Shawn's First Roadster - Fuel System (Rear Mounted Regulator)

[smccoy]

I have been looking for a project car for quite a while and decided I should go ahead and build the Roadster I have wanted for many years! I love to tinker, fabricate, and wrench on cars so I am really looking forward to this project. My plan is to have a nice cruiser that I will also use for Autocross and maybe a few days at the track in the future. I am in Houston so there are good opportunities to drive all year.

My kit completion date is February 5th and I will be anxiously awaiting the call from Stewart regarding delivery.

For the engine, I will be using a Gen 3 Coyote with TKX and hydraulic clutch. I am 6’3 so have deleted the seats and will be using Kirkey 55 Pro Drag high-back seats. I debated between these and the Kirkey Vintage seats, but the additional support and safety afforded by the high-back won. I am sure some of my choices will change as the build progresses (and some decisions are still up in the air), but I know that this car will be what I am dreaming it will be when done.

From FFR:

Complete Kit
Powder Coating
Body Cutouts
Hydraulic Clutch
IRS
FFR (Speedhut) Gauges
Wind Wings
Sun Visors
Floor Mats
Driver and Passenger Chrome Rollbars
Trunk Struts
Full-Length Coyote Ball Headers
Power Steering
Coyote Install Kit
Front and Rear Swaybars
Heater / Defroster (Even though I am in Texas)
Wipers
Blank Dash


Other:

Russ Thompson Drop Trunk and Turn Signal
Breeze Radiator Mounts and Fan Shroud
Trim Parts from Replica Parts
17X9 and 17X10.5 Bullitt Wheels
Lizard Skin Heat and Sound Insulation
Gas-n Touring Sidepipes
Whatever else I come up with to blow my budget…


I will be using a Gen 3 Coyote with TKX and hydraulic clutch from Forte’s. I am also using Forte’s power steering pump so did not order the full KRC kit from FFR. I already have my engine on order due to the lead time issues for the Control Pack.

Based on EdwardB’s excellent build threads, I have ordered the ProM high flow hanger, Walbro pump, and Trick Flow fuel filter. I have also ordered the Moroso 63806 coolant expansion tank and plan to plumb the Coyote cooling system the way Ford intended.

I’m not set on the paint yet other than knowing it will be red. I’m a fan of the Randy Apple Red series from Painthouse, but we’ll see what I end up choosing…

[JeffP]

Sounds almost identical to my plans, my completion date is 2/26 and I’m getting the same drive train for Forte at the same time. Look forward to following your build!

[smccoy]

I am always working on some project or another and the garage has become quite a mess over the years so my first project was to work on the garage! Along with general clean-up and getting rid of unneeded “stuff”, I added shelving both for the kit components and all the other garage ‘stuff’.
https://thefactoryfiveforum.com/attachment.php?attachmentid=161892&d=1644118837

I have never been in a shop with too much light so added 14 4’ fixtures each with 2 2700 lumen LED tubes. They are individually controllable to have just the right amount of light and to not blind someone that just wants to take out the trash! I also added the ceiling fan which really helps keep the air moving. Oh, and hose and cord reels to make life a bit easier. The camera does NOT do the lighting justice!
https://thefactoryfiveforum.com/attachment.php?attachmentid=161803&d=1644039019

I am fairly well set on tools, but what fun would a project be with no new ones? I have been wanting a drill press and sanding station so built a rolling cart for both so I can move them out of the garage. The casters are total locking and I am surprised by how hard it is to move even hanging on the vise. This table will also hold my bench grinder.
https://thefactoryfiveforum.com/attachment.php?attachmentid=161806&d=1644039019

Even though I have a small compressor, I decided to go with the Milwaukee cordless rivet gun for this build due to convenience and not needing to have a compressor running at night. I also picked up a cordless impact during the Christmas sales for the same reason. I should note that the garage is still a mess in these pictures (and it still a work in progress). I have told myself I MUST have it straightened out before the kit arroves.

[smccoy]

I found a good deal on a rear dropout from a 2021 Mustang with 6000 miles and have already stripped it for the required parts. I was surprised to be able to sell the rest on Marketplace and recover my freight costs. I will probably get the spindles modified and all parts cleaned up and clear coated while waiting for the kit to arrive.

https://thefactoryfiveforum.com/attachment.php?attachmentid=161804&d=1644039019
Having access to a loading dock sure makes life easier!

https://thefactoryfiveforum.com/attachment.php?attachmentid=161805&d=1644039019
The leftovers.

[GoDadGo]

Sounds Like You've Got A Heck Of A Good Plan!
Congratulations & Welcome To The Family!
A Grand Adventure Has Just Begun!

[Jeff Kleiner]

Sounds like you’re well on your way with a good plan! You mentioned Painthouse Randyapple, I just did one for a customer in Randyapple3. :cool:

https://thefactoryfiveforum.com/attachment.php?attachmentid=161894&d=1644148560

I’ll look forward to following along as you build!

