Perfect quarantine project #9815

[alexmak]

Greetings all,

We are Alex and Alex, father and son, and we are building Roadster MK4 #9815. Ordered on Jan 31st, build date 3/21/2020, loaded on truck the day FFR shut down due to COVID-19, and delivered to Newtown Square, PA the next day, exactly a week ago — on March 25th. It's still hard to contain the excitement when we enter our garage! It's good that we have it now considering all self-isolation orders happening in PA and other states.

Some specs:

Complete kit
powder coated chassis
IRS, including brake kit, center section and spindles
headers
body cut outs
power steering
FFR GPS gauge set
Dash with glovebox
Right side rollbar (powder coated in black).
15" wheel/tire package.


we also got a BluePrint 347 carb engine with TKO600 gearbox.

We already went through the boxes inspecting the parts (really helps to get acquainted with a lot of things). Only a couple of things were missing:
- aluminum panel 10906 (rear tunnel cover)
- 1 brake line adapter. There are two on the list in Box 2A (25502 10mm brake line metric adapter and 12409 1/4” brake line adapter). One of them is available - we think it’s a 1/4”, but couldn’t identify with 100% certainty). So I guess it’s a 10mm adapter missing.

I sent an email to FFR, but since they are shutdown, no response yet.

POL parts that are missing:
- the wheels and tires package
- FFR badges
- wood steering wheel
- transmission bolt-on mount
- side exhausts
- power steering return hose
- power steering pressure line
- right side rollbar

Our garage after accepting shipment (much worse now, of course)
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Our garage after taking the body off
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some parts are on, yay!
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Drilling and cutting the spindles and a center section was a bit nerve-recking
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So far the hardest part was to pull in the bolts into a hub. We've read the tips here on the forum, and somehow managed to fix one of the hubs, but I'm still considering dropping another hub off to a mechanic and asking for help. We can spend the energy that it requires on something more productive:
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Now we are putting the center section on a frame. Rear bolts are not aligning very well, but there is some wiggle room for us to try, we'll handle it tomorrow.
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So far — a lot of fun! My only wish is for FFR guys to take a look at LEGO kits' assembly manual and get some inspiration from there for improvements, some clarity and details wouldn't hurt!

Edit: apologies about some photos being upside down!

[GTBradley]

Congratulations! You’re going to love it. Best decision I ever made.

[KDubU]

Congrats and you will love the build. The question is, who gets to drive it because once she is road worthy, neither of you will want to give her up.

[alexmak]

We'll figure the who gets to drive thing when we get there. meanwhile here we are, pretending like we are ready to roll
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[SerpantFL]

God bless you guys, stay safe, stay well, and enjoy your jigsaw puzzle.

[bil1024]

Congrats and enjoy

[alexmak]

Let's just say that inserting upper and lower control arms in the back is not for the faint-hearted! A lot of swearing and sweating.
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[D Stand]

Congrats guys! Perfect time for it to arrive. You shouldn’t get bored cooped up in the house...

[alexmak]

So far we’ve gotten pretty far along with the build, finishing off the front and rear suspension. We’ve moved on to the pedal box and encountered a problem. It seems that several parts are missing from the kit. They are not listed on the parts list for some reason. Just in case, we’ve searched all the boxes and still weren’t able to find the clutch quadrant and other parts. The photo of the missing parts is attached (the missing parts are circled).

Has anyone upgraded to a hydraulic clutch and might be willing to sell the parts from the assembly? We’ve obviously contacted FFR, but who knows when they are coming back.
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[Kmcallahan]

Congratulations on your project. As for as missing the Clutch quadrant parts, I would go back to the pack list see it it was packed and shipped. Maybe they did not ship it.

[alexmak]

Congratulations on your project. As for as missing the Clutch quadrant parts, I would go back to the pack list see it it was packed and shipped. Maybe they did not ship it.

yeah, we went through the whole list twice, and don't see neither quadrant parts, no clutch cable, and a couple of other minor things related to the pedal box.

[ArcticAZ]

I have a slightly used cable and the quadrant parts. Yours for shipping costs.
AAZ

[alexmak]

so for now we decided to skip the pedal box assembly, still working on getting the parts. Put a steering together (no steering wheel either), installed a fuel tank, bunch of panels and got to the fuel lines section in the assembly manual. I noticed in other threads that a lot of people do not use FFR provided fuel lines, instead opting for braided shiny fuel lines. Any suggestion on the fuel lines brand, length, routing, etc?
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[alexmak]

Here's where we are so far:
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and now we are at the fuel lines and brakes lines stage, and it gets a little bit more complicated. We'll see how it goes. Brakes lines should be fine, except the missing 10mm adapter (I also couldn't fine a page in the assembly manual that would mention using that adapter).

