The start of a new project

[LDave]

Hello all! I have finally Joined the club. I'm the owner of a new Type 65 Coupe as of Saturday October 26th. 2011. So far I'm impressed with the whole experience, Bob from Stewart is the man! As well as Jason Lavigne from FFR. I'll be documenting my entire build with pics and all. Any Q's, ask 'em, because I'm sure i'll be asking plenty of my own.

So far I've got the car in the garage on stands, inventory done, and will be taking the body off this weekend. Then its GO TIME!


http://home.tiora.net/tony/Daytona%20Coupe/IMG_2426small.jpg

http://home.tiora.net/tony/Daytona%20Coupe/IMG_2430small.jpg

http://home.tiora.net/tony/Daytona%20Coupe/IMG_2445small.jpg

http://home.tiora.net/tony/Daytona%20Coupe/IMG_2446small.jpg

http://home.tiora.net/tony/Daytona%20Coupe/IMG_2452small.jpg

http://home.tiora.net/tony/Daytona%20Coupe/IMG_2470small.jpg

http://home.tiora.net/tony/Daytona%20Coupe/IMG_2474small.jpg

[LDave]

Oh, and this one is for Bob!

http://home.tiora.net/tony/Daytona%20Coupe/IMG_2462small.jpg

[Hankl]

Dave,

Raise your right hand and say after me,

"I (State your name), do swear/affirm, that upon acceptance of this "Revered Coupe Jacket", will willingly subject myself to all manner of frustration and abrasion that my FFR Type 65 will provide. I further pledge that any and all fellow Coupe builders will have free reign in using the cash available in my wallet as they see fit to improve my build plan. I will not look down upon our fellow Roadster builders, but rather take pity on those not talented enough to build a race car with a roof, So Help Me God!"



It is my pleasure to present you with the "Revered Coupe Jacket", Here's your sign!!

http://i179.photobucket.com/albums/w284/hankl_album/straight_jacket_backFS-1.jpg

Hank :cool:

[bil1024]

Congrats Dave! Did you get the complete or basic kit ? Hoping to order next year

[Georgia Coupe]

Congrats on the new Coupe project! What are your build plans?

[rj35pj]

Welcome and have fun!! :)

[xylonmedia]

Might as well hand me your wallet for safe keeping!

[trichardson]

Your pictures have me all excited. My completion date is tomorrow and my ship date is set for next week.

[TNcoupe]

Damn, this make me want to build another one.

[riptide motorsport]

Welcome!

[Jacob McCrea]

Dave (and Trichardson),
Welcome aboard. I hope you find the build to be as creative and engaging as I have.

[Russ Thompson]

Welcome aboard! These are always great shots, can't beat the grins on everyones faces.

Have fun, we are here for you!

[LDave]

Hank, I knew the day would come when I would receive the jacket. Thanks for making it happen. ;-)

Bil, Thanks! I did get the complete kit, with a seat upgrade, carpet kit, and floor mats. I also deleted a few things that I will not be using from the kit. Such as engine mounts, headers and drive shaft.

GA coupe, I've already got my mind set on where I would like to go with this car. And I'm not so sure everyone else is going to be as happy about it as I am. So I might just hold off on stating the choice of engine until it comes time to throw that bad boy in there. Unless you guys promise not to burst into tears? I went with a 4 link rear, cuz I'm not a huge auto X kind of guy. Although, with the car it might be time to get out and give it a try. I plan to use a 6 spd. manual transmission and a V8. Rear end has 28 spline axles and 2.73's now, but somewhere down the line I'll be beefing it up to a 31 spline unit. And probably something closer to 3.73's or 4.11's

Everyone else, Thanks for the welcomes! I've built myself several project cars in the past, but I don't think I was anywhere near as excited as I was when I got this thing in my garage. I do 100% of all my own work , minus paint / body. And I also love pictures! So you'll have plenty to look at along the way here.

Russ, everyone in the pic is grinning, But I'm the one with the biggest smile! Haha

[firechicken]

So awesome. I cant wait to be the one posting some pics like that.

[xlr8or]

Where abouts in San Diego are you? I'm the only F5 coupe in town that I know of that is on the road but there are lots of roadsters running around town.

[LDave]

Scott - I'm located in El Cajon, But spend a lot of my time up in Mira mesa / poway area. My girl friend lives up in Rancho Bernardo near you. I've been meaning to give you a call one of these weekends to come check out your car but things have been pretty busy lately. This weekend I'm going to try and get a bunch of work knocked out on the car. I only know of one other car besides yours that is up an running here in SD. Blue with white stripes, and running on an electric motor.

[vnmsss]

Welcome Dave!!! Sounds like you've got all the skills, and as far as the driveline, individual choices are one of the greatest things about these cars...Build it you own way! You may get some of the "Wanna B's" out there tossing a few volleys here and there, but I've never seen a lot of criticism come from any of the real builders....As for the rest, I hope someday they have the courage to do what you're doing.....Go for it!! Can't wait to follow your build

Karen

[Colonist]

Ditto -- build it your way; sounds like you have the drive train nailed down already. I'm envious of your back glass, though. Mine did not show up with the coupe and still hasn't appeared yet. And do your inventory carefully. What the paperwork says is there and what got packed (or not) are not always the same.

