Sturdy Roadster Build

[sam_sturdy]

Introduction to the Sturdy Roadster Build
My name is Sam and my father (Dave) and I will be building a mk4 starting in 2 days.

Little background on us. My dad (65) has been around fabrication/carpentry/electronics/fiberglass his entire life and works for an engine company (the big C) while also running a bus wash company. He raced in the late 70s/early 80s in Canada and then did a season in Formula 3 in England (co-built his car). I am a full time college student (18) and go to school close to home so working on the car over spring break, weekends, and summer is the plan. I have been working for his construction business since I've been 8 (not child labor) and have also done a lot of carpentry projects/shingling/boat restoration/time with tools, etc. I have been working as an assembler at a hardware store for 3.5 years and have put a lot of those profits towards my share of