's a temperature pic of the exhaust - the Drummer Mike Shields with the zero-clearance makes a HUGE difference!!

the pics were taken about 3 minutes after the car was shut down - yes that's 53 degrees cooler with the shields and insulation!

https://i.ibb.co/x5VbkfD/IMG-4029.jpg (https://ibb.co/mzQKjXG) https://i.ibb.co/X7fvVmW/IMG-4032.jpg (https://ibb.co/zXW0NKm)

another postitive today, passed brake and light inspection ($225 eek!)
also got my VIN # from CHP, just need to wait for my SPCNS number to be assigned to visit the BAR Referee to finish my SB100 - then back to DMV to finalize plates!

Nigel Allen

09-04-2024, 04:17 PM

Hi Todd,
I have similar shields on my side pipes (legally required here) although drummer Mikes are nicer :). They work well.

The temperature readings you are getting may be false as infra red sensors don't get along well with reflective surfaces.

Cheers,

Nige.

Mike.Bray

09-04-2024, 04:32 PM

The temperature readings you are getting may be false as infra red sensors don't get along well with reflective surfaces.

Or curved surfaces. We use contact thermocouples in these types of situations.

toadster

09-23-2024, 11:28 AM

little things while I wait for my SB100 paperwork to arrive... slow process, but at least nearly done!

added the rear fender shields and the whitby fillers for behind the seats
https://i.ibb.co/d7WGt2b/IMG-4162.jpg (https://ibb.co/d7WGt2b) https://i.ibb.co/jTD62m0/IMG-4161.jpg (https://ibb.co/jTD62m0) https://i.ibb.co/pLNbwCc/IMG-4159.jpg (https://ibb.co/pLNbwCc) 204430https://i.ibb.co/5RZW9zg/IMG-4158.jpg (https://ibb.co/5RZW9zg)

it's crazy the size of the gap in the rear wheel well

204432 204433 204431
not a pretty install, I had to flip both parts top/bottom to fit the body spacing - but it will seal up the wheel well, and honestly who sees this?

have a car show this saturday - no plates yet, but hopefully nobody will complain :)

toadster

09-26-2024, 09:06 AM

another pic of the rear shield (passenger side) used Raptor bedliner coating (https://amzn.to/3ZFVkVn) - it's not super thick (at least the spray can version) but it will hopefully remove some of the resonance/tinny sound for rocks ;)

204498 204497 204496

In case you're wondering, the blue hose is my fuel vapor canister (link to install (https://thefactoryfiveforum.com/showthread.php?34952-25th-MKIV-9772-Build-NOR*CAL-post-paint-checklist&p=495371&viewfull=1#post495371))

Fman

09-27-2024, 08:57 AM

IMHO, these are worth the $$$ will prevent any starring in your paint from a hard rock hit in you wheel well.

http://vraptorspeedworks.com/mk-4-wheel-well-liner-kit/

toadster

09-27-2024, 09:36 AM

IMHO, these are worth the $$$ will prevent any starring in your paint from a hard rock hit in you wheel well.

http://vraptorspeedworks.com/mk-4-wheel-well-liner-kit/

Thanks Travis - yes they're on my list, will have to customize them a bit due to the footbox blowers in front - I think you re-purposed your blowers right? any pics of your liner install?

JohnK

09-27-2024, 01:09 PM

I agree with Travis on the recommendation for the wheel well liners. Besides giving a clean, finished look they will prevent rocks from being kicked up and hitting the underside of the body. Bed liner on the underside will protect, to a point, but IMO these provide far more protection. Here's a link (https://thefactoryfiveforum.com/showthread.php?31167-Greek-Guys-Garage-Roadster-Build-9509-(Nice-shoutout-on-Insta-about-my-build)&p=520117&viewfull=1#post520117) to how I installed the rear liners. I didn't post an update to my build thread about the front liners, but they're basically the same process, other than coming up with some way to secure the front of the liners. One note worth mentioning, splash guard positioning is important, as it will determine how deep into the wheel well the liners sit. If the splash guard is close to the edge, the wheel well liners and their bulb seal will be very close to the fender lip. I wanted them a bit recessed and out of sight so I ended up doing a bunch of trimming to the splash guards to set them further back than the typical install to give plenty of room for the wheel well liners.

toadster

11-07-2024, 11:56 AM

it's been a long 2 months waiting for my SB100 build number

I got #120 for 2024, assigned in September, but not mailed to me until 2 days ago - yes it took 2 months to get a piece of paper to allow me to move forward - crazy!
I talked with the BAR Referee yesterday, he called me early because all my paperwork was in order, and the photos were just what he needed. Yay for being thorough :)

I have my appointment on November 19th to have the visual inspection and pass my SMOG verification, then I can finally go back to DMV and get this car registered

I have almost 600 miles on the car now, going to replace the oil, trans fluid and differential fluid just to make sure things are good and check for any metal, etc.
I'll probably do an Oil analysis https://www.blackstone-labs.com/free-test-kits (https://www.blackstone-labs.com/free-test-kits/) - the kits are shipped for free, just pay when you get the analysis done

for me it's a great way to see how things are wearing, etc. like a blood test by your labs for your annual checkup :cool:

JohnK

11-07-2024, 02:37 PM

Congratulations! This part of the process definitely tests your patience but well worth it in the end. BTW - if you want a personalized plate, expect to wait another 9 months :rolleyes:

toadster

11-20-2024, 04:38 PM

well it's taken 10 months, but I now have a fully registered car in California! SB100 #120 for the year which is pretty low considering they offer up to 500 of them each calendar year!

https://i.ibb.co/svRz4sD/IMG-5020.jpg (https://ibb.co/ynP7CgM)

pretty excited to get this part done and registered! about 640 miles on the car so far and it's been awesome!

toadster

10-02-2025, 06:14 PM

Believe it or not, I've put about 1,300 miles on the car and realized that I hadn't put the door cards on! They were tucked away on a shelf in the garage, so I pulled them out and gave the leather a good treatment.
These match the FFR seats, transmission tunnel and radio box upholstery.

219681

I was really adverse to drilling into my doors, so I opted for some really strong velcro. It's maybe overkill, but everything in this build has been like that.

I used VELCRO Brand Extreme Outdoor Double Sided Mounting Tape | Holds up to 15 Pounds on Brick or Other Rough Surfaces | UV and Weather Resistant | 14Ft Heavy Duty Roll (https://amzn.to/3KuRyc1)

One thing's for sure, this stuff is sticky - which is the whole point! Two long strips, one across the top and one on the bottom, these panels should be set for quite a while.

The door cards came from Factory Five with the 25th Anniversary stitching, but the panels were in horrible shape from FFR.
Sadly, they didn't do anything about it, so when I had my transmission tunnel and stereo box wrapped, the guys at Fine Line Trim (https://www.finelinetrim.com/) in Rancho Cordova, CA did a solid for me and rebuild the door cards for free!
You can see the panels with two long strips of velcro attached. I pressed pretty hard to ensure the tape adhered, and once it's attached, it's really on there!

219682219683

Time to say goodbye to those beautiful San Marino Blue painted doors, and add the new door cards. I think the new door cards look awesome!
219684219685