Building Skuzzy's Coupe

[Skuzzy]

And it begins.......

Back in 1965'ish, on any given Friday night, the family would pack into the 54 Ford with a dual quad flat head V8 and rumble over to the local A&W for cruise night. Dad owned the auto parts store at the other end of the block and sponsored the night by giving away stuff to the various “best of” categories. All voted on by the local attendees of the day.

This night would be different. As we waited for our order, a rumbling car came up beside us. It was the first time I had seen a Cobra. While it was a paint Cobra, it still imparted an impression on me I vividly recall to this day. When it pulled up besides us, I recall Dad saying,..”Damn....”. Mom punched him for cussing in front of the kids. Little did Mom know I heard much, much worse at the track on Saturday nights while helping repair cars, which broke down during the races. I was small and dangled nicely in engine compartments.

As our food arrived, I could not stop looking at the car. Looking around the girl, to see the car, while everyone was grabbing for food and floats was all I could think of. I was hooked.

Over 50 years later, as I approach my 67th birthday, I finally have to accept I will never have a Cobra. I just do not have the finances to support a fair weather car. I did have a Cobra kit. Twelve years ago, I bought a kit. Lost the build budget three times (unexpected expenses), then a massive house repair expense forced me to sell the uncompleted kit.

Now I am back and this is going to happen. One way or the other. Only now, instead of a Cobra, it has to be the Coupe as I can only support a daily driver and this is it. Spent quite a bit of time researching various options and getting a handle on the build process. The many build logs have been very helpful. Now it is time for me to give some back. So here we go......

[Skuzzy]

I'll update the table of contents as things shake out.

Table of Contents
The Order (https://thefactoryfiveforum.com/showthread.php?39827-Building-Skuzzy-s-Coupe&p=457507&viewfull=1#post457507) (completed 5/27/2021)
The Engine (https://thefactoryfiveforum.com/showthread.php?39827-Building-Skuzzy-s-Coupe&p=457508&viewfull=1#post457508)(in progress)
Arrival (https://thefactoryfiveforum.com/showthread.php?39827-Building-Skuzzy-s-Coupe&p=474888&viewfull=1#post474888)(completed 11/19/2021)
Inventory (https://thefactoryfiveforum.com/showthread.php?39827-Building-Skuzzy-s-Coupe&p=475307&viewfull=1#post475307)(completed 11/24/2021)
And it begins.... (https://thefactoryfiveforum.com/showthread.php?39827-Building-Skuzzy-s-Coupe&p=475485&viewfull=1#post475485)

[Skuzzy]

The order.

Gen 3 Type 65 Coupe Complete Kit
Uncoated Chassis

I know I will be cleaning up the welds, drilling some holes, as well as the possibility of adding things to the frame. No sense in wasting a powder coat. I'll deal with it once I am happy with the frame.

Body cutouts

I really am not crazy about cutting fiberglass. I know it is unavoidable, but this will help to minimize that pain.

302/351W Mounts

The engine is the one I was building for the sold Cobra kit. I kept it when I sold my kit so it is going in this one. I would rather use the Coyote, but this is what I have. I'll have to make it work. Doing so without compromising the performance of the engine will be a challenge.

Hydraulic Clutch
31 Spline driveshaft for 302/351W with TKX transmission

I'll be using the wide ratio TKX (3.27, 1.98, 1.34, 1, 0.72) transmission.

Black Vinyl Roadster Seats (to be replaced)

The seats are proving to be a challenge. I am 6'3” tall and weigh in at 210 pounds, with a 34” inseam. I am going to wait until I can get accurate measurements on the interior before deciding which way to go.

Power Steering Kit
2015+ Mustang based IRS
A/C Heater Defroster for 302/351W
Black Carpet Package
Leather Steering Wheel upgrade

I may make the attempt to use the Ididit 12” tilt column in place of the standard wheel and column. Measurements of the space and evaluating a mounting system for it will drive this decision.

Front and rear swaybar
Double Adjustable Koni shocks for IRS
2018 Mustang Center Section with 3.55

I'll be taking this to a professional differential shop to have the gears updated with a 3.31 ford performance gearset, and installing an Eaton Truetrac.

Stewart Delivery


Conspicuously missing are the wheels and brakes. Wheels are yet to be determined. I need a 18”x12” rear wheel for the 335/30ZR-18 tires I plan on using. I plan on using 275/35ZR-18 tires up front. I have the brakes on a shelf in the garage left over from two different car builds which got axed.