Jeff

161894

[smccoy]

Thanks everyone, I can't wait for the build to begin! Jeff, that Randyapple 3 looks great! After seeing it on a car (instead of just a sample), it is currently way up on the list.

[Straversi]

Congratulations and welcome. Looks like you have a solid plan. Have fun!
-Steve

[John Ibele]

Welcome to the forum and congrats on starting in on a great adventure. If you do any aluminum fab whatsoever you'll be stepping up to the sanding station right away. Although I've gotten proficient with the my new jigsaw and a lot of hand tools for taking aluminum cutouts down to a pattern line, that tool is tops on my "wish I'da done that" list. Good luck on delivery day - make sure to post the obligatory picture or two - it's major milestone #2 after placing the order!

[Blitzboy54]

Looks like a great space to build a car. Congratulations and welcome aboard!

[NYMike]

Congrats! Looks like you've got a great build planned. Cant wait to follow along.

[460.465USMC]

Welcome, Shawn! I'm working on a pretty similar set of options on my build, so will be interested to watch yours come together.

Couldn't agree more with you about enough lighting in the garage! I recently upgraded my headlamp, and boy, what a gamechanger! You're making great progress on your garage setup.

Hopefully, you received the highly anticipated Stewart call by now. I think you're going to have a blast with this project!

[smccoy]

While waiting for the call from Stewart, I'm continuing to work on getting the garage in order and amassing parts I know I will need. After looking at numerous builds with the Tangent fog lights, I decided I like the look and will be fabricating something similar so ordered a set of lights from Ebay and am designing the grill / mount for them. I’m kicking around a few other tweaks that I might implement into the build as well. Also, after spending some more time looking at wheels, I think I will be going with FR500s instead of Bullits. There's just something I like about the look.

I got an update from Jegs that my seats are shipping well before the backorder date. I was hoping they would be here before the car so that I can do a quick test fit (and sit complete with making engine sounds) before pulling the body to make sure there aren't any fit issues I will need to address.

Got this picture from Factory Five the other day:
https://thefactoryfiveforum.com/attachment.php?attachmentid=162569&d=1644893839

[WIS89]

Shawn-

Yeah, that picture really gets the heart pumping, doesn't it?

Welcome to the club, and like others have said, I look forward to watching your plan come together! We all love updates and pictures, so feel free to do plenty -- even with engine noises, if you like!

I imagine your delivery will be very soon, so hang in there in the meantime!

Regards,

Steve

[mgk172]

Congrats Shawn! Good plan - excited to follow along on progress.

[Real Time]

You know,
All these cars look the same at this stage.
But I bet when you see one with your name on it, it lights up like a Christmas tree!!

Best of luck with your build Shawn!

George

[smccoy]

I got the call from Stewart Transport this evening. My kit should be loaded My kit should be loaded Monday or Tuesday of next week (3/14 or 3/15) for delivery midway through the next week (around 3/23). Now I just need to get the final touches complete in the garage!

[John Ibele]

Don't forget to hand the photography assignment to someone else during the delivery, so you get a photo record of the experience. 100% guaranteed you'll forget in all the excitement, and you'll need a photo or two in your build thread to prove it happened. Have fun next week!

[Springsyeti]

Following along. Your build will be a few weeks ahead of ours. Congratulations!

[smccoy]

It’s finally delivery time!

My mom came into town the night before to serve as the designated photographer as well as help with inventory, etc after delivery. It was great having extra help with the process.

Al from Stewart showed up first thing Friday morning and despite my worries about living at the end of a winding cul-de-sac, managed to skillfully maneuver his truck right to my driveway. I had been going through back-up plans in my head so this was a great relief! With his help we got the frame on my dolly (that crane sure is handy) and everything in the garage. A quick look at the POL showed that 28 items are still on back-order including some front suspension components (UCAs, springs), PS rack, and miscellaneous parts. There’s plenty of work to do while waiting on these parts so I don’t see any of them as a show stopper. One of the advantages of my kit sitting for a month before pick-up is that 39 items on the POL were fulfilled with the kit.

Before turning around:
https://thefactoryfiveforum.com/attachment.php?attachmentid=164726&d=1648520676
Right in the driveway:
https://thefactoryfiveforum.com/attachment.php?attachmentid=164734&d=1648520697
It fits!
https://thefactoryfiveforum.com/attachment.php?attachmentid=164738&d=1648520737
The cats were unimpressed with the interruption:
https://thefactoryfiveforum.com/attachment.php?attachmentid=164731&d=1648520697

[smccoy]

We started inventory Friday night and finished up on Saturday. There were 23 lines that were either missing or short parts. Factory Five is taking care of these items so no worries there.