Most of all, have fun!

[John Dol]

Welcome aboard, just tell us already we don't bite (hard).

John

[LDave]

Spent a little bit more time on the car this weekend, Got the glass off the body, and the body off of the frame. The sound of twisting / popping / crackling fiber glass is never something I would want to get use to. It was extremely nerve racking! Also got a bunch of the suspension and steering components installed in the front.

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Body/DSCN2927.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Body/DSCN2933.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Body/DSCN2939.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Body/DSCN2936.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Suspension%20%26%20Steering/DSCN2943.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Suspension%20%26%20Steering/DSCN2951.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Suspension%20%26%20Steering/DSCN2952.JPG

I've actually found a couple items that were said to be in the box's, but are not turning up anywhere. I'm sure FFR will take care of the problem. Not too worried about it.
So I have never really been too much of a ford guy. My last project car was a Datsun 240Z with an LS1. After that I've grown pretty fond of the LSX motors and also put one in a Volvo 740. AND swapped a 5.3 from an avalanche into my 1971 Chevy C20. So I ended up selling the Datsun project, and the Volvo 740 in order to fund the Factory Five project. Left over from my Datsun is a 2004 Chevy Avalanche 5.3 long block that is going to make its way into my coupe. I had originally purchased it as a spare for the 240Z, but ended up never needing it.

[xlr8or]

I know what it is....

;)

[LDave]

Hey Scott, it was nice meeting you the other day! Thanks for stopping by and letting me check out the car. I'm sure I'll have to take a peak at it again for future reference.

[xlr8or]

Anytime. Just let me know. I'll use any excuse to go for a drive.

[CJBergquist]

Welcome aboard. I sure wish I had the glass back hatch like yours...I may have to give FFR a call...

[rj35pj]

Welcome aboard. I sure wish I had the glass back hatch like yours...I may have to give FFR a call...

I have seen the back glass (don't have mine yet). If you can swing it, it is really nice and adds to the overal quality of the car in my opinion.

[John Dol]

There is one other Coupe with I believe an LS1. You'll have to search for it on the other forum. Might be a time saver as far as figuring things out.
If you keep up this pace you'll have her done by the end of the month.;)

John

[xlr8or]

Didn't Badger use an LS1 in his SPF coupe?

[jkrueger]

LDave

keep us posted on the LS specifics of your build. I plan on doing the same thing when I get mine (as soon as I sell my roadster, which is posted in the for sale section).

JC

[LDave]

I've heard of another guy putting an LS1 / T56 in a Roadster and it looked pretty straight forward. So far I've got a 2005 LM7, Iron block 5.3 Litre with stock 706 casted heads.Pulled from a Chevy Avalanche. I have a Comp cam installed, will be swapping out the valve springs with some Comp Beehive springs, and with be using an LS1 intake manifold. Also going to be using the stock 5.3L exhaust manifolds. Going to be using the stock PCM for now, but later down the road I plan to use a MegaSquirt standalone fuel computer, and an MSD unit for the ignition. Don't worry, I'm taking pics of everything I do so you'll see how it goes.

The other night I was able to get all the front brake parts installed, as well as get all the aluminum panels marked and ready for removal. I'm REALLY dissappointed that I have to work this weekend. :-( Other wise I would be in the garage taking care of business. I'm still waiting on some back ordered master cylinders so I won't be able to finish up the brake stuff in its entirety just yet. Pics to come!

[RonSchofield]

Dave,

Since you are putting in a LS1, I suspect you will have to be making clearance in the hood for the engine. It would be a shame to cut into that nice red body. But look who's talking.. I think the top of the hood and roof are the only areas that I didn't cut on my build. I only have about 75 percent original fiberglass in my build. ;)

Welcome to the insanity..

Ron

[xlr8or]

Do not look at Ron's website. It will put your brain in overdrive with new ideas for your car and destroy your budget. ;)

[RonSchofield]

Do not look at Ron's website. It will put your brain in overdrive with new ideas for your car and destroy your budget. ;)

Except to look at the hood lock brackets. :)

BTW: Sharon and I will be down in your area in Feb. I will keep you updated. Maybe a group meet.

Ron

[LDave]

I'm not too sure if I'm going to have clearance issues or not, I guess I will cross that bridge once I get there. Luckily the intakes on the LS1's are pretty low profile and out the inlet pointing straight forward. The LS1's that I've seen in Roadsters have at least a few inch's of hood clearance on top.