If any of you know those tires will not work, or will work, please let me know. I have not ordered them yet and do not intend to do so until I get the kit here so I can measure things.


NOTE: I got a date from Factory Five of November 6, 2021. Not sure if that date is the delivery date, or the build date for them.

[Skuzzy]

The Engine

The engine is left from my previously attempted Cobra build. I would rather have used a Coyote, but this is what I have and I have to make it work.

It is as follows:

427 Dart SHP 9.5” Windsor block
SCAT Forged crankshaft and rods
Diamond pistons
Total Seal rings
ATI Harmonic Balancer
Twisted Wedge 205 11R heads
Edelbrock Performer RPM Airgap manifold (Yes, I know. What can I say,....I like a challenge.)
Holley Sniper EFI
Custom ground camshaft
Holley Distributor
Kevko oil pan
Meizure electric water pump
Quicktime Bellhousing
ACT Flywheel
ACT Clutch and Pressure plate
Melling Oil Pump
Internally balanced

An engine I designed and built, it was originally built for the Cobra kit I had. Converting this to a street engine will take some work. A daily driver is a chore to manage with a rough/lumpy idle. Then again, to make that high speed run is going to take more engine than just a daily driver. I may build it for the run, then rebuild it after that.

You will note the electric water pump. I have designed an intelligent PWM controller, for the water pump and electric fan, which will allow me to run the engine without a thermostat in it.

[cob427sc]

Sounds like a great build and you have the perfect start with the engine ready to go. My story is similar. In 1969 I was a freshman at Univ. of Utah in Salt Lake. A rich kid in the dorm had a Cobra. Asked me once if I wanted to make a beer run to Nevada (80 miles) to get some real beer, not that 3.2 stuff. Rumbled through the city to a stop light at the continuation of route 40 (I-80 wasn't built then). He smiled and nailed it! Return trip was just the same and I was hooked. Took me until 1997 to buy and build my first FFR Cobra. You are about to embark on a great experience that you will always cherish.

[Skuzzy]

Thank you!

In case I have not said it, I welcome all inputs. You never know when that one comment could take you down a path you never thought of. Truly appreciate it.

Once I get full fledged status on the forum I will start my photo album.

[Skuzzy]

I know about GasN's pipes and headers. Has anyone used the Spintech (https://spintechmufflers.com/factory-5-daytona-coupe-5-oval-side-pipes/) side pipes? I am curious as to which is quieter.

[Skuzzy]

So as I wait for the kit, I am getting other parts in here and prepping them for the build. My target priorities are;

1) Safety
2) Comfort
3) Performance
4) Serviceability

There was a day when performance would have been number one, but I hope I have gotten a little wiser with age. Then again,...who in their right mind would build a 600+HP, 2#00 pound car as a daily driver? Yet, just saying it makes me smile.

[TheMole]

Smiles all around Skuzzy!

[Skuzzy]

This is not my first foray into the world of high performance cars. This "build log" is but a small portion of my "build diary". The Wife is my editor, as I tend to be very, very detailed in my writing. She helps me interface with the real world. As goofy as that might sound, I need it.

Thank you for the smiles TheMole. I hope to give as much fun as I will have in building this car.

[coup in australia]

Great order sounds exactly like my coupe and engine but I have gone TKX with a midshift, I ordered mine last november and was hoping for Feb 2021 but it arrived last week whilst I am away on holidays so my mate has already unpacked it.
150476

[Skuzzy]

Great order sounds exactly like my coupe and engine but I have gone TKX with a midshift, I ordered mine last november and was hoping for Feb 2021 but it arrived last week whilst I am away on holidays so my mate has already unpacked it.
150476

I really wanted to go with the TKX. The TKX gear ratios are so well spaced, and the light weight make it a really nice transmission. Unfortunately, I would have had to go with a 3.31 rear gear (the bucket list thing), which would have made driving on the street a chore. As this is going to be my daily driver, I had to compromise.

Congratulations on receiving your kit! I got a date of November 11 for mine. Not sure how accurate that is. It does give me some time to gather up things I know I am going to need to finish it.

Looking forward to your build log.

EDIT: Well heck, I bit the bullet and switched to the TKX and the 3.31 gearset. FF was nice enough to take care of the change order for me.