With inventory done, we got started removing the body. Even after watching the video several times, this seemed much more daunting than it actually was. We moved the body to the back porch where it will remain until I am ready to re-install it.
https://thefactoryfiveforum.com/attachment.php?attachmentid=164742&d=1648520750

With the body off, I proceeded to mark and remove all of the aluminum panels. As I am going to powder coat all of them, the panels will be fitted and drilled sooner than later.
https://thefactoryfiveforum.com/attachment.php?attachmentid=164743&d=1648520750

[smccoy]

Tonight I fit the F panels. After much experimentation, this is the best fit I was able to come up with that didn’t leave the panel proud of the top of the frame. Hopefully this will be OK and I can always trim something to fit or adjust the panels if that would be better. Again, held with Clecos so I can remove them for powder coating later.

DS:
https://thefactoryfiveforum.com/attachment.php?attachmentid=164775&d=1648608693

https://thefactoryfiveforum.com/attachment.php?attachmentid=164776&d=1648608693

PS:
https://thefactoryfiveforum.com/attachment.php?attachmentid=164777&d=1648608693

https://thefactoryfiveforum.com/attachment.php?attachmentid=164778&d=1648608693

[JB in NOVA]

It’s finally delivery time!

My mom came into town the night before to serve as the designated photographer as well as help with inventory, etc after delivery. It was great having extra help with the process.

Al from Stewart showed up first thing Friday morning and despite my worries about living at the end of a winding cul-de-sac, managed to skillfully maneuver his truck right to my driveway. I had been going through back-up plans in my head so this was a great relief! With his help we got the frame on my dolly (that crane sure is handy) and everything in the garage. A quick look at the POL showed that 28 items are still on back-order including some front suspension components (UCAs, springs), PS rack, and miscellaneous parts. There’s plenty of work to do while waiting on these parts so I don’t see any of them as a show stopper. One of the advantages of my kit sitting for a month before pick-up is that 39 items on the POL were fulfilled with the kit.

Before turning around:
https://thefactoryfiveforum.com/attachment.php?attachmentid=164726&d=1648520676
Right in the driveway:
https://thefactoryfiveforum.com/attachment.php?attachmentid=164734&d=1648520697
It fits!
https://thefactoryfiveforum.com/attachment.php?attachmentid=164738&d=1648520737
The cats were unimpressed with the interruption:
https://thefactoryfiveforum.com/attachment.php?attachmentid=164731&d=1648520697

Oh, Yeah! The day that FFR truck pulled up to my house was a great day. The beginning of an amazing adventure. I look forward to following along with yours.

[GoDadGo]

Now the fun begins so do the following:

1. Make a copy of your inventory sheet.
.....Trust me on this seemingly insignificant task.

2. Place a copy of each sheet on the corresponding box of part.
.....Doing this simple task makes chasing down part easier when you start your build.

3. Do a detailed inventory and determine if any parts are missing.
.....Contact Factory Five about any items that don't seem to be there.

4. Store your parts in a place that is easy to get to and keep them together.
.....I used the living room because my wife is the greatest gal in the world.

5. When you start your build, check off each part used so you know that it is on the car.
.....You need to know what parts you've installed as your build progresses.

Once you complete these tasks, pour yourself your favorite adult beverage and get ready to enjoy the journey of the build.

[JeffP]

I’m curious about your pol as ours was built around the same time. Did you get a fuel tank? Seats? Rims? Pipes? Steering wheel? I seem to be missing all the big stuff you’d think they wouldn’t want to be shipping.

[smccoy]

Now the fun begins so do the following:

1. Make a copy of your inventory sheet.
.....Trust me on this seemingly insignificant task.

2. Place a copy of each sheet on the corresponding box of part.
.....Doing this simple task makes chasing down part easier when you start your build.

3. Do a detailed inventory and determine if any parts are missing.
.....Contact Factory Five about any items that don't seem to be there.

4. Store your parts in a place that is easy to get to and keep them together.
.....I used the living room because my wife is the greatest gal in the world.

5. When you start your build, check off each part used so you know that it is on the car.
.....You need to know what parts you've installed as your build progresses.

Once you complete these tasks, pour yourself your favorite adult beverage and get ready to enjoy the journey of the build.

Thanks for the tips!

I scanned the inventory sheets and tucked the originals away. I've got a printed copy on the workbench to mark parts off on as well. I like the idea of placing a copy on the boxes to help identify contents so will be doing that too. Inventory is done and FFR has shipped at least some of the missing parts according to Fedex. Thankfully, I have a wall of shelves in the garage to dedicate to the build (and everything fit).

[smccoy]

I’m curious about your pol as ours was built around the same time. Did you get a fuel tank? Seats? Rims? Pipes? Steering wheel? I seem to be missing all the big stuff you’d think they wouldn’t want to be shipping.

I did receive my fuel tank, but my pipes, steering wheel, PS rack, etc are all on the POL still. I deleted the seats and did not order rims from FFR so not waiting on those.