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Brakes/DSCN29531.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Brakes/DSCN29541.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Brakes/DSCN2955.JPG

[LDave]

Last weekend I was able to get a little bit more progress done to the car. Managed to get the rear end, and rear suspension installed. And when the book says that you need two people and to be careful to avoid hurting yourself, I know what they mean. ;-) I was solo and still managed to get everything installed. (I only smashed one finger)

So here is what i'm starting out with. Its just a plain 'ol 8.8 with 2.73 gears. Poly bushings and a nice coat of black paint. I've installed a set of upgraded stock 28 spline axles with 5 lugs on them. I also installed a set of 95 mustang rear disc brakes.

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Rear%20Axle/DSCN2896.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Rear%20Axle/DSCN2897.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Rear%20Axle/DSCN2903.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Rear%20Axle/DSCN2924.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Rear%20Axle/DSCN2941.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Rear%20Axle/DSCN2959.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Rear%20Axle/DSCN2960.JPG

[LDave]

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Rear%20Axle/DSCN2962.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Rear%20Axle/DSCN2965.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Rear%20Axle/DSCN2966.JPG

I was also able to get the steering shaft on and start on a little bit of the aluminum paneling. Its so much fun putting this thing together, I just wish I had more time to work on it. I'm in for a 3 day weekend this week but unfortunately I'll have to spend it in Las Vegas on a little vacation. :-( Oh well... There's always next weekend!


http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Suspension%20%26%20Steering/DSCN2973.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Suspension%20%26%20Steering/DSCN2976.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Suspension%20%26%20Steering/DSCN2977.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Suspension%20%26%20Steering/DSCN2981.JPG


So I guess technically the car would be considered a roller, wahoo!

[bil1024]

Looking good!

[xlr8or]

Lookin good so far. Remember to stock up on drill bits before you begin the aluminum panels.

[DARKPT]

Look at all those shiny new parts! Congrats on the new kit!

[LDave]

Things have been slow the last couple weeks and I haven't gotten to spend much time in the garage. But today I started getting the engine buttoned up. And also worked on the pedal box, or at least TRIED to work on the pedal box. I ran into a snag, and wonder if you guys could give me some advice. Here's what I've got:

The kit came with the wilwood pedals, and the two steel pieces that are cut to mount the pedals into the car. first piece mounts to the front of the drivers foot area like so...

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Pedal%20Box/DSCN3011.JPG

Next, I'm assuming that the pedals bolt to the top of this piece like so:

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Pedal%20Box/DSCN3013.JPG

THEN, once you got the pedals mounted down, the second piece connects to the front like this.

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Pedal%20Box/DSCN3014.JPG

Does this look good so far? With everything in place like this, Where the second metal piece would mount to the frame, Its both too high and not centered over the square tube, Like this:

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Pedal%20Box/DSCN3017.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Pedal%20Box/DSCN3018.JPG

Now I know that where there is a welder, there is a way. But Maybe I'm doing something wrong here? I would like to fix it the correct way, before I resort to the Dave way.

Also. what is the purpose of the two drilled holes in the front left area of the 1st steel bracket? I wish I could just read all about it in the installation manual, but there is pretty much no information about installing the wilwood pedal book in there. Did anyone else have this kind of problem when installing their stuff? Thanks in advance for any kind of input you guys could give me.

[Jacob McCrea]

Dave,
I am not sure if the pedal box goes on the top or the bottom of the horizontal mount, but it looks like putting it on the bottom would get you closer to where you need to be, at least with respect to height. Hopefully someone who actually knows will weigh in on that.

Assuming the pedal box goes on the top, I would first consider re-drilling the holes in the "horizontal" bracket, which as I mention below, may solve both problems in one step. If that doesn't seem like a viable fix, you could try taking the "horizontal" bracket off of the frame, put it in a vise, and bend it downward (where it bends at the front of the footbox) until the "vertical" bracket hits the 3/4" tubes. The bracket looks like 1/8" cold rolled steel, which is some tough stuff, but with a pipe wrench or something similar for leverage it should bend without heat. Maybe use a piece of hardwood or some scrap metal between the vise jaws/pipe wrench jaws and the bracket to avoid gouging it, if you care. Doing so will also help to keep the bend uniform and not distort the metal where you aren't tring to bend it. You could try to bend the bracket with it still on the frame, but you might kink the forward-facing part of the bracket, rathern than bend it at the angle. You may end up with the pedals in crooked. On that point, I'd take a carpenter's square and check how everything lines up vis-a-vis the 2"x2" bulkhead at the bottom of the front loop. Maybe check out some of my latest photos on my thread re: frame mods to the Coupe, where I made a litany of changes to make my pedals fit with my frame mods.

As for making the horizontal mount line up with the 3/4" tubes, from the photos it doesn't look like the distance between the bracket's bolt holes is the same as the distance between the center lines of the 3/4" tubes. If they are pretty close, you could just correct the whole problem by redrilling the horizontal bracket so that the vertical bracket lines up with the 3/4" tubes, as mentioned above. But if, as the photos suggest, they are not drilled consistent with the centerlines of the 3/4" tubes, you could weld some additional steel tabs onto the vertical mount, plug weld the old bolt holes and drill new bolt holes. I would do that before I welded something onto the 3/4" tubes, which are fairly thin and not the easiest to weld to, especially using thicker metal. Also, no need to disturb the powder coating if you don't need to. The vertical bracket will be much easier to modify, regardless of your welding skills.