[B Campbell]

Congratulations looks like a cool build. I ordered my Coupe in March hope to have it delivered this month. my completion date from Factory Five was 7/31

[Skuzzy]

Congratulations looks like a cool build. I ordered my Coupe in March hope to have it delivered this month. my completion date from Factory Five was 7/31

Awesome! Looking forward to hearing about it.

[Skuzzy]

Big day today! The Coupe has arrived. A big shout out to Stewart Transportation. They were awesome. I presented them with a small challenge and they took to like a hot knife through butter. The kit was offloaded and in my garage in just over one hour. That included setting the body/frame on my lift, on the jack stands.

Now the fun begins. It is a tight fit in my garage, but I am so glad for the lift and gantry.

NOTE: Still trying to figure out how to post without thumbnails and have them fullscreen. 35 years as a programmer and computer hardware designer,...*sigh*.

156577156578156579156580156581

[Logan]

Congrats! And nice shop setup you have there.

[David Hodgkins]

Big day to day!
NOTE: Still trying to figure out how to post without thumbnails and have them fullscreen. 35 years as a programmer and computer hardware designer,...*sigh*.

So Skuzzy comes for the hard drive format? I was wondering about that...

Check out this thread:
https://thefactoryfiveforum.com/showthread.php?18962-How-to-use-the-Image-Gallery-to-embed-pictures-in-posts

If you are still having trouble after trying to use the Pic Gallery as described in the linked thread send me a PM and I'll talk you through a sample or two.

:)

PS Congrats on the delivery!

[Skuzzy]

Congrats! And nice shop setup you have there.

Thank you. It's small and cozy, but I can make it work. The lift is a real space saver.



So Skuzzy comes for the hard drive format? I was wondering about that...

Check out this thread:
https://thefactoryfiveforum.com/showthread.php?18962-How-to-use-the-Image-Gallery-to-embed-pictures-in-posts

If you are still having trouble after trying to use the Pic Gallery as described in the linked thread send me a PM and I'll talk you through a sample or two.

:)

PS Congrats on the delivery!

Thank you. I will probably need some help with the images. I thought I followed all the instructions. Then again, my images might be too big. I'll look at that.

[B Campbell]

Congratulations. I like the lift and hoist set up you have. be patient with the POL list. lots of things you can work on. My Coupe was delivered this last August and I`m just now getting parts on my POL list delivered.

[David Hodgkins]

I keep my images to 2000x2000 max. Usually do 1600 width and I’ve never had an issue.

:)

[dstelter]

Hey Skuzzy. Congrats on the arrival. Curious on what S/N they are up to. Mine was delivered in July of 2019. I got S/N 169. Also see your TX, Me too. Outside of Austin TX. Car is in paint and body now. still waiting on the drivetrain. I hope to be up and running by spring. Doug

[Skuzzy]

Congratulations. I like the lift and hoist set up you have. be patient with the POL list. lots of things you can work on. My Coupe was delivered this last August and I`m just now getting parts on my POL list delivered.

Oh, there is plenty to do. I could spend weeks just prepping the body. :) I am rebuilding my new engine with a different cam and pistons as well.



I keep my images to 2000x2000 max. Usually do 1600 width and I’ve never had an issue.

:)

My native picture size is 5184x2912, jpeg. That is my camera resolution.



Hey Skuzzy. Congrats on the arrival. Curious on what S/N they are up to. Mine was delivered in July of 2019. I got S/N 169. Also see your TX, Me too. Outside of Austin TX. Car is in paint and body now. still waiting on the drivetrain. I hope to be up and running by spring. Doug

I have not opened the package yet. We have a catered dinner we are hosting tonight, so I am in the house just about as antsy as one can get to get out there and open up stuff! The dinner was planned last month.

I doubt I will be up and running by spring. Just depends on how well things go together and how many things I remake/redo/customize. :)

I am an engineer.....all bets are off.

[David Hodgkins]

../My native picture size is 5184x2912, jpeg. That is my camera resolution.


Yep, that's you issue. There are a few free windows pic resizers or you can just use paint to create a set of reduced pics tp post.

Sorry about the pain of resizing. I could easily write a pic resizing method but I don't code PHP...

I'll look to see if there are any resizing mods available for this site.

:)

[Skuzzy]

Yep, that's you issue. There are a few free windows pic resizers or you can just use paint to create a set of reduced pics tp post.