[smccoy]

After reading and re-reading the instructions multiple times, I decided it was time to cut down the rear spindles. Using a Sawzall felt a bit too barbaric for my liking so I decided to use a hacksaw instead. Much slower, but much more controlled. Drilling out the holes on both the spindles and center section went smoothly as well. I ended up using a cordless drill with the clutch set to slip if the bit bound and essentially plunged the bit through at high speed. Minimal binding and clean holes. I cleaned the cut edges up on the belt sander and will give the spindles a coat of clear enamel.
https://thefactoryfiveforum.com/attachment.php?attachmentid=164995&d=1649039893

With the IRS components out of the way, I started fitting the cockpit aluminum. I’m just working through each section of panel fitting in the manual sequentially. So far, the firewall, DS footbox front, and most of the PS footbox panels are fitted. Only a few thousand more holes to go!
https://thefactoryfiveforum.com/attachment.php?attachmentid=164997&d=1649039893

[smccoy]

My Coyote kit from Forte’s got delivered to the office on Monday. The weather looked iffy so we stashed it in an open bay and unpacked the crate to make handling the engine at home easier. Mike does a great job stuffing everything into the crate to save freight!

https://thefactoryfiveforum.com/attachment.php?attachmentid=165146&d=1649213932

https://thefactoryfiveforum.com/attachment.php?attachmentid=165147&d=1649213932

Yesterday, the weather outlook was much better so we loaded up the pallet and headed for the house. Honestly, I had worried way too much about unloading the Coyote and moving it into the garage. With a little finagling, it was tucked away until time for install.

https://thefactoryfiveforum.com/attachment.php?attachmentid=165148&d=1649213932

I checked through all the remaining boxes of parts and everything looks to be in order including the Controls Pack. With those tucked away, it’s time to get back to drilling aluminum. In other news, I received my first POL shipment the other day - the power steering rack. Nice to have one more part crossed off the list. I forgot to mention before, but I shipped my steering boss to Russ Thompson last week to get modified for his turn signal kit (I also ordered the drop trunk).

https://thefactoryfiveforum.com/attachment.php?attachmentid=165149&d=1649213932

https://thefactoryfiveforum.com/attachment.php?attachmentid=165150&d=1649213932

[Anonymoose]

Congrats, I’m a few months behind you but looking forward to mine coming in. I’ve been in contact with Mike for my engine and I was curious, how long did it take for you to get your coyote? He was saying the ship dates from Ford have been way off.

[460.465USMC]

Exciting times, Shawn! It's a good feeling to have the drivetrain in your garage.

[smccoy]

Congrats, I’m a few months behind you but looking forward to mine coming in. I’ve been in contact with Mike for my engine and I was curious, how long did it take for you to get your coyote? He was saying the ship dates from Ford have been way off.

I ordered my drivetrain in late December. Mike had everything but the Coyote Controls Pack ready in mid-late March. By a stroke of luck, Mike received a large shipment of Control Packs including mine right before my order was crated. The Control Pack and oil pan seem to be the biggest variables and Ford Racing has been all over the place on their promise dates versus ship dates. With the current supply constraints, I decided it was better to order early and potentially have to store components than to be wishing I had the drivetrain sitting in-house when I am ready for it.

[smccoy]

Very exciting! Knowing that the drivetrain is ready when I am is a great feeling.

[smccoy]

April was a slow month. Between Easter, training for a bike ride, and then the 2-day 180 mile charity ride itself, not a ton got done on the car. I did get most of the remaining cockpit and trunk aluminum fitted. I also laid out and installed my drop trunk. After checking the layout what felt like 100 times, I cut the trunk floor with a jig saw and then cleaned up the edges with both a file and a DA sander to get the final waviness out. Looking at my timesheet, I spent about 8 hours on this project and the additional trunk space will definitely be worth it!.

https://thefactoryfiveforum.com/attachment.php?attachmentid=165926&d=1650940917

https://thefactoryfiveforum.com/attachment.php?attachmentid=165927&d=1650940917

Now that I should have some more weekend and evening time, I hope to get the panel fitment complete, panels removed for powder coating, and move on to the next phase of assembly!

[460.465USMC]

Congrats on the trunk progress. Looking good!

[Fman]

Nice work on the drop trunk! and a belated congratulations on taking delivery of your Roadster. Looking forward to following along your build journey!:cool:

[smccoy]

Thanks everyone! The trunk took some tinkering, but it was totally worth it for the added space! I've been making progress and need to get an update posted soon...