I would be cautious about how much you elongate any of the holes. You don't want that pedal box to shift around any more than it otherwise would. I'd also add that the pedals run fairly close to the 1"x1" square tube out to the front suspension towers, the steering shaft, and the 3/4" square tube. I taped paint sticks to the latter two while fitting the pedals to ensure adequate clearance. Also, it looks like you are using a hydraulic clutch, so you have some leeway to move the pedal box around. If you are using a cable, I'd guess, from looking at others' photos, that you need to take into consideration the clutch cable's travel when moving the pedal box around, and would be much more constrained in locating the pedals.

Bottom line: I'd try re-drilling the horizontal mount holes and correcting both problems in one fell swoop, and it that doesn't seem viable, move on to the other options. I will be by a phone all day if you want to touch base about any of this - just send me a PM.

[rj35pj]

6266The pedal box bolts under the steel bracket. To get the bracket to line up with the 3/4 square tubing, FFR advised me to assemble the bracket to the firewall loosely and then move (force) the bracket over to line up with the square tubing, drill and bolt it and then tighten everything down. It sounds a little iffy, but it does work.
Good luck,
Bob

[LDave]

Thanks for the suggestions guys, I took Jacobs advice and re-drilled the front mounting plate. Moved the pedals under the bracket, and made it all fit.

[CJBergquist]

Dave, here is a link to some photos of my Wilwood installation that my help. I did not have any fit/install issues.

http://www.flickr.com/photos/51103049@N00/sets/72157622799552919/

[LDave]

Thanks, looks good! Unfortunately I think maybe the fitment of the metal installed into my car may not have been the same as others. It was clearly off by a lot and I wasn't able to bolt it in like it should have been. But its all figured out and in there, thanks to the help and suggestions from this forum. ;)

[LDave]

Here's a little teaser pic for you guys!

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3075.JPG

[LDave]

So a buddy of mine came over with his Cannon 5D and took some pretty cool pics of my car. Just felt like sharing with ya'll.

http://home.tiora.net/tony/Daytona%20Coupe/IMG_0748small.jpg

http://home.tiora.net/tony/Daytona%20Coupe/IMG_0752small.jpg

http://home.tiora.net/tony/Daytona%20Coupe/IMG_0762small.jpg

[Tpa65cpe]

Nice job so far LDave!! Keep up the great work and pic's, pic's, pic's!!

[LDave]

Was able to hit another mile stone today. Body is back on!

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Body%20%26%20Interior/DSCN3265.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Body%20%26%20Interior/DSCN3266.JPG

[xlr8or]

Lookin good.

[MuddyRoverRob]

LDave...

That looks FANTASTIC!

the LS1 looks really happy in the coupe...

[rj35pj]

It looks great, you are really moving along, much faster than me. :)

[loeffler1]

LDave

Hey, are you building the coupe in your kitchen? Looks like a kitchen floor with appliances in the background.

Bill

[LDave]

Hahah, The people who owned the house before I did had turned the garage into a living space. I quickly turned it back into a garage by spilling lots of coolant / oil in there. Haven't found the time to remove all the Linoleum squares though.

Building the car in the kitchen would be fun, Arms reach from a cold soda whenever you felt like it!

[Sailor]

Soda? Surely you jest. Beer is what you reach for. Soda? Forsooth! LOL

[skullandbones]

Nice pics. I too had more than just minor fitment problems with the bracket on my roadster. It was not from FFR but very similar in construction. I don't think the providers like to admit that variation in construction of these smaller items (welding variations: heating and cooldown) can cause real fitment issues. I ended up persuading the bracket to fit with a large adjustable wrench after partially bolting it into place. But once installed it is very solid. I didn't adjust the cast Wilwood bracket but did use a couple of washers as spacers to improve the fit. WEK.

[Mad Dog]

Love the black and white photo, as well as the other, but the b&w one caught my eye. Great looking build!

[Jacob McCrea]

Yes, the black and white photo does look great. I need another hobby like I need a hole in my head, but becoming skilled at photography would be pretty cool.

[LDave]

Teaser pics! Teaser pics!!! Everyone likes pics!!!

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Body%20%26%20Interior/DSCN3273.JPG

[skullandbones]

LDave,
Did you already cut down your seams in the hood or does the Gen II come that way? The gelcoat looks nice. I thought you had painted it red when I first saw the body pic but then I remembered: "they come that way!!!!" Keep the pics coming. I noticed you refined your cool air and simplified it. I used a rubber plumbing fitting to connect my throttle body and stock induction tube. Sometimes those things work pretty well. Keep the pics coming. WEK.

[WIS89]

LDave-

She's beautiful! I echo the comments about the b & w photo; your friend is quite skilled!

Your build looks awesome, and I look forward to more pics.

