MKIV Roadster Re-build after accident!

[Ed-PV]

Hi All! I am new to this forum, but have loved and worked on cars since high school in the 80's. I have built plenty of 60's and 70's muscle cars but have never dealt with any Factory Five cars. A buddy of mine completed a BEAUTIFUL MKIV Roadster build a few months ago. He was an airplane mechanic and currently a corporate pilot so the build definitely shows his attention to detail! He called me a few weeks ago and told me that he had gotten in an accident and wanted to sell the car. I purchased it over the weekend and on Monday I will take a good look at is and see what needs to be done to get it back on the road! I am pretty excited to work on it. I will try and post pictures and detail the repairs. I would appreciate any feedback and recommendations!

Before pictures:

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After picture:

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[egchewy79]

Hopefully you got a deal. Lots of twisted metal in that pile. Good luck. This forum has tons of knowledge

[rich grsc]

I agree, hope you got it for not much.

[GoDadGo]

I agree, hope you got it for not much.

It could be a heck of a buy at the right price to use as a donor for a base kit build.
Might be a Gold Mine, truly a treasure trove of usable parts.
Good Luck & Happy Wrenching!

[Ed-PV]

I did get what I would consider a pretty good deal! I couldn't wait to take it apart and see what was damaged! Actually looks really simple!

It looks like I will need only parts for the drivers side front...the rest of the car is unharmed! I will need upper and lower control arms, front wheel, manual steering rack, braided brake line, one side pipe, radiator and some aluminum tins that got damaged! Hopefully, I can get everything from Factory Five directly. Hopefully, Factory Five will sell me the front driver's side fender and front end or at least the front clip so I won't have to purchase the entire body!

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[Ed-PV]

The frame and major components were undamaged.

[GoDadGo]

The frame and major components were undamaged.

If the frame is still square, then you may be able to easily repair it.
There's another member that is fixing one that is way, way, way worse.
Try searching for repair threads because he may give you some ideas & insight.
In the meantime, here is his video channel from YOUTUBE:

https://www.youtube.com/channel/UCYB1B4OfSOZ4lixb-JIWRcw/videos

Good Luck & Watch Your Pinkies!

[FF33rod]

Hey Ed
Welcome, there are some pretty darn good roadster builders here with lots of sage advice. Hope your friend is okay!

The only thing that might be a pain is the body work. The front fender is not separate, all fenders.quarter panels are part of the main body. Hood, doors and trunk lid are the only separate pieces.

Look forward to seeing a build/repair thread from you to document progress.
Steve

[Ed-PV]

Thanks GoDadGo! The one on YouTube is definitely much worse than mine. Thanks for the info!

[Joe Campbell]

Good luck with it. I'm also in the middle of repairs, though not as hard a hit as yours. FFR can send you new bumper support 3/4 tubes for the frame, I needed both sides for mine. When I was talking with them about it, they said they can do a whole body, or a front or rear clip.

[Papa]

Depending on how much you plan to spend to bring it back, you can buy a replacement body from Factory Five. Sometimes that can be the most affordable way to do a repair like this considering the time and materials needed to repair the damaged body.

http://www.factoryfiveparts.com/16900-mk4-roadster-main-body-shell/

[Higgybulin]

You need to look in the classifieds on this forum for parts before you order them from FF. Lots of guys buy complete kits then sell off the things they don't use or upgrade for a fraction of the cost of them new from FF.

[silver_pilate]

I'm not surprised that the frame was undamaged. First, they are really solid, and second, looking at the wreck pictures, it appears he was in a side-slide situation in soft/muddy soil, and the DS wheel and edge of the body dug it and were pulled off.

When I took delivery of my kit, the trailer had a front clip in it that was being delivered to the west coast.

[AC Bill]

So the header itself wasn't damaged? Carefully check the header flange all along the cylinder head for cracks at the mounting bolts. There must have been some serious stress put on the header, with the side pipes damaged as they appear..

I can't believe the windshield didn't break:confused: Usually you just have to look at them hard, and they crack..:p

Those aluminum tins you mention, are likely brake fluid reservoirs. Should be easy to come by, as is all the other items you mentioned.
As Higgy suggests, check the forum classifieds for items, and perhaps put a "want to buy" post in yourself. Also check the FFCars.com forum classifieds, as some may list stuff there, but not here.

[Ed-PV]

Thanks for the info! I will post a WTB in the proper place!

[juddster]

Good luck with the rebuild. New here myself with a partial build I purchased from someone on the forums. I imagine you will come out ahead after you are all done.