[smccoy]

Long time, no update. Over the last few weeks progress has been made on multiple fronts. The majority of aluminum panels have been fitted and drilled. Of course, the splash guards and nose aluminum will be done later in the process, but it feels good to have finished drilling what feels like 10,000 holes. As I mentioned in a separate thread, I had a bit of an issue with the rear cockpit wall lining up, but was able to do some massaging and got it to line up pretty well.

https://thefactoryfiveforum.com/attachment.php?attachmentid=166941&d=1652841170

I also decided to order the FFmetal firewall forward and transmission tunnel top. These are some SOLID parts. The tunnel top will definitely give a solid feel to one of the often touched areas of the car. With the addition of the firewall forward kit, I can move the heater forward enough to install a glovebox. Now to research the many different glove boxes that have been fabricated on this forum…

https://thefactoryfiveforum.com/attachment.php?attachmentid=166940&d=1652841170

I finished the session by assembling the pedal box and slipping it into place to see how it fit.

https://thefactoryfiveforum.com/attachment.php?attachmentid=166945&d=1652841181

I know I have mentioned powder coating a number of times, but after more debate about the look I wanted, I decided to try brushing a scrap piece of aluminum with 220 grit sandpaper and really liked the look so ordered some Sharkhide and gave it a try. I am happy with the look and ease of application of the Sharkhide so will be proceeding with the brushed look on all visible panels. I will also clean and coat the hidden panels for some additional protection.

https://thefactoryfiveforum.com/attachment.php?attachmentid=167021&d=1653013985

[smccoy]

My front UCAs came in last week so I decided to tackle the suspension after completing the aluminum panels. I was unable to achieve the suggested initial alignment numbers so went ahead and drilled the rear adjuster sleeves. Both cut quickly with a hacksaw and cleaned up with the disc sander. It was a quick change now to prevent additional headache later. I am at a standstill on the front suspension as the bolts for the steering arms are still on my POL (one of what is becoming a short list).

https://thefactoryfiveforum.com/attachment.php?attachmentid=166942&d=1652841170

I also applied a coat of clear enamel to the rear spindles to keep them looking a bit cleaner.

[smccoy]

With the decision to brush and Sharkhide the panels, I still needed to powder coat some additional parts (sway bar brackets, etc) that are raw steel. I had been looking at DIY powder coating for a while so decided to pick up the Harbor Freight coating gun. I was able to find a nearly new wall oven for $50 on Nextdoor so picked that up as well. I had been looking for an oven to use in the shop anyway so this was perfect! Sitting on a dolly, the oven fits perfectly under my main bench and 220V power is available to the right.

https://thefactoryfiveforum.com/attachment.php?attachmentid=167020&d=1653013985

The first parts I coated were the rear sway bar brackets in flat black (HF powder). After some tinkering with compressor settings, etc, I was quite happy with the result. I did miss a spot on one bracket and was able to apply just enough powder to touch it up without making a mess. Also a tiny amount of orange peel on the inside of one. This powder is a bit flatter than the satin that FFR uses, but is a close enough match for misc. brackets.

https://thefactoryfiveforum.com/attachment.php?attachmentid=167135&d=1653269705

https://thefactoryfiveforum.com/attachment.php?attachmentid=167136&d=1653269705

[smccoy]

My uncle came over on Saturday to help with the rear differential. After some head scratching, we ended up using a floor jack to help lift it into rough position and then a ratchet strap to assist in nudging it into the final position. As others have observed, the final fit is TIGHT! Very happy to have that installed! This is definitely one of those jobs that is easier with another set of hands.

https://thefactoryfiveforum.com/attachment.php?attachmentid=167134&d=1653269705

I spent the rest of the weekend working on installing the rear suspension including the powder coating mentioned above. The LCA interface to the spindle was a tight fit and required a bit of adjustment, but everything went together without too much drama. I am short 2 of the LCA bolts (which are coming from FFR), but was able to find some bolts in the parts I removed from the donor IRS that fit to keep everything aligned while I wait.

https://thefactoryfiveforum.com/attachment.php?attachmentid=167138&d=1653269705

https://thefactoryfiveforum.com/attachment.php?attachmentid=167137&d=1653269705

I am planning to upgrade the brake pads to Hawk so need to determine the correct ones and get them on order so I can continue with the rear brakes. The donor rotors look brand new (the car only had 6,000 miles on it) so I will be re-using them as well.

[460.465USMC]

I'm jealous of your full size oven! I've really enjoyed my DIY powder coating. So many smaller, misc parts that look pretty decent after powder coating, not to mention the protection. Looking good. Build on!

[Springsyeti]

It is interesting to see other builds around the same time as ours and what parts were delivered with the kit. Seems you get this and you get this. We have been ordering fasteners from McMaster Carr to keep things moving along.

[smccoy]

I'm jealous of your full size oven! I've really enjoyed my DIY powder coating. So many smaller, misc parts that look pretty decent after powder coating, not to mention the protection. Looking good. Build on!

The full size oven was a great find! I was ready to settle for a toaster for now, but really wanted a bigger oven in the shop for both powder coating and general heating. It's great being able to just coat the random parts I come across that would be better coated!

[smccoy]

It is interesting to see other builds around the same time as ours and what parts were delivered with the kit. Seems you get this and you get this. We have been ordering fasteners from McMaster Carr to keep things moving along.

It really is interesting to see how different kits around the same time are missing different pieces. Mine did sit at FFR for over a month waiting on Stewart to pick it up which did lead to a bunch of POL parts getting shipped with the kit.