So, spill.... what color?

Regards,

Steve

[LDave]

I told my buddy about your guys photography comments and he was quite happy to hear the compliments! His Exact words were, "wait till I take some pics of it once its completed!"

I haven't sanded or cut down any of the body yet, I just connected the nose to the hinges and laid it down on there for the time being.

My extra long intake pipe was off of my truck and was just on there temporarily for my "first start up" Hahaha, I wasn't planning on using that thing permanently.

As for colors... I'm not 100% set on anything as of now, I was thinking about doing a flat or gloss black with some stripes. but who knows, that could change at any time.

[LDave]

Got my exhaust all finished up. Here is a quick little video. http://www.youtube.com/watch?v=ch3QVWzDVcs&feature=youtu.be

[xlr8or]

I got to come check out your progress.

[LDave]

I got to come check out your progress.

Anytime man! Its going to be 100% different then when you first came over. 0% progress to a damn near finished car.

[xlr8or]

Cool. I'll need to pick your brain about an LS swap I am considering. I'll PM you when I have some time to come over.

[LDave]

Sounds like a plan. I've got about 4 - 5 LS swaps under my belt now. So I should be able to help you out with any questions.

[LDave]

Took the car out for a little spin around the block tonight, Must say that I haven't had that much fun in a long while!!! What a great feeling. :-)

Looks like my buddy had a good time too. Haha

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Finishing%20up/imagejpeg_266%20%281%29.jpg

[jkrueger]

So cool! Lets see some pics of what you did with the exhaust pipes.

2 months till I pick my car up.

JC

[LDave]

For the exhaust I used Cadillac CTS-V manifolds flipped around. They tucked in the tightest with the flange placement where it needed to be. On the driver side I still had to add an extension off the collector and put a flange down there. Ended up fitting pretty well though.

So first I had to merge the two pieces of the side pipe together by means of this... And ended up using my own flanges.

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3278.JPG
http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3279.JPG
http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3281.JPG
http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3282.JPG
http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3283.JPG

The driver side was a little more tricky, but still not too bad. I purchased a stainless Weld EL 2.5" ID and welded it straight onto the manifold. Relocated the flange down lower since in the original position it would make contact with the engine mount, After trimming the engine mount a little I discovered that the flange that would bolt to the manifold would make contact with the frame. So rather then cut the frame relocation was a must.

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3284.JPG
http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3285.JPG

[LDave]

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3286.JPG
http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3290.JPG
http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3291.JPG
http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3292.JPG

[Jacob McCrea]

That's some really nice fab work there, Dave; thanks for sharing. I was surprised to see how much hood clearance there is with that engine. Also, I'm curious about how you welded to what I assume is a cast manifold? My understanding is that the best practice is to preheat the cast iron in an oven. Any guidance would be appreciated. Again, nice work.

[jkrueger]

very cool. Thanks for sharing.

JC

[riptide motorsport]

Fantastic work!!

[LDave]

Thanks for the comments guys!

As for the welding... The manifolds are cast iron, and the elbow is stainless. Lots of people out there are probably going to tell me that I'm doing it all wrong, but it has gotten me by so far. I just tig weld the two together with stainless filler rod. And sometimes when it cools I'll hear a loud POP, which is the weld cracking. So I'll lay down another bead over the entire thing. If it cracks again I'll weld another bead over the entire thing, until it stops cracking. Every time I have done this, it always eventually stops cracking. That's pretty much all I do. I've welded a few V-band flanges to turbine housings of turbo's, Tubing / flanges onto cast manifolds for waste gates, and several flanges onto the ends of manifolds to better suite my application. So far so good!

I have heard of people putting the work in the oven to pre-heat it. I might consider doing that but my oven is broken. Haha! Usually by the time you're doing the second bead, the manifold is already damn hot from all the tig welding.

[LDave]

So... is my Gen2 coupe the only one that does not have the Metal bar where the front of the body would rest on?

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Aluminum%20Paneling/DSCN3223.JPG

Not having this support here causes the front of the body to sag slightly when the nose is closed. And when it sags, it tweaks the windshield flange a little bit. Did FFR accidentally leave this piece out??? Or was it left out for a reason?

[xlr8or]

Remember I pointed that out when I first saw your car? We figured the new coupe must just use the firewall sheet metal to support the body with weather strip going across it. That firewall piece is different from the black body coupe too.

[rj35pj]

All the gen 2 coupes including ours do not have the bar....I don't know why.

[Jacob McCrea]

Here is an email I got from FFR on this very subject after asking where my bar was:

Hi Jacob,

I just talked to welding and engineering, and the way that your Gen 2 Coupe
is constructed in that area is correct. That area has changed from the Gen 1
to the Gen 2. The reason that you see a Gen 2 on the forum with the Gen 1
dash steel, is that component was a running change. There is a handful of
Coupes that have the MK4 front end, but still retain the Gen 1 Coupe dash
setup. So in short, you are all set, and your frame is good to go.