One recommendation to consider would be to add the electric power steering while you have it all open and exposed and since you will have to adjust your alignment. Mine came with a manual rack and I am strongly considering the electric PS due to price considerations ($1150 vs $745), simplicity (no PS pump, lines, etc) and I already have the manual steering rack. There are some posts about electric PS on the forums. But if you have to get a new rack it could make sense to go with the standard PS.

Here is a link for electric PS:https://epowersteering.com/purchase/product/factory-five-mk3-4-roadster-kit

[AC Bill]

Thanks for the info! I will post a WTB in the proper place!

I see a FFCars.com member named mattmc, is selling a set of ceramic coated side pipes on the classifieds over there. He mentions they should be re-coated. Maybe you can buy the pair reasonably cheap, and stick them on, and you could sell the one good stainless one you have, to pay for a fresh coating.

[Ed-PV]

Thanks! I will definitely look into it!

[Joe Campbell]

Roughing in to repair the crack on mine, still in progress.
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I put the Epowersteering kit in mine and converted to power brakes while the body was off. Pretty easy install, just want a good welder for the steering couplers. Welding the bracket to the 3/4 tubes is optional but wise.
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[Ed-PV]

THANKS Joe! I am planning on doing electric power steering.

[Planecrazy1976]

Hey Ed-PV. I am Greg with the YouTube channel. Looks like you got youtself into a way easier rebuild than ours.Good luck with your project. Ours drive last week under its own power. We are heading to paint tomorrow. If you need anything please reach out. We have the power steering kit on our website. It is awesome. Www.520Speedworks.com

[Cobradavid]

Good luck with the rebuild! Looks like the while took quite a hit based on the damage to the control arms and shock. It's good the control arm mounting brackets on the frame look to be undamaged. How did the mounting bolts look?

By the way, is that a directional tread on the tire? If so, is it mounted backwards?

Looking forward to watching your progress!

David

[Ed-PV]

Hey Greg, mine is definitely much easier than yours! Great job rebuilding yours! I watched some of the videos, very helpful!

[Ed-PV]

Thanks David, the mounting bolts are all straight and measured everything and once I removed the damaged suspension everything is square. I am having a bit of a hard time getting a quote for parts from Factory Five. I got it touch with Jon and David at Factory Five a couple of weeks ago and am still waiting for them to get me a quote for all the parts! I even gave them all the part numbers, not sure why it's taking so long, I am ready to order!

The tire in the picture is just sitting there and it is inverted because the outer side was damaged and I didn't want anyone to get cut when walking by it :)

[Ed-PV]

FINALLY heard back from FFR about the parts I need. I guess it was good they took so long to get back to me as a lot of really nice people on the Forum have reached out to me regarding parts I need at a huge discount comparted to FFR new parts! THANKS everyone! I will be posting pictures soon!

[Ed-PV]

WOW! A lot of great guys on this forum helping me out with the parts I need! THANKS!

[Ed-PV]

Since I am upgrading to power steering, I needed to modify the steering shaft to accommodate the power steering rack shaft.

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[Walt]

Make sure you realize the fittings on mine were different sizes so have the correct one welded on the correct shaft!!

[Ed-PV]

Yes sir! I welded the correct one in! THANKS!

[Ed-PV]

I put a normal Mustang 2 power steering rack on but for the pump I am going to use the electric power steering pump from a Volvo. I will get some pictures and let you guys know how it turns out. I have used this volvo electric power steering pump on a 69 Camaro and it worked great!

[juddster]

I put a normal Mustang 2 power steering rack on but for the pump I am going to use the electric power steering pump from a Volvo. I will get some pictures and let you guys know how it turns out. I have used this volvo electric power steering pump on a 69 Camaro and it worked great!

I think I'd like to try the Volvo pump as well. Do you have any ideas on where you will place it?

[Ed-PV]

I fabricated and welded some brackets on the frame on the passenger side front of the engine. I used some of the bracketry that came on the pump so I could use the bushings for vibration isolation. I went to Pirtek and had the hose made to go from the power steering rack to the pump. Turned out really nicely I think. I will wire it up this weekend and test it!

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[Ed-PV]

I also FINALLY received the suspension parts from FFR! I was able to work on the MK4 a bit the past couple of days. I got the suspension put together, put on the side pipes, welded the replacement front radiator supports in and installed the radiator. I will try and start it tomorrow! Getting excited! All I am waiting for is the front clip from FFR.

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[michael everson]

I would replace that top radiator mount with a piano hinge. The radiator is not supposed to be parallel with that mounting surface. When you force it down to the correct angle your going to stress the top of the radiator.
Mike

[Ed-PV]

Got ya..I will look into that! THANKS!