Fuel lines is something else entirely, as I could see in other threads a lot of people use flexible lines (partially). Please advise which to buy?

Also a couple of questions regarding a location for fuel filter and a fuel pump:
- what is the correct order? (carb engine, inline filter)
- what is the best place to install both of them?

[GTBradley]

The brake lines that come with the kit are fine, but more rigid and somewhat more difficult to work with (I used them). Some people opt for the softer Nicopp brake lines. I think they are a nickel/copper material.

There are tons of posts regarding enlarging the fuel line size too. I preferred the flexible braided fuel line throughout. It’s super easy to work with and Mark at Breeze was helpful in deciding what to use.

FYI, You are beyond the 20 post limitation now, you might consider doing a signature line. It’s a good place for quick information like engine type and other mods that will help people respond without investigating background info. No requirement by any means, but you might find it handy.

[alexmak]

FYI, You are beyond the 20 post limitation now, you might consider doing a signature line. It’s a good place for quick information like engine type and other mods that will help people respond without investigating background info. No requirement by any means, but you might find it handy.

thank you, will do that

[alexmak]

Guys, we need some help from the experts!

Couple of posts ago I asked about a quadrant and a cable for clutch pedal that was missing from the FFR kit. Apparently, our transmission from Blueprint is already "hydraulic-ready" — it has hydraulic throw-out-bearings, so we don't need them:

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One hose is a bleeder valve, the other is a feed line that needs to be connected to a master cylinder.

I was considering getting a hydraulic clutch conversion kit from Forte's, but if I understand correctly, I no longer need Forte’s complete kit.

We ordered a master cylinder, a reservoir and a hose, and got some instructions from BP on setting all this up. https://wilwood.com/MasterCylinders/MasterCylinderProd?itemno=260-10372 (https://wilwood.com/MasterCylinders/MasterCylinderProd?itemno=260-10372)

Will update on the progress.

[alexmak]

fabricated a bracket for holding all three reservoirs - two for brakes, one for hydraulic clutch. turned out pretty decent :)
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dashboard and electric harness, here we go.

[Caddy Dad]

Guys, we need some help from the experts!

Couple of posts ago I asked about a quadrant and a cable for clutch pedal that was missing from the FFR kit. Apparently, our transmission from Blueprint is already "hydraulic-ready" — it has hydraulic throw-out-bearings, so we don't need them:

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One hose is a bleeder valve, the other is a feed line that needs to be connected to a master cylinder.

I was considering getting a hydraulic clutch conversion kit from Forte's, but if I understand correctly, I no longer need Forte’s complete kit.

We ordered a master cylinder, a reservoir and a hose, and got some instructions from BP on setting all this up. https://wilwood.com/MasterCylinders/MasterCylinderProd?itemno=260-10372 (https://wilwood.com/MasterCylinders/MasterCylinderProd?itemno=260-10372)

Will update on the progress.

I also have the same HRB setup from BPE. I bought the hydraulic clutch master cylinder option from FFR. It has a 3/4" master cylinder and once I bench bled it, bleeding the rest of the hydraulic clutch line was super easy. Did BPE mention anything about using a clutch pedal stop? I'm not using one but have read that others do.
Thanks!

[alexmak]

I also have the same HRB setup from BPE. I bought the hydraulic clutch master cylinder option from FFR. It has a 3/4" master cylinder and once I bench bled it, bleeding the rest of the hydraulic clutch line was super easy. Did BPE mention anything about using a clutch pedal stop? I'm not using one but have read that others do.
Thanks!
I haven’t heard anything about it, and didn’t see anything in the FAQ Johnny has sent out. Probably will have to ask him about that.

We only bought a reservoir from FFR, I bought a cylinder kit separately. Not moving fast because FFR is closed and we don’t have the wheels

[Ernie67]

Yes, the manual is a bit clunky. No matter how well you try to follow it, you will need to utilize photos in later sections to understand some of it. We have all been there!

It's part of the build-Congrats!