Thank You


Dan Golub
Technical Support
Factory Five Racing, Inc.


I haven't given it more than a few moments of thought, but perhaps riveting a piece of 1" aluminum angle horizontally across the back side of the "firewall" piece would stiffen it enough to prevent the body from drooping. Perhaps you could position the aluminum angle facing upwards and contour it at the edges so that it would accept a bulb seal, and the body could also rest on it.

[LDave]

Rj and Jacub, Thanks for the info. I feel a little better knowing that something wasn't left out. But don't feel good knowing the the body "tweaks" slightly when the hood closes. I already have a seal on the top of the aluminum under the body there but I would like to add some more support. As always, I'll figure something out.

[LDave]

So I ended up making a piece that runs along the bottom side of the body and is secured by the screws that come down through the rubber bump stops for the hood. It anchors to a piece of 1x1 on the passenger side on the foot box, and the other side anchors to the right side of a piece of the driver foot box 1x1. When I had it all mocked up the body was VERY stiff in that area, so I don't think I will have any flex problems after this. :-)

BTW... I'm just about at the point where the windshield needs to go in. And when reading the manual it says to shim the body between it and the frame until the flange makes full contact on the glass. Then you're suppose to run a nut / bolt through it to act as another body mount. Do any of you guys have pics of what you did at this step? The book didn't have any pictures of this, although I think it should Let me see what you guys got! Thanks in advance. I'm getting so close I can taste it!

[rj35pj]

So I ended up making a piece that runs along the bottom side of the body and is secured by the screws that come down through the rubber bump stops for the hood. It anchors to a piece of 1x1 on the passenger side on the foot box, and the other side anchors to the right side of a piece of the driver foot box 1x1. When I had it all mocked up the body was VERY stiff in that area, so I don't think I will have any flex problems after this. :-)

BTW... I'm just about at the point where the windshield needs to go in. And when reading the manual it says to shim the body between it and the frame until the flange makes full contact on the glass. Then you're suppose to run a nut / bolt through it to act as another body mount. Do any of you guys have pics of what you did at this step? The book didn't have any pictures of this, although I think it should Let me see what you guys got! Thanks in advance. I'm getting so close I can taste it!
LDave,
If you have any pictures of what you did to the body for reinforcement I would sure like to see them.
Thanks,
Bob

[70gtvert]

Why the two steering shaft spline pieces? Is the large one to big to hook up to the rack? Where did you find the smaller one at? Thanks, John

[LDave]

The kit came with the other one, I don't exactly remember which one I ended up using. Small one I think? Maybe the larger would be used on a power steering rack, I don't really know. But it certainly was too large to put on the rack that came with the kit.

Bob - For my support piece, I just stretched a bar across the body to fit on the underside of where the hood rests. I had to bent it slightly to fit the curvature of the body. Then just welded a couple legs to it. Pass side will bolt to the 1x1 Drivers will bolt / rivet to the side of the foot box, or I may extend it to rest on the top of the foot box where the top 1x1 is (or whatever size that bar might be.)

Probably not the best design, but it will support it enough to make that section of the body not budge at all when I lean on it with my bodies weight. Hope that helps.

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Body%20%26%20Interior/DSCN3294.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Body%20%26%20Interior/DSCN3295.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Body%20%26%20Interior/DSCN3296.JPG

[rj35pj]

LDave,
Thanks, I always need someone to show me a picture rather than just words. :)

[LDave]

LDave,
Thanks, I always need someone to show me a picture rather than just words. :)


Trust me, I feel the same way.

[LDave]

So my buddy with the Cannon 5D came over again and snapped a few cool pics of the coupe in its current state. I think they turned out pretty awesome!

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Finishing%20up/IMG_3630small.jpg

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Finishing%20up/IMG_3641small.jpg

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Finishing%20up/IMG_3642small.jpg

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Finishing%20up/IMG_3653small.jpg

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Finishing%20up/IMG_3648small%20%281%29.jpg

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Finishing%20up/IMG_3655_1small.jpg

BTW, if anyone in San Diego area wanted him to take some pics of their car I'm sure he would be willing to do a photo shoot. Just let me know.

[rj35pj]

As always, very nice. :)

[John Dol]

Wow,

Thanks for making me feel like more of a snail then I already do !!LOL
Great progress, looks like the new body makes a lot of diff as far as fit goes.

John

[jetsbaby]

You need to use 309L stainless filler wire for welding stainless steel to carbon steel..It will keep cracking especially on exhaust pipe..Here is a short video on what happens when welding carbon steel to stainless steel and the fix for it..By the way like the LS engine install. What did you use for motor mounts? The Ford 4.6 mounts with extending the one arm to fit the back mounting hole on the block?

http://www.weldingtipsandtricks.com/weld-stainless-steel-exhaust.html




Thanks for the comments guys!