[Ed-PV]

My son and I connected all the hoses and electrical, checked all the fluids and she started right up! Sounds GREAT! Just waiting for the front clip!


https://photos.app.goo.gl/77dUThgApRzkWPEu7

[silver_pilate]

You'll likely want/need to trim the rear sleeves on both upper control arms in order to get to the caster settings you want with power steering. Take off most of the round/non-faceted end of each side of both rear sleeves (a bit over 1/8" on each side).

[Ed-PV]

Will do! THANKS!

[Ed-PV]

What settings do I need to tell the alignment guy to set to? THANKS!

[silver_pilate]

-0.5 to -1 degrees camber, 7-8 degrees caster, 3/32 toe in.

[Ed-PV]

Thanks!

[Ed-PV]

Still waiting for my front clip from Factory Five...10 weeks and counting!!!! I think I could have had this car done in a couple of weeks if Factory Five could get the parts out in reasonable time!!

[jamminj]

have you tested the power steering yet?
and is there a specific Volvo electric pump or are they all about the same?

[Ed-PV]

have you tested the power steering yet?
and is there a specific Volvo electric pump or are they all about the same?

Tested at low speeds and high speeds...works great! I have used this setup many times before. Volvo electric power steering pump from 2005-2013 S40.

[juddster]

How do you hook up the electrical on the Volvo pump? Is there any adjustment to the level of assist?

Thanks!

[Planecrazy1976]

Juddster I sell a complete kit for MK3-Mk4 roadsters includes everything you need. $740 shipped. Fully adjustable from no assist to all the assist you could ever want, mount included. https://520speedworks.com/shop/ols/products/electric-power-steering

[juddster]

Juddster I sell a complete kit for MK3-Mk4 roadsters includes everything you need. $740 shipped. Fully adjustable from no assist to all the assist you could ever want, mount included. https://520speedworks.com/shop/ols/products/electric-power-steering

I've seen this and would love to go this route since I already have the manual rack, but I've got the Coyote engine and as far as I know this won't fit. Do you know if it will fit with the Coyote?

[Nigel Allen]

I have a RHD Coyote with this same kit. I threw the supplied mounting kit away as I couldn't make it fit. Instead:

1. I removed the firewall mounted steering shaft bearing.
2. Fabbed my own mounting adaptor. The mount was then attached to the firewall by bolting it to the existing steel plate that the steering shaft bearing had been attached to.
3. Mounted the PS unit hard up against the firewall. Actually ended up with plenty of space to mount it, even with cat converters and the ECM mounted nearby.
3. Fitted the supplied splined input adaptor directly to the lower end of the female telescopic section of the upper steering shaft. Therefore no universals required on the input section.
3. Once the PS unit was installed, I shortened the lower steering (output) shaft to suit.

Gotta say, was absolutely worth the effort and expense.

LHD will pose some different problems, but if you have decent welding and machining skills, including making sure to align shafts (using a dial indicator), or a friend that does, all should be rosy.

I did take some photos, but they are very ordinary. Let me know if you need further info.

[Ed-PV]

How do you hook up the electrical on the Volvo pump? Is there any adjustment to the level of assist?

Thanks!

Wiring is pretty easy. Big read wire goes to hot all the time, big black wire goes to ground. There are three small wires remaining. I have found that the colors are different depending on the year of your pump. Just take a test lead and figure out which wire turns on the pump when the neg and pos are hooked up then connect that wire to an Ignition on source. I also used a large (40 or 60 amp) breaker inline with the red pos. wire and a fuseable link with the trigger wire. There are no adjustments but it feels good at low speeds and high speeds feels good as well. Hope this helps!

[Ed-PV]

After 12 weeks of waiting for the front clip and MANY MANY MANY unanswered emails and calls to Factory Five, I finally got a call from them yesterday regarding my order! I called the shipping company and they are going to deliver the front clip by months end. Actually, if I would have know it was going to take this long I would have made the damaged part myself and would have been driving weeks ago! I know they blame supply chain, personnel, COVID etc for the delay, but there is no excuse for not returning my emails or calls!! On the bright side, body parts will be here (fingers crossed) in a couple of weeks and I will have the MK4 done shortly after! I have been driving it around "go-kart" mode and I know I will love it! Thanks everyone for all you help sourcing other parts. This Forum has been a HUGE help!

[GoDadGo]

Ed,

Niche companies like Factory Five tend to have trouble with their supply chain even in the best of times because scaling is always troublesome.
Add in COVID-19 and the fact that they are in a state that is locked down just compounds the matter.