Ernie

[LOBO 302]

Who did you guys purchase the powertrain through? What an awesome Father Son project during the Quarantine

[alexmak]

We went with BluePrint engine

[alexmak]

So we are almost done with harness routing (I’m sure there’s gonna be a lot more of electrical stuff in the future), and I was pleasantly surprised how easy it was to set up FFR Vintage gauges with the dash harness provided (eve though our electrical experience is quite limited).

Anyway, we got to the “drivetrain install” section in the assembly manual, and here’s a question. Our 15” wheels/tires combo from FFR is backordered, and FFR is closed, so ETA is unknown. So far we had the frame on the dolly, but it looks like the dolly is not really compatible with the drivetrain. So to install the engine we need to swap it for jack stands. The fact that the frame will become immobile for the time being is an inconvenience, but we can live with that. Is it OK to drop in the engine and the gearbox while the frame is on jack stands? Is it stable/safe enough for such major undertaking? (I have 3-ton jack stands)

[alexmak]

OK, so FFR cannot send me my wheels and tires package because they are backordered, and the wheels from my Camaro don’t really fit, but the mad max look is totally worth it
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[400BA]

I think that looks appropriate!!

Just wanted to say that I've been reading your posts along the way. I do not yet have my roadster (damn this pandemic!) so watching you and your son make progress is keeping me sane. I don't have much to contribute as I don't have experience, but please know it is helpful for those of us coming up behind you to watch how you get around issues.

Keep up the great work and enjoy the time with your son!

[alexmak]

I think that looks appropriate!!

Just wanted to say that I've been reading your posts along the way. I do not yet have my roadster (damn this pandemic!) so watching you and your son make progress is keeping me sane. I don't have much to contribute as I don't have experience, but please know it is helpful for those of us coming up behind you to watch how you get around issues.

Keep up the great work and enjoy the time with your son!

Thank you so much for these kind words! Frankly I feel bad we don't post many updates like some people do describing all the struggles and issues we discover and solve. But it's so much fun. the steepest learning curve but so satisfying!

[Ducky2009]

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FYI...
I know the manual says to install the steering bearing flange on the engine compartment side of the mount but you should install on the inside/cockpit side. If you ever have to remove the steering shaft, it's darn near impossible the way you have it now. I found out the hard way.

By the way.... Your build looks great. Making great progress, quickly.

[alexmak]

It's ALIVE!!!

https://youtu.be/8nirBDGgQjA

not without surprises, but we will get those ironed out. Holy sh.. what an amazing feeling!

[KDubU]

Congrats! That was quick to first start.

[alexmak]

Congrats! That was quick to first start.

Thank you! About 2.5 months, but yesterday was probably more intense. That’s the start after about three hours of meddling with fuel delivery issues, then fuel leaking, then replacing fuel line completely, then trying to fix power steering leaking, then solving the no sparks issue, etc, etc… and then it finally started! ��

[JB in NOVA]

Nice! I'm still a few months away (at least) from go-carting, but it's nice to see a successful start. Congrats!

[alexmak]

I can just listen to this on repeat

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

[Fman]

Nice work!!! Wow, 2.5 months to go-kart.... impressive. Your good motivation for me, I still have a long way to go. Congrats on the first start... sounds great!

[alexmak]

OK, at this point the drivetrain and wiring are officially finished! We had Mark the traveling builder checking on the build, confirming that everything looks good, and now the body part begins!
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[Straversi]

Well done. You are doing nice work at a record pace. Glad to see quarantine time being put to good use. Thanks for sharing that sound.
-Steve

[Chilly]

Thank you! About 2.5 months, but yesterday was probably more intense. That’s the start after about three hours of meddling with fuel delivery issues, then fuel leaking, then replacing fuel line completely, then trying to fix power steering leaking, then solving the no sparks issue, etc, etc… and then it finally started! ��

Well Done. Getting ready to start my build next week. You have inspired me. Also a father-son build.

[D02G]

curious how you attached the dash?

[alexmak]

curious how you attached the dash?

The dash has Everson’s support panel underneath and some heavy duty Velcro on the tube and a dash. It makes it removable if needed, without hideous bolts visible in it.

[alexmak]

Took some photos for inspection

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Nevermind the wipers wire hangin there - it’s for the inspection only. Also mirrors are on double-sided tape, thermal tape wrapped exhaust is also just for the pictures, oh, and the hood is not attached in anyway! But hey, looks finished, so we will see :)

[alexmak]

OK, so the quick jacks were the issue with enhanced PA inspection, so had to purchase bumper over riders. Now that’s photographed, mechanic signed off on those, and the papers are officially filed for registration! We still have some work to do on seats and carpet, but now it’s mostly sit and wait for the plate! (Oh, and resolving power steering leaks)
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[ActionBa5tard]

Holy crap... you guys went so fast. I really need another set of hands.