[smccoy]

Vacation at the end of May and returning to a garage that is well over 100° when I get home slowed build progress a bit. I have pulled all the aluminum panels, cleaned off the marker lines, and deburred the holes in preparation for eventual brushing and SharkHide application. While working on the panels, I went ahead and drilled for the master disconnect. As I have an extra round filler plate, I drilled it as a reinforcement. The switch really feels solid now.

https://thefactoryfiveforum.com/attachment.php?attachmentid=168595&d=1656123931

[smccoy]

I was reviewing the front sway bar instructions and decided to swap out the shock bolts and get it installed before the front end becomes any more cluttered. I ground the bottom of the bushing mount brackets to clear the welds on the frame and everything seemed to go together fine. I ended up removing the bar this evening to add washers to the back side and exchange the front washers for the ones that come with the bushings (I only found 3 initially as one had escaped from the bag into the bottom of the box). The bar seemed to bind as the bolts were removed and upon further investigation, I found this:

https://thefactoryfiveforum.com/attachment.php?attachmentid=168599&d=1656123931 https://thefactoryfiveforum.com/attachment.php?attachmentid=168597&d=1656123931

While the bar *seemed* to be installed correctly, it was clearly rubbing and the coating got scraped off when I was shifting the bar laterally to get it aligned in the suspension. Certain I did something wrong, I mocked the bar up a second time ensuring that I had the right side as high as it would mount and there is no clearance between the bar and the tie down bracket. The left side has plenty of clearance. Using a tape measure and digital angle finder, it appears that the right hand tie down is bent / welded at a different angle and thus the highest point is almost 3/16" higher on the right hand side. Unfortunately, I'm not sure the best course of action to resolve this and wonder if anyone has any suggestions? Edit: After thinking on this more, it looks like I might be able to grind a small bit of the edge down for clearance and touch up the spot...

Right side:

https://thefactoryfiveforum.com/attachment.php?attachmentid=168596&d=1656123931 https://thefactoryfiveforum.com/attachment.php?attachmentid=168600&d=1656123942


Left side:

https://thefactoryfiveforum.com/attachment.php?attachmentid=168598&d=1656123931 https://thefactoryfiveforum.com/attachment.php?attachmentid=168601&d=1656123942

[GTBradley]

If you don’t think the front sway bar will work you could ask FFR to take it back and use one that fits in a different location. I bought Mike Forte’s and it mounts to the tie down brackets. It’s a basic sway bar like the one you have, but it has the added benefit of being oriented more parallel to the ground, which is a good thing.

[smccoy]

If you don’t think the front sway bar will work you could ask FFR to take it back and use one that fits in a different location. I bought Mike Forte’s and it mounts to the tie down brackets. It’s a basic sway bar like the one you have, but it has the added benefit of being oriented more parallel to the ground, which is a good thing.

Thank you for the reply. For some reason I didn't receive a notification email so it went by the wayside. I went back out the next morning (always a good idea when things aren't fitting) and realized that it was just the very edge of the bracket that was dragging so a quick clean-up with a file and a touch of paint and everything fit as designed. My late-night geometry skills made the problem seem much worse than it was.

[smccoy]

Unfortunately, I seem to have fallen behind on updates for the latter half of the summer. Due to the oppressive temperatures, I seemed to be working on smaller bits and pieces whenever I felt like going out in the heat. I was also adopted by a shop cat who insisted on re-reading the directions before allowing me to accomplish any work (and provide the required ear rubs and treats). Meet Shelby who has since become an indoor cat:

https://thefactoryfiveforum.com/attachment.php?attachmentid=173948&d=1666236705

After resolving the sway bar issues, I proceeded with the steering rack. Nothing too earth shattering here as everything went by the book. I did use the Breeze offset bushings and really liked the adjustability. As of yet, I have not gone through the rack centering procedure so still have that on the list.

As has been suggested, I went ahead and installed the footbox bearing on the inside after grinding the flange for clearance. The two halves of the upper steering shaft would only slide together a few inches before becoming stuck so I spent some time polishing the shaft with emery cloth and Scotchbrite until the fit was smooth. The Russ Thompson turn signal installed as outlined in the directions although I did need to add one additional washer to clear the 2” tube and welds.

https://thefactoryfiveforum.com/attachment.php?attachmentid=173950&d=1666236731

After a small delay (a missing clutch MC which Mike Forte was quick to ship out), I got the pedal box installed. The push rods have been trimmed but not so much to cause issues with travel. I was able to use the included mount for the Coyote DBW pedal after some filing on the pedal body. The provided screws had much too high of a profile and would contact the steering shaft as it was rotated. Replacing them with button head screws provided ample clearance. I was able to align the brake pedal as desired, but I don’t seem to have enough adjustment (especially with the Coyote clutch switch plate) to move the clutch pedal into the same plane. I’m sure I can live with this setup if required, but it would be nice to get it closer to the other pedals for legroom.

https://thefactoryfiveforum.com/attachment.php?attachmentid=173947&d=1666235785

https://thefactoryfiveforum.com/attachment.php?attachmentid=173951&d=1666236731

I also laid out a template for the upper trunk sides. Now I just need to pick up some .040 sheet and get them fabricated. I know it isn’t a necessary addition, but I like the bit of finish it adds. I wouldn’t want anyone to see the square tubing while helping me wedge groceries in the trunk. Ha!