Sorry about the pain of resizing. I could easily write a pic resizing method but I don't code PHP...

I'll look to see if there are any resizing mods available for this site.

:)

Not a big deal for me. I have tools for resizing. Just did not occur to me. You really do not want to do that server side. It could place quite a load on the server. I would rather it kick it back to me and fuss about being too big.

[Skuzzy]

Hey Skuzzy. Congrats on the arrival. Curious on what S/N they are up to. Mine was delivered in July of 2019. I got S/N 169. Also see your TX, Me too. Outside of Austin TX. Car is in paint and body now. still waiting on the drivetrain. I hope to be up and running by spring. Doug

Chassis number: F5R1000342DC.

Which side of Austin? UT is my alma mater.

I do not see my car being ready until sometime in 2023. Looking forward to the destination, but really excited about the journey.

[Skuzzy]

Day one of inventory. Got about 1/3 the way through. So far, missing 2 nuts, one washer, and have several unidentified parts.

Word to the wise: Do not open the last box first. Bad idea. It has parts in it from every other list. Can truly confuse the inventory taker.

[edwardb]

Word to the wise: Do not open the last box first. Bad idea. It has parts in it from every other list. Can truly confuse the inventory taker.

I'm sure you figured out that box is made up of parts that were originally on the POL when they first staged your kit. But were filled in one last pass through the warehouse before shipment. Agree save it until last. I put those parts into the box they were originally supposed to be in and mark the inventory sheets accordingly. Same as the other POL items as they arrive. Staying organized is a huge part of these builds.

[David Hodgkins]

Here’s my inventory tip: I wrote the parts on the side of the box in black sharpie. That way I could just stack them but still see what was in the box at a glance. No more “what was in box #8 again??”

:)

[Skuzzy]

I'm sure you figured out that box is made up of parts that were originally on the POL when they first staged your kit. But were filled in one last pass through the warehouse before shipment. Agree save it until last. I put those parts into the box they were originally supposed to be in and mark the inventory sheets accordingly. Same as the other POL items as they arrive. Staying organized is a huge part of these builds.

Yes, that is my plan as well. I have a separate box containing parts from boxes that were not on the inventory sheets. There are also inventory sheets pointing at the incorrect boxes. (example, the two CV axles are 20 and 21, but the inventory sheets for 20 and 21 do not list the axles, instead they list a bunch of parts for suspension attachments, which I have not found yet). Also finding extra parts not listed in the inventory sheets for any given box.

I just figure to do the complete inventory. Then go through the sheets and make a list.



Here’s my inventory tip: I wrote the parts on the side of the box in black sharpie. That way I could just stack them but still see what was in the box at a glance. No more “what was in box #8 again??”
:)

Way ahead of you. I am making new sheets for each box so I can check off what I take out as I do. Takes some time, up front, but I think it will pay off in the long run.

[cgundermann]

Reference the earlier Spintech question -

Dan at FFR used Spintech to create his Daytona pipes and said they are much quieter.

Chris

[Deldiablo]

On my September 2019 visit, Dan was our tour guide, and when asked about ways to bring the coupe noise level down, he mentioned the Spintech Oval pipes on his build, but he said the bigger difference was probably made by turbocharging it, taking some volume out of the exhaust stream.

[Skuzzy]

Reference the earlier Spintech question -

Dan at FFR used Spintech to create his Daytona pipes and said they are much quieter.
Chris

Thank you for the information.



On my September 2019 visit, Dan was our tour guide, and when asked about ways to bring the coupe noise level down, he mentioned the Spintech Oval pipes on his build, but he said the bigger difference was probably made by turbocharging it, taking some volume out of the exhaust stream.

Certainly turbocharging would reduce the DB levels.

The practical side of me likes the quieter pipes, but the aesthetic side is having a hard time not going with the dual round pipes. I have time.

[Logan]

I built custom sidepipes purely based on sound. I do a lot of autocross with the local club (TAC/TVR if anyone is in northern Alabama). Our limit here is 96dB, measured at 50ft from the driving line, when vehicles are at WOT. The stock FFR pipes are easily over that.