[Chilly]

Great pictures, thanks for the build thread.

[alexmak]

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It’s hard to believe that I’m saying this, but we are done. There are a couple of minor things here and there, extracurricular stuff mostly like wind wings and seat heaters, but otherwise we have nothing else to do. I repeat, WE RAN OUT OF TASKS. Quarantine Cobra is completed.

PS obviously not the official graduation, since paint stuff will happen next year, most likely, but I just can’t believe we did it.
(Sorry, was not much of a thread, just some updates, but we were really busy!)

[alexmak]

OK, our Quarantine Cobra is tagged and on the road! First real gas refuel!

https://thefactoryfiveforum.com/attachment.php?attachmentid=134522&d=1598883636

[nuhale]

Lookin' good!

[GTBradley]

Wow, gotta love those Goodyears. The meatball is a nice touch, where'd you get that?

[alexmak]

Wow, gotta love those Goodyears. The meatball is a nice touch, where'd you get that?

these are just from someone at eBay, since the sticker is on a gel coat and will be removed later. $26 for pair.

[Straversi]

Best use of quarantine time ever. Well done.
-Steve

[alexmak]

https://youtu.be/xnqfg1uBiVY

Building Shelby Cobra replica in 25 minutes

[speedfreak1211]

Great Video of your build

[JB in NOVA]

Loved the video! Thanks for posting.

[thwrightstuff]

Alex, this is incredible and so inspiring. Your build gives me confidence that I will be able to get this kit done or 90% complete in 8 months! Were you guys working all day every day or just a couple of hours each day, plus full weekends? Like you guys, when I get started on a project, I can be a machine haha. I'll also have my brother-in-law to help me out a bit along the way.

[alexmak]

I did another video! :)
I've been asked "how much did it cost you?" so many times (including by some people from this forum), so I did a video trying to get a somewhat general overview of the cost structure. please don't judge me :)


https://www.youtube.com/watch?v=wcJ0sJghbUw&lc

[alexmak]

Also, since it's a build thread, I dropped off my car yesterday at this very nice place in Hershey, PA, for the final panels trim and fit, and then it will be sent to get painted! I'm so excited!
https://thefactoryfiveforum.com/attachment.php?attachmentid=143397&d=1614260089

[alexmak]

Alex, this is incredible and so inspiring. Your build gives me confidence that I will be able to get this kit done or 90% complete in 8 months! Were you guys working all day every day or just a couple of hours each day, plus full weekends? Like you guys, when I get started on a project, I can be a machine haha. I'll also have my brother-in-law to help me out a bit along the way.

Yes, I think we basically worked on the project every day. Sometimes it could be some minor tinkering for a half an hour, sometimes it would be 6-8 hours. Due to the lockdown, there wasn't much to do anyway.

[egchewy79]

great video! what color have you decided on?

[Daddy O]

Thanks for posting the videos! Well done! Question - how have the brakes been? With the recent discussion on sticking front calipers, I am a bit concerned since that is what I have going on my build.

[alexmak]

great video! what color have you decided on?

we've decided on Viking Blue, not stripes, with black roll bars and black exhaust pipes.

[alexmak]

Thanks for posting the videos! Well done! Question - how have the brakes been? With the recent discussion on sticking front calipers, I am a bit concerned since that is what I have going on my build.

I didn't have any issues with the from calipers (yet?). I had my rear calipers sticking after a handbrake, but solved that with an extra spring on the cable near the calipers (I found this solution on the forum). I swapped the original brake pads for Hawks, and so far they stop better, with two side effects:
- after swapping the pads the pedal got somewhat spongier. I plan to do another brake system flush and see if there's any air in it
- due to the new pads it became much easier to lock the wheels. so I have to work harder with my head and foot to avoid that.

[alexmak]

OK, I have to admit that the painting process took a lot longer that I'd like it to be (not the painting process itself, but a lot of arrangements around it), but the body is finally painted:
https://thefactoryfiveforum.com/attachment.php?attachmentid=149952&d=1624897541

https://thefactoryfiveforum.com/attachment.php?attachmentid=149950&d=1624897541

next is the final assembly.