D's FFR MK IV Roadster by FormaCars Build Thread

[Elizabeth @ FormaCars]

We’re chronicling our build process at FormaCars as we build a signature FFR MK IV Roadster for our client, D. We want to offer some insight to our build process and custom components. We look forward to answering your questions and hearing your suggestions.

D contacted FormaCars after a disappointing experience with another builder. He’d made a deposit and with great anticipation awaited completion of his Roadster. The previous builder finished his build but opted to return his deposit instead of selling him his car. It was unclear why but, as you can imagine, this would be devastating for anyone building their dream car. And so, our work begins building D’s FormaCars FFR MK IV Roadster…

D’s MK IV Roadster Build Specs:

435 HP Ford Mustang 5.0 Coyote Engine
Ford MT82-G2 6 speed manual transmission
Stainless Headers
S550 Ford Mustang-based IRS
Adjustable traction control
Koni coilover shocks
Power steering
Stainless steel fuel lines & brake lines
FormaCars chassis control module w/ wiring harness
Custom Speedhut Gauges
Waterproof switches & electronics
Wipers
Electric parking brake
LED headlights
FormaCars Heated/Cooled seats with adjustable head rests
FormaCars signature interior
Premium audio with Bluetooth
Factory Five Racing 18” Halibrand wheels
Performance Summer Tires NTO1 275/35-18 Front, 305/30-18 Rear

Estimated delivery November 2020

[Elizabeth @ FormaCars]

At FormaCars we complete our body prep a little differently, before our bodies are sent off for prep and paint. We noticed early on that body seams tend to be a challenge and there’s nothing worse than a bubble in beautiful paint job, especially when it seemingly wasn’t there fresh out of the paint booth. We realized that with the traditional method of sanding seams and applying body filler still had the potential to trap tiny air pockets under the paint, so we developed a method for filling with fiberglass resin.
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Fiberglass bodies are created by bolting the mold panels together, applying mold release, followed by Gel Coat, then alternating fiberglass mat and resin. Excess mold release at the seams often bubbles into the Gel Coat when it’s applied to the mold, this is what creates air pockets in the gelcoat and first resin layer.
The pink area you see at the seam is excess mold release that settles into the mold seams and is trapped in the Gel coat.

First, we sand the seams a few inches wide and then use a sharp tool to fully expose the air pockets.
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Once the air pockets are well exposed, we apply resin to the seams, using a brush. The resin will settle in, filling the fully exposed air pockets. Larger defects may need an additional coat or resin.
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Once fully filled, the body is sanded and sent for final prep and paint, without risk of air pockets under the paint job.

This process is tedious and extremely time consuming but is the best way we've found to ensure the paint looks perfect along the body seams.