I built stainless steel 4" tight radius 1D elbows, with a flange that bolts to the stock FFR Coyote headers, with a V-band on the other end. Then 4" diesel truck stacks for the sidepipes...filled with 36" of stainless augers and 4-6" of stainless wool. The turndown tips are also V-banded so I can rotate them to any angle. Pointing them down makes a very noticeable difference in sound level to the meter (although not much change to the occupants in the car).

https://thefactoryfiveforum.com/attachment.php?attachmentid=148543&d=1622071099

[Skuzzy]

I built custom sidepipes purely based on sound. I do a lot of autocross with the local club (TAC/TVR if anyone is in northern Alabama). Our limit here is 96dB, measured at 50ft from the driving line, when vehicles are at WOT. The stock FFR pipes are easily over that.

I built stainless steel 4" tight radius 1D elbows, with a flange that bolts to the stock FFR Coyote headers, with a V-band on the other end. Then 4" diesel truck stacks for the sidepipes...filled with 36" of stainless augers and 4-6" of stainless wool. The turndown tips are also V-banded so I can rotate them to any angle. Pointing them down makes a very noticeable difference in sound level to the meter (although not much change to the occupants in the car).


I saw that in your build. Kudos to taking the intiative to solve that problem. I understand the physics of audio pretty well, but I am not a TIG welder (I really want stainless steel for this). I could design mufflers with low back pressure and be very good at damping audio, but have no way to make them.

I am going to try the GasN side pipes as I have heard they are quieter than the FF5 pipes. I'll see how that sounds. If it is not good enough, then I'll design a set and hire a TIG welder to make them.

It is hard to get away from wanting the dual side pipes. They are just such a design cue for the Daytona Coupe.

[Logan]

https://www.youtube.com/watch?v=cjlQjmCppB8

Autocross video from this weekend ^^^, so you can get an idea of the sound inside the car with no doors, windows, hood, etc. There is also a video of the car on the dyno on my YouTube channel, but being inside a building the audio is not very useful for real-world comparisons.

I actually prefer the look of dual-pipes better than a big single pipe too. In fact, this set I built was intended to be a rapid solution to an immediate problem, and long term I plan to build a set of dual-pipes that look like the original FFR set. By the way, I put a spool of stainless wire in my MIG welder to build these...I do not have a TIG welder (yet).

[Skuzzy]

I should clarify. I own a nice Hobart MIG welding machine. I hire a kid from across the street who is a wiz at welding. I cannot weld due to a problem with my eyesight. It takes minutes for my eyes to adjust to sudden changes in lighting. I am the guy who goes to a movie and stands off to the side, for a few minutes, waiting for my eyes to adjust well enough to get to a seat. Birth defect and has gotten worse with age.

I am working on a welding helmet using a CMOS sensor which will allow me to finally see what I am doing when welding. Right now, all I see is the spark, nothing else. No puddle, nothing, just the spark. CMOS sensors cannot transmit the damaging wavelengths of light from the spark. It just shows up as a white dot. The CMOS sensor would be damaged over time, but they are fairly inexpensive to replace.

[dstelter]

Hey Skuzzy. Im out northeast of Austin, small town called Paige. #342. cool. just wondering how many have are out there since mine. Mine was a 2 yr plan but with delays it will be 3 years. Good luck. Doug.

[Skuzzy]

Hey Skuzzy. Im out northeast of Austin, small town called Paige. #342. cool. just wondering how many have are out there since mine. Mine was a 2 yr plan but with delays it will be 3 years. Good luck. Doug.

Being retired allows me to work on it every day. While I would like to be done in a year, I figure 18 months is more realistic, given some of the custom work I want to do to it (mostly interior).

Good luck with yours! When we are done, we can get together and trade horror stories. :)

[Skuzzy]

Finished the inventory on the boxes today. A few missing parts, nothing outrageous. Screws, nuts, and bolts, mostly. Took a moment to take the standard seat out of the box, place it in the car, and sit in it. Wow! Okay, I was really surprised by how much room there is. I am 6'3" tall, 35" inseam and weigh 210 pounds and I had a good 3" of head room with my legs stretched straight out. Now that 3" is to the ceiling. Add a headliner or any insulation and that number diminishes.

Foot box space is at a premium with my size 12 shoes. I am definitely adding cruise control. Having to hold my leg up on the accelerator for a long period of time would be painful. I actually found the default seats to be comfortable. They need to be tilted back a bit, but I was surprised at how comfortable they are.

Now, getting in and out is as hard as everyone has said it would be. The door opening is very small making it really hard it you are tall. The sill height is huge.