Shown below is ar link for Boston Ma. which looks pretty bad from this Southern Man's perspective:
https://www.boston.gov/health-and-human-services/covid-19-reopening-city-boston

I think Dave & his band of Merry Men & Women are in a position where their Rulers & Royals aren't letting them work together much less play.
Hang in there and try to be patient because I don't think that life is fun in Bean Town and surrounding areas like Wareham.

Steve

[Ed-PV]

Thanks for the reply Steve! I am a very rational person and have owned 6 business in the past and currently personally run 3, some relying on parts and services coming from half way around the world. I totally understand the difficulties, especially in this COVID environment; but in my humble opinion, in this age of technology including smart phones that are with us 24/7, there is no excuse for not taking a quick minute to email, text or call me back for an update. All my correspondence went unanswered for weeks! It was like they closed down and nobody was even checking their emails! All I needed was information, just a quick email/text with an update. When a company gets too busy, too big or too unorganized to properly care for their customers, they need to re-evaluate. I am very happy with the parts that I have received so far, but the lack of communication has really put me off regarding potential future purchases!

[Ed-PV]

FINALLY got the front clip. Looks pretty good! Now time to fuse it with the good rear half, do some body work, paint and drive!

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[Ed-PV]

quick question....does anyone know if the right and left body mounting brackets that mount to the turn signal lights are symmetrical (mirror images of each other)? They look different but I think the drivers side one may have been bent in the accident. THANKS!

[Ed-PV]

I do have a good passenger side front fender if anyone needs it!

[BradCraig]

I do have a good passenger side front fender if anyone needs it!

Someone will....eventually.... :-)

[Papa]

quick question....does anyone know if the right and left body mounting brackets that mount to the turn signal lights are symmetrical (mirror images of each other)? They look different but I think the drivers side one may have been bent in the accident. THANKS!

They are mirror images of each other, but you may opt to ditch them as many others have. They add stress to the body at the marker/TS lights.

[Ed-PV]

Thanks for the info! I think I will end up not using them.

[Ed-PV]

I worked on the Cobra this weekend with my son! We sectioned both bodies to match up and started installing all the parts to mock up an get ready for paint. Everything went on pretty well. I will still need to work on the hood and door gaps, but other than that all was smooth. I did find out I was missing a couple of parts. I need the drivers side headlight assembly (everything except the plastic tub. The right and left may be the same, not sure). I also need one of the long chrome tubular standoffs that are used on the front bumpers. And the last thing I need is the rear view mirror. Thanks for everyone's help!!

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[Railroad]

Nice work!

[egchewy79]

You should just go with the 2 tone look! Lol

[Ed-PV]

nice work!

thanks!

[Papa]

You should just go with the 2 tone look! Lol

I was thinking the same ... red, white, and blue!

[Ed-PV]

Worked on the MKIV the past couple of days. I was able to get the windhield on as well as all the trim pieces. It is looking pretty good. I tested all the electrical items and they all work as they should. I am planning on getting it aligned this weekend and driving it as is for a bit until I decide the color. I toyed with the idea of painting it the same color as my Daytona Coupe, but not sure!

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[otto halstead]

Just looking through this thread, looks like your doing a great job! I noticed that the wrecker had Jacksonville FL on it. Was this car titled in Fl? What type title did you get, if the previous owner filed an insurance claim and it was listed as totaled,(like mine was) it would be given a salvage title.

[rich grsc]

What could be more patriotic than a red white and blue car.:D

[Ed-PV]

What could be more patriotic than a red white and blue car.:D

I served in the Navy as an aviator so I do love Red White and Blue, but for the cobra I do like the black with gray stripes or red with white stripes!

[Ed-PV]

Toughest part of the entire build...Picking out the color!!!

[J R Jones]

Ed, You can consider "as-is" colors documenting the effort of reconstruction; kind of like having your broken arm cast signed.

No worse than this:
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Another analogy: If your significant other was dressing for sex, would she dress like a Bengals football player?
jim

[Ed-PV]

FINALLY decided on the color! Black with Silver stripe! I will post some pics when I get them!

[Geoff H]

Really nice work bring it back - looking forward to seeing it with paint!

[Ed-PV]

In the booth this week!

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[GoDadGo]

Won't Be Long Now!

[runamuk]

This car is going to look fantastic, great job

[Ed-PV]

this car is going to look fantastic, great job

thanks!

[Ed-PV]

In Primer yesterday!