As for the welding... The manifolds are cast iron, and the elbow is stainless. Lots of people out there are probably going to tell me that I'm doing it all wrong, but it has gotten me by so far. I just tig weld the two together with stainless filler rod. And sometimes when it cools I'll hear a loud POP, which is the weld cracking. So I'll lay down another bead over the entire thing. If it cracks again I'll weld another bead over the entire thing, until it stops cracking. Every time I have done this, it always eventually stops cracking. That's pretty much all I do. I've welded a few V-band flanges to turbine housings of turbo's, Tubing / flanges onto cast manifolds for waste gates, and several flanges onto the ends of manifolds to better suite my application. So far so good!

I have heard of people putting the work in the oven to preheat it. I might consider doing that but my oven is broken. Haha! Usually by the time you're doing the second bead, the manifold is already damn hot from all the tig welding.

[LDave]

Thanks for the video! I'll refer back to the video for some pointers if / when ever the time comes to make some repairs.

For the motor mounts I did use the ford 4.6 mounts. But since I am using an iron block, there is no threaded hole further back on the block. So instead of extending the arm back, I cut it off and flipped it inward. Then tried to add some sort of gusset on there for some extra strength.
http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3010.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3033.JPG

[LDave]

Its registered and legal!!!! WAHOO!!! Just drove it to work today for the first time too. Feels great to be able to take it out for a spin now. :-) On my way home I stopped by my moms house to show her what kind of "toy" I'm working on now. And she made me pose in front of the car like it was my first day of High School. Haha

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Finishing%20up/DSCN0139.JPG

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Finishing%20up/DSCN0140.JPG

[xlr8or]

Way to go. You made quick work of that thing. How's the engine and gearing feel?

[smithtlw]

That looks pretty darn good for gel coat! Nice job on the preliminary hood and door fit.

Do you have any pictures of the transmission mounting? I assume it is the LS T56?

Congrats on being legal.

Todd

[LDave]

engine feels pretty smooth and strong. Doesn't really pull to hard from a dig. Probably because of the 2.73 rear end. Haha. On the freeway i'm at 1100rpm at 70mph. So a new rear end set up is on the wish list. Otherwise, everything is pretty darn good!

For the T56 I used an energy suspension trans mount. Had to trim the bracket on the frame a little bit and drill a new hole. Didn't take too much to make it work.

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Engine%20%26%20Transmission/DSCN3080.JPG

[Benji]

Just over 6 months from start to road-legal, very impressive! Nice build!

[Jacob McCrea]

Very impressive indeed in multiple ways - congrats on reaching this milestone.

[jkrueger]

Congrats Dave. The car looks good! My Dad and I are all a$$es and elbows on ours right now.

JC

[LDave]

Hello all! just wanted to give you guys an update on the car. Since I lasted posted in here I've installed a set of turbos on the car, and changed the ring and pinion from a 2.73 over to 3:54's(MUCH BETTER) This thing is a blast to drive! I've taken it out to the track a few times as well. The car gets a ton of attention, and holds its own against the other guys. Of course I drive the car to and from the track too. Here are some pics and a video.

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Finishing%20up/222143_676946872280_2035368691_n.jpg

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Finishing%20up/317650_676946827370_2127859550_n.jpg

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Finishing%20up/400800_676947012000_1889486049_n.jpg

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Finishing%20up/403190_676946657710_1352551377_n.jpg

http://home.tiora.net/davidc/Factory%20Five/Daytona%20Coupe/Finishing%20up/527271_676946922180_1528567461_n.jpg

http://www.youtube.com/watch?v=OisknmmtiGs&feature=channel&list=UL

[Benji]

Let me be the first to say:

HOLY.

SMOKES.

And judging by your other videos, you're no stranger to this...

Maybe I'm missing something, are they 7 second 1/4 miles?! How much power are you putting out and I'm guessing that's an air to water intercooler?

[Movieman]

Boy does that pull strong from the line for a street car.. VERY nice!
Yea, same interest, that can't be 7 second 1/4 mile times with a trap speed of 99MPH..
Enquiring minds want to know!:D

[Jeff Kleiner]

...are they 7 second 1/4 miles?

1/8 mile. Although conversion isn't an exact science Dave's ~7.2 1/8 mile would approximate an 11.2-11.4 quarter mile :cool:

Great work Dave; I always enjoy your updates!

Jeff

[jkrueger]

Dave

I just watched your video. Pretty cool! You really creamed that vette! How much boost are you running?

A couple of questions. Where did you run the steam line that comes of the heads? What throttle cable are you using? I am getting close to putting my engine back in for good.

JC

[STLMARSHALL]

Dave

I just watched your video. Pretty cool! You really creamed that vette! How much boost are you running?

A couple of questions. Where did you run the steam line that comes of the heads? What throttle cable are you using? I am getting close to putting my engine back in for good.

JC

JC on my LS I used the FFR throttle cable. I made my own bracket at the TB as my engine was originally a drive by wire. The steam pipe I ran straight to the vent port on the upper drivers side of the FFR supplied radiator. BTW I ran one autocross this sumer in 104 degree temps and after 10 hard runs the car was still doing fine on temps and never overheated.