The other issue I see coming at me is the shifter location. I know about where it will come up through the tunnel, and it looks like I will hit the back wall with the 1-2 or 3-4 shifts with my elbow. Definitely going with an electrically activated e-brake. I cannot see getting enough leverage on a manual e-brake handle due to how high the tunnel floor is.

Tomorrow the body comes off with the rest of the aluminum panels. Yes, I know it is Thanksgiving. Where do you think I am going to get the extra hands needed to get the body off? :)

I hope all of you, who are celebrating the holiday, have a safe and Happy Thanksgiving.

Inventory completed. Missing parts list generated and submitted to FFR.

Overall it went well. Aside from the one parts box which was filled with parts for other boxes, there was the occasional, "wtf?" moment when something was listed in the inventory which I could not identify. For those times, I relied on the process of elimination to discover what part they were referring to.

[Suzie coupe]

I find it interesting you think this is a reasonable daily driver which will somehow save you money vs having two cars. It’s hard to beat having a ****box at your disposal which can be left at the airport, in the rain, snow, sun, etc. I admire the spirit especially at your age, but let’s be real these cars are not daily drivers hahah. But, I’m not here to slow your roll, just wanted to point out that the money saved by having two cars will pay off in the long run. I’m currently shopping for a Mazda to be my daily. You can pick them up in great shape with low miles for like 5k$ and take the pressure off the Daytona when it needs to be laid up for mods or weather. Just a thought. Carry on.

[cgundermann]

Well talked about, but getting in & out is made easier with the Daytona by having the steering wheel removable. Did this with my roadster and I like the freed up space. Have the 3D printed jig to do the mod if you so desire.

Chris

[Skuzzy]

I find it interesting you think this is a reasonable daily driver which will somehow save you money vs having two cars. It’s hard to beat having a ****box at your disposal which can be left at the airport, in the rain, snow, sun, etc. I admire the spirit especially at your age, but let’s be real these cars are not daily drivers hahah. But, I’m not here to slow your roll, just wanted to point out that the money saved by having two cars will pay off in the long run. I’m currently shopping for a Mazda to be my daily. You can pick them up in great shape with low miles for like 5k$ and take the pressure off the Daytona when it needs to be laid up for mods or weather. Just a thought. Carry on.

I never said I thought it was a reasonable daily driver. I think it is nuts. Being retired, I have no place I have to be unless I want to be there. If the car is down for upgrades/overhauls, then I am a happy camper because I can be in the garage working on it. As far as weather goes, I never drive in the ice/snow. Rain may slow me down, but it will not stop me. Weather[-proofing this car will be a challenge. I look forward to it.

I roll my way, you roll your way. It's all good. For me, I am not one to let challenges stand in my way. Never have been. Each time someone tells me I cannot or should not use this car as a daily driver it just strengthens my resolve.

EDIT: Now that all sounded nothing like what I wanted it to. Allow me a different tack. How many people have tried to make this car a daily driver? Of those who did, was a success or a failure? If it was a failure, then what was the nature of the failure? If it was a success, then what contributed to the success?
Are you of the mindset that one cannot correct whatever it is which makes it unsuitable as a daily driver? If so, please elaborate.



Well talked about, but getting in & out is made easier with the Daytona by having the steering wheel removable. Did this with my roadster and I like the freed up space. Have the 3D printed jig to do the mod if you so desire.

Chris

I am looking at putting in a tilt wheel. However, right now there is no wheel in the car and it is quite a challenge. Squeezing through the door opening, when you are tall, is interesting. It will get better once the car is on the ground and off the jack stands,...I hope. :)

[J R Jones]

I find it interesting you think this is a reasonable daily driver which will somehow save you money vs having two cars. It’s hard to beat having a ****box at your disposal which can be left at the airport, in the rain, snow, sun, etc. I admire the spirit especially at your age, but let’s be real these cars are not daily drivers hahah. But, I’m not here to slow your roll, just wanted to point out that the money saved by having two cars will pay off in the long run. I’m currently shopping for a Mazda to be my daily. You can pick them up in great shape with low miles for like 5k$ and take the pressure off the Daytona when it needs to be laid up for mods or weather. Just a thought. Carry on.