[facultyofmusic]

Definitely test fit the driver foot-well firewall. I found I have to shave quite a bit off of the pedal. Good progress! and Hi Shelby!

[Springsyeti]

Looking good!

[smccoy]

Definitely test fit the driver foot-well firewall. I found I have to shave quite a bit off of the pedal. Good progress! and Hi Shelby!

Thanks for the heads up! I have added that to my to-do list and will be doing a test fit this weekend.

[smccoy]

As I mentioned in my introduction, this Texas Roadster is getting a heater. Maybe I’m soft, but there are plenty of beautiful days to drive that are a little chilly at the beginning or end. My heater did not match the template provided in the manual, but was an exact match for the one that phileas_fogg uploaded HERE (https://thefactoryfiveforum.com/attachment.php?attachmentid=64655&d=1488634667).

https://thefactoryfiveforum.com/attachment.php?attachmentid=174054&d=1666577677

Additionally, I was unimpressed with the use of sheet metal screws to anchor the heater through the firewall. I know it has been used on many builds as-is, but it just felt flimsy to me. After verifying hole positions, I cut two strips of ¾ X ⅛ aluminum bar to just fit inside the heater box. I then drilled and installed 10-32 rivnuts located appropriately for the blower mounts and drilled out the holes on the heater box for clearance.

https://thefactoryfiveforum.com/attachment.php?attachmentid=174056&d=1666577677

The strips were tacked into the heater with a bit of RTV so that there was still a bit of give for assembly. While the RTV was still wet, I tightened the screws and allowed everything to set. Once installed on the firewall, everything is extremely solid. The bottom left screw is nearly impossible to get started so I slotted the blower bracket to allow it to slide onto the screw. I can just reach the head with a stubby ball-end hex wrench so I can still install/remove it.

https://thefactoryfiveforum.com/attachment.php?attachmentid=174055&d=1666577677

I ordered a servo controlled bypass valve from Old Air Products for controlling the flow of coolant. Since I needed a full bypass valve anyway, it wasn’t much more to go electronic and I am working on a control scheme for it to eliminate the need for 2 knobs on the dash. More to come on that.

On the subject of creature comforts, I decided that I wanted some form of stereo on the build. I know this is a hotly debated topic, but I know I will be driving in traffic (this IS Houston after all) and can’t imagine being without some sort of music in those instances. I’m not doing anything super fancy, just 6.5” rear speakers between the seats and 4” below the door, all tied to a Bluetooth receiver with a small control pad. I will likely try to find a way to conceal the control pad too. I might be able to make a new board that is small enough to put the whole thing in an ashtray. We’ll see. The speakers are Polk DB652 and DB402 respectively and the receiver is a Boss MC900B. Bench testing, it is quite loud and sounds fine considering the application. I can always go with an external amplifier if needed.

https://thefactoryfiveforum.com/attachment.php?attachmentid=174058&d=1666577920

I cut the holes under the doors but still need to lay out and cut the ones in the back wall. Incidentally, the aluminum strip on the transmission tunnel is one of the support bars for the heater that I mention above.

https://thefactoryfiveforum.com/attachment.php?attachmentid=174057&d=1666577677

[smccoy]

I have been finishing the exposed side of all panels with Sharkhide. Over two HOT days, I got most of the panels processed and coated. I still have a few left to coat with Sharkhide and a few for bedliner (splash panels, rear cockpit wall in wheel well), but nice to be nearly complete.

https://thefactoryfiveforum.com/attachment.php?attachmentid=174063&d=1666579180

With that done, I permanently installed the passenger footbox and firewall. I really like the Milwaukee rivet tool. It’s really convenient to not drag an air hose behind you.

https://thefactoryfiveforum.com/attachment.php?attachmentid=174059&d=1666579180

I am using the stock 13” rear brakes and kit provided front brakes. For a bit more stopping power, I went ahead and installed Hawk HPS pads before installing the brakes on the car. The part numbers were:
Front: HB274F.610
Rear: HB803F.639

I went ahead and installed the pulleys for Paul’s parking brake cable mod. With the specifies Lokar part no longer available, I will be using a clevis and the Lokar block for my cables. I will document that as it is installed.

https://thefactoryfiveforum.com/attachment.php?attachmentid=174062&d=1666579180

My last MIK items arrived and I was finally able to finish the rear sway bar and suspension. Several of the bolts for the rear LCAs were missing so I had used bolts of the same diameter from the donor IRS pallet as temporary pins to allow construction to continue.