Nice build Dave! It is amazing how quickly you got it done. With my stock LS1 I can't hook up until 3rd gear. I can only imagine the traction problems with the boost on the street.

[LDave]

Thanks guys! Jeff is correct, this is an 1/8th mile track. The closest 1/4 mile track is about 120 miles from me. Which I would imagine I'll be making my way up to sometime. I am also running an air to water intercooler. I couldn't think of any way to make a front mounted air to air intercooler work, unless I ran small diameter piping. My IATs are pretty solid between 95 - 100 degree's. If I could figure out a way to get the air filters to suck up cooler non-engine bay air I'm sure they would drop a lot more. But it will do for now. I am running a Lokar throttle cable P/N TC-1000LS148. I've used this cable on all LS swaps I've ever done and it works great. The boost is pretty low, roughly 8-9psi. I feel like it should be faster for the boost its at, but I guess its a good starting point.

JC - I just capped my steam line off. I know you're suppose to use it to purge air from the system but I have never done anything other then cap it off. The car doesn't get hot by any means either. 185* all day long.

Marshall - I actually haven't ripped on it in the streets too much. I don't have too many long straight open roads around me, and I'm too scared of 1. getting pulled over, and 2. loosing control and wrecking the car. But every now and then when I want to pass someone on the freeway... :)

[cobradl]

have fun with your build,just bought my 65 about 3 months haveing fun with it yes lots of questions ,but someone comes through with the answer

[cobradl]

just started my 65 coupe working on the door hinges anyone have any pictures thanks

[gq4life]

Thanks guys! Jeff is correct, this is an 1/8th mile track. The closest 1/4 mile track is about 120 miles from me. Which I would imagine I'll be making my way up to sometime. I am also running an air to water intercooler. I couldn't think of any way to make a front mounted air to air intercooler work, unless I ran small diameter piping. My IATs are pretty solid between 95 - 100 degree's. If I could figure out a way to get the air filters to suck up cooler non-engine bay air I'm sure they would drop a lot more. But it will do for now. I am running a Lokar throttle cable P/N TC-1000LS148. I've used this cable on all LS swaps I've ever done and it works great. The boost is pretty low, roughly 8-9psi. I feel like it should be faster for the boost its at, but I guess its a good starting point.

JC - I just capped my steam line off. I know you're suppose to use it to purge air from the system but I have never done anything other then cap it off. The car doesn't get hot by any means either. 185* all day long.

Marshall - I actually haven't ripped on it in the streets too much. I don't have too many long straight open roads around me, and I'm too scared of 1. getting pulled over, and 2. loosing control and wrecking the car. But every now and then when I want to pass someone on the freeway... :)

Ever think about methanol injection to keep the air intake temps down?

Love this build.. been thinking about a Daytona coupe.. really would like to do a supercharged coyote but wondering about fitment.. Seeing your turbo ride makes me think that might be the way to go.. really looking for atleast 500wHP..
current daily driver is 630wHP Camaro.. would like the idea of this daytona being faster..

[LDave]

just started my 65 coupe working on the door hinges anyone have any pictures thanks

Sorry, I don't think I took any pics of that part of the build. But its fairly straight forward. Let me know if you have any questions.


Ever think about methanol injection to keep the air intake temps down?

Love this build.. been thinking about a Daytona coupe.. really would like to do a supercharged coyote but wondering about fitment.. Seeing your turbo ride makes me think that might be the way to go.. really looking for atleast 500wHP..
current daily driver is 630wHP Camaro.. would like the idea of this daytona being faster..

I actually am planning to put an AEM methanol kit on the car. But I'm waiting on getting a few pieces of it back from AEM (warrantee) If you are only looking to get 500 at the wheel that shouldn't be too difficult to do. So what kind of times does a 630hp camaro get you at the track?

[Movieman]

Just watched your video..That little Beast pulls strong!:D
Any 1/4 mile times yet?

[LDave]

Just watched your video..That little Beast pulls strong!:D
Any 1/4 mile times yet?

Thanks movievan! No 1/4 mile times yet, just heard that the closest 1/4 mile track that use to be 120 miles away is now shut down. So the next closest is about 250 miles away! Lame...

BTW, I took the car out to the strip again and managed to pull off a 6.9 @ 103! Finally broke into 6's on pump gas. Which has been my goal for many years now. :)

[Movieman]

Thanks movievan! No 1/4 mile times yet, just heard that the closest 1/4 mile track that use to be 120 miles away is now shut down. So the next closest is about 250 miles away! Lame...

BTW, I took the car out to the strip again and managed to pull off a 6.9 @ 103! Finally broke into 6's on pump gas. Which has been my goal for many years now. :)
Grab two buddies, a 3/4 ton pickup and rent a trailer..Worth the trip just to know.
If It was me I'd be itching to know what that beast would do.
From that vid for a pure street car it REALLY pulls strong out of the gate. Yes, you do hear a little jealousy in my words ..LOLOL..Very well done.