Su Cou, we are on the same page here, I too am pragmatic about my rolling stock. I have an exotic sport coupe for summer only. My wife has a mid-size high end SUV for shopping and her shoes. In the park-off is a mid-size 4X4 pick up for big stuff and nasty stuff, and winter.
A caveat based on my observation here is that many kit cars get built and quickly sold, perhaps due to builder remorse. They are not great daily drivers, and the reasons are not just spatial. Ambition often creates performance that is difficult to handle and uncomfortable in several ways. (ergonomics, HVAC, noise, burned legs on egress) Creativity results in complexity that would cause Mr Goodwrench to ROFL, but not assist at any cost. That too reduces resale value to knowledgeable shoppers.
jim

[Skuzzy]

EDIT: I am editing this post to answer the concerns about making this car a daily driver, as I really want my build log to have a different vibe to it.

The first thing anyone should ask or know about themselves is, what constitutes a daily driver. It is different for different people. Some people want the car to drive itself, some want to be driven by others, some do not mind driving but expect a level of comfort and so on. There are as many types of drivers as there are models of cars to drive all with varying degrees of desires for what any vehicle will provide them.

Me, I grew up around race cars. My Dad and a friend of his would reserve track time to race each other every three months. The time between races would be time spent finding a way to beat the other guy. They raced their daily drivers. By the time I graduated form high school, I owned three cars (I paid for all of them), a 68 Falcon Station Wagon, a 67 Mustang Fastback, and a 69 Road Runner. None of them were stock. None had a/c or power steering or brakes. All were very quick. The Mustang was the biggest handful. The 289 barely idled at 2K RPM, and did not make enough power to get out of its own way until 3K RPM. It lived between 3.5K and 8K RPM. I drove that car for seven years and racked up 90,000 miles on it. Yes, it was rebuilt a couple of times.

My Wife, currently, has a Lexus RC350. A very competent car. Does most everything pretty well. Comfortable, quiet, relatively quick, competent handling, and mindnumbingly (Yes, I know it is not a word, but let's start a trend) boring to drive. It is a nice, well thought out, appliance.

A good daily driver, for me, is difficult to drive. You have to think about launching it. You have to stir the gear box to keep the engine happy while not breaking every law in the book. It is rough around the edges, noisy, raucous, and just down right nasty to ride in. That is the car that will make me smile each time I fire the engine up. I love to drive and not be driven.

That said, there are some things I like just because they allow a higher level of concentration on driving. A/C is a good thing. I am old and not as hearty as I once was. Cruise control for those long runs on the expressway/freeway. Keeps my legs relaxed. Self-dimming rear view mirror keeps my eye strain to a minimum at night.

So, yes, there are some things I like in modern cars. I got older and so my tastes changed. The one which has not changed. The smile from knowing I am in charge and what happens next is completely up to me as long as me and the car are in sync.

I hope that clarifies things as it pertains to what I mean when I say, "daily driver".

[Skuzzy]

So, back to building.

Removing the body from the frame was not too much trouble. The hood came right off. The body was captured in three places, after removing the 4 screws holding it down for shipping. While trying to spread the pontoons out, and rotate while lifting, there were two pieces of the interior aluminum which held the body from being easily released. Once we got passed those, there was something in the rear holding it down.

I gave it a hearty tug and it popped free. A bit concerned about getting it back on, but that will come later. No room to put the body in the garage, so it is sitting outside, at the moment.

Once the body was off, I went to work marking all the aluminum pieces with an ID and also placings arrows to indicate which edges went under which pieces.
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(still cannot get the image to be inline, even after shrinking to 1920 wide)

During the process of removing the body and aluminum panels I took the time to look around and see what it would take to isolate the passenger compartment from the outside world. I noted how much headroom I have so I know how much insulation I can place in the roof. I noted the space for my feet. It is a bit snug and requires further investigation once I get some more of the bits in place.

The steering wheel location is a bit close for my comfort. Looking at how that can be altered. All these things, and more need to be looked at and thought about if I am going to succeed in making this a daily driver.

While rooting around in the frame, I marked where I need to spend some time grinding the welds of the frame to help with the fit the aluminum panels.

I took a bright light and made note of areas of the body where there was no fiberglass. Virtually all those spots were at parting seams. I'll go back and add fiberglass to strengthen those areas.
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You will note I did not get the frame powder coated from FFR. I am not a big fan of the satin powder coat and will take care of that myself. I would have ground a good bit of it off anyway. Some of the welds were already ground, but some are untouched. I'll hit all the welds and clean them up a bit.