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[Ed-PV]

All block sanding done! Color this week!

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[Mr. B]

I need a right front fender. 171149 Please check your PM. My crash is a mirror image of yours.
Bruce

[Ed-PV]

Finally getting color!


https://youtube.com/shorts/RiQf7aUYPqM?feature=share

[Ed-PV]

I need a right front fender. 171149 Please check your PM. My crash is a mirror image of yours.
Bruce

See if the MKIII is the same as the MKIV and I will send it to you. Best of luck with your build!

[Ed-PV]

Fresh out of the paint booth! Cut/Buff then final assembly...Hopefully, driving this weekend :)

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[Avalanche325]

I saw Jacksonville mentioned. Is that where you are? There are a few of us in the area that get together for cruises.

[Ed-PV]

Cool, I am in Ponte Vedra Beach! PM when you guys meet up!

[Ed-PV]

I guess the first build was consider College Graduation, now she has her Masters!

My paint guy driving it out of the body shop into the Floirda sunlight for the first time...then I drove it home!

https://youtube.com/shorts/l7b94dH2v9M?feature=share

Thanks for all the help on this forum to get her back together and all the kind prople that sent me parts! Such a great group of people!

It is a total blast to drive!

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Colors were the toughest to pick but I went with:

M6873 ford black
stripes are Lambo Titanium Metallic Silver
Glasurit Paint system

[Geoff H]

Looks awesome! Congratulations - a lot of work went into the rebuild!

Geoff

[runamuk]

She looks beautiful

[Chopper]

Looks super! I bet you're glad to have her back, and the silver lining of choosing a new colour!

[AC Bill]

Amazed how bad it looked on the flat deck, yet the damage wasn't really as bad as it looked.

Did you learn of how the accident happened? Looks like it spun off the road, or was it in a collision?

[Ed-PV]

Hey Bill, buddy said he was taking it out for a ride early in the morning, cold tires and a little dew on the road...went to merge onto the highway and lost control, spinning off the road and impacting a light pole at the very end of the skid. Definitely, the pic on the flatbed looked bad but these cars were definitely designed very well. Damage was surprising not too bad! I do love the car in black and silver and it drives GREAT! Thanks for everyone's help getting it back on the road!

[Nigel Allen]

G'day Ed,

Thanks for the rebuild log. I have really enjoyed following along. Love the colour and change to single roll bar. Happy motoring.

Nigel

[egchewy79]

Bravo on keeping this thing in the road. Just curious, how much do you think you saved over a new build? 25-30%?

[Ed-PV]

I have a personal auto hobby shop and personal mechanic and I did a lot of the work myself with my kids. We actually calculated it and we saved about 48% over a new build, and saved A LOT of time. Most of the build time was waiting for parts!

[Ed-PV]

She fits right in!!

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[Ed-PV]

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[Ed-PV]

I do have a ton of detailed pictures and videos of the rebuild in a google album. If anyone thinks it may help with their build, I can PM you the link. Thanks again everyone!!

[Blitzboy54]

That is quite a collection. Congratulations on all fronts.

[Ed-PV]

Thanks!

[Ed-PV]

First time in public...Ponte Vedra Car Show. Well received!

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Son driving it home:


https://youtu.be/faw7yPgAnTM

[Higgybulin]

First time in public...Ponte Vedra Car Show. Well received!

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Son driving it home:


https://youtu.be/faw7yPgAnTM

Great thread! Car turned out real nice! I was digging the Camaro in the back ground of some of your pics!!
Higgy

[Ed-PV]

Thanks Higgy! If you are talking about the blue and white Camaro, it's a 1970 1/2 Split Bumber RS/Z28. It's my daughters Highschool car. She helped me rebuild the motor when she was in Middleschool and drove it every day to highschool! Warmes my heart knowing that my kids love cars as much as me :)

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[Peeker]

Ed,

Glad to see it’s all come together. Been fun following your progress. I’m enjoying mine also.

Ed

[Ed-PV]

Thanks! It was a journey, but the finished car was well worth it! Kids really enjoyed getting it back on the road!

[Geoff H]

Thanks Higgy! If you are talking about the blue and white Camaro, it's a 1970 1/2 Split Bumber RS/Z28. It's my daughters Highschool car. She helped me rebuild the motor when she was in Middleschool and drove it every day to highschool! Warmes my heart knowing that my kids love cars as much as me :)

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Nothing better!!

Would love to see more pics of her car!

[Ed-PV]

Our for a spin on a beautiful winter afternoon in Florida!

https://photos.app.goo.gl/9VrXAts2TChdqYte9