[smccoy]

At this point, I really need to get fuel and brake lines run so they are not impeding future panel work. To begin, I temporarily hung the fuel tank. The front posts required some bending to flear the tank properly, but a large clamp and a mallet made quick work of the problem.

I modified the bracket for the Trick Flow filter and installed it in the same location that many others have used. I also made up the first flex line.

https://thefactoryfiveforum.com/attachment.php?attachmentid=174061&d=1666579180

Mounting the Breeze battery tray was next. I powder coated it black to match the frame but decided to leave the tie rods bare stainless to look more like the rest of the hardware. The Milwaukee river tool had no issues pulling the 3/16 stainless rivets. There is NO way I would have pulled them by hand

https://thefactoryfiveforum.com/attachment.php?attachmentid=174060&d=1666579180

[smccoy]

With the F panels finished, I added 10-32 rivnuts to the rear flange for attaching the elephant ears later. To make alignment easier, I laid out the hole pattern and drilled ⅛” holes in the flange. Then I aligned the elephant ear and used the holes I had drilled to match-drill them. When the time comes, the ⅛ holes can be enlarged as required. I then opened the holes in the F panels to the appropriate size for the rivnuts.

I went to install the F panels and immediately saw the error of my ways. With the upper suspension installed, there was no way to actually reach a number of rivet holes. Thankfully, it was fairly straightforward to remove just the UCA bolts to gain access. With that, I got the F panels riveted, the UCAs re-installed and more torque seal applied. This wasn’t the first thing I have done twice and it sure won’t be the last!

I also cleaned up and installed the front brake line tabs.

https://thefactoryfiveforum.com/attachment.php?attachmentid=174068&d=1666579582

[smccoy]

Whew! These posts have finally caught up with the present!

Over the weekend I tackled the fuel system. Previously, I had installed the tank (temporarily) and fuel filter.

Initially, I routed a supply and return to the engine compartment as described in the manual and was planning to mount the regulator forward.

https://thefactoryfiveforum.com/attachment.php?attachmentid=174140&d=1666665969

With the firewall forward, heater, wipers, etc. there was a lot going on under the hood and I wasn’t thrilled to mount the regulator alongside everything else. I began thinking about mounting it in the back near the tank similar to the Corvette regulator some have used with the Gen 2 Coyote. I stumbled across Paul’s comment in THIS (https://thefactoryfiveforum.com/showthread.php?44293-Fuel-Pressure-Regulator-Location) thread and the wheels started turning. I was able to mount the regulator over the rear suspension. It’s not the most convenient spot in the world, but is accessible from both under the car and through the wheel well. This made for short supply and return lines and now only a single line leading to the engine. Everything is held with ½ cushion clamps.

https://thefactoryfiveforum.com/attachment.php?attachmentid=174065&d=1666579582

https://thefactoryfiveforum.com/attachment.php?attachmentid=174066&d=1666579582

https://thefactoryfiveforum.com/attachment.php?attachmentid=174064&d=1666579582

The plastic mount for the regulator was a temporary 3d printed test piece to verify fitment and has been replaced by aluminum. The line running forward drops slightly under the footbox to allow a gentle bend into the engine compartment. Final routing will be determined when I test fit the Coyote.

https://thefactoryfiveforum.com/attachment.php?attachmentid=174139&d=1666665969

All the lines will be pulled for a pressure test, but it is a huge relief to have this part of the project done. Brake line installation is now underway!

[JohnK]

Nice work. Looks great, and a lot less plumbing to the engine compartment. One small suggestion - I'm assuming you're not going to run a vacuum line to the fuel pressure regulator (not needed, and Lund recommends not to) you should remove the barb fitting and put a filter/breather on that port so the regulator doesn't suck a bunch of debris in through that port. This is what you need:

https://www.summitracing.com/parts/aei-15662?seid=srese1&gclid=Cj0KCQjwteOaBhDuARIsADBqRegh7qv4oUQByAggYD-9HHKLcjFasKjIQRu0grCb7HPLRXs-PxuBaVkaAiZ8EALw_wcB

[smccoy]

Nice work. Looks great, and a lot less plumbing to the engine compartment. One small suggestion - I'm assuming you're not going to run a vacuum line to the fuel pressure regulator (not needed, and Lund recommends not to) you should remove the barb fitting and put a filter/breather on that port so the regulator doesn't suck a bunch of debris in through that port. This is what you need:

https://www.summitracing.com/parts/aei-15662?seid=srese1&gclid=Cj0KCQjwteOaBhDuARIsADBqRegh7qv4oUQByAggYD-9HHKLcjFasKjIQRu0grCb7HPLRXs-PxuBaVkaAiZ8EALw_wcB

Thanks! I really like the simplified lines and reduction in parts under the hood. I actually installed that very same breather in the regulator when I had it out to put in the final aluminum plate.