I also need to tear apart the engine to replace the pistons and camshaft. Get that assembly rebalanced. Get the pumpkin over to the differential shop to get the gearset changed to 3.31 and add the Eaton Trutrac.

Lots to do, lots to do.

[Skuzzy]

Things are moving slowly. Spending time getting all the measurements of the frame so I can do "what if's" on the computer. One thing I am going to note.

During the inventory days the body of the car was in the garage. The out-gassing was significantly higher than I expected. Last week, after I removed the body and panels from the frame, I stored the body outside. It has been two weeks since I get the kit and the out-gassing is still pretty significant.

Anyone have a feel for how long it takes to diminish to acceptable levels (yes, I know,..subjective)?

[edwardb]

Things are moving slowly. Spending time getting all the measurements of the frame so I can do "what if's" on the computer. One thing I am going to note.

During the inventory days the body of the car was in the garage. The out-gassing was significantly higher than I expected. Last week, after I removed the body and panels from the frame, I stored the body outside. It has been two weeks since I get the kit and the out-gassing is still pretty significant.

Anyone have a feel for how long it takes to diminish to acceptable levels (yes, I know,..subjective)?

Assume you're talking about resin related fumes? Through multiple builds, I've never encountered that. Maybe because the main bodies are typically molded well in advance? There have been pictures posted in the past of multiple bodies lined up outside at Factory Five. Don't know if that's typical though. But even the smaller parts they mold in house I don't know how long they sit around before delivery. And I've never noticed any fumes from them either. Only thing I can think of is several here and on Facebook have commented about recent Coupe deliveries and looks like Factory Five has modded the mold to address some of the issues earlier ones had. (Like mine...) Maybe you just got a really fresh one. Bottom line, I don't think it's typical. Alternate theory, you have an exceptionally sensitive sense of smell. :p

[Skuzzy]

Assume you're talking about resin related fumes? Through multiple builds, I've never encountered that. Maybe because the main bodies are typically molded well in advance? There have been pictures posted in the past of multiple bodies lined up outside at Factory Five. Don't know if that's typical though. But even the smaller parts they mold in house I don't know how long they sit around before delivery. And I've never noticed any fumes from them either. Only thing I can think of is several here and on Facebook have commented about recent Coupe deliveries and looks like Factory Five has modded the mold to address some of the issues earlier ones had. (Like mine...) Maybe you just got a really fresh one. Bottom line, I don't think it's typical. Alternate theory, you have an exceptionally sensitive sense of smell. :p

Actually, my sense of smell is pretty poor. I forgot to turn on my exhaust fan one day during inventory and got a bit woozy (doors were closed due to weather). The Wife walks in and she backed out asking how I could breathe in there.

I know the hood came from a fairly new mold. The body seems to be from an older mold. Must have shipped right from the mold. I am glad they are outside, under tarps. They will have time to outgas to acceptable levels.

[Skuzzy]

Okay, I did some homework and found most people familiar with vinylester resins agree it takes about two weeks for the styrene (the chemical which causes the smell) to dissipate from the molded product. It depends on the temperature and humidity post removal from the mold. With the moderate temperatures we have been having and the high humidity, it could take a bit more time.

Not a bad thing as it is going to be a bit before I am ready to do much with the body.

[FracAG1980]

Skuzzy,

While the body is releasing gases from the chemicals used to make it, is the physical nature of the material changing at all? Is it becoming stiffer, less pliable? Is it more critical how you store the body while it is outgassing?

I'm expecting mine just after the first of the year.

Thanks, FracAG1980 (Steve)

[Skuzzy]

Skuzzy,

While the body is releasing gases from the chemicals used to make it, is the physical nature of the material changing at all? Is it becoming stiffer, less pliable? Is it more critical how you store the body while it is outgassing?

I'm expecting mine just after the first of the year.

Thanks, FracAG1980 (Steve)

There is a risk of the body becoming more brittle if it cures too fast. Heat will cure it faster. Long, slow cure times are best. Just shade it from UV exposure (I have some UV blocking tarps) while still allowing air to flow around the parts.

There really is not much risk of damage. Curing it faster requires heat in excess of 110F. UV damage takes several hundred hours, of intense exposure, to hurt it.

I am leaving my body outside for the duration of the build. It could be out there for a year. You really do not want to be breathing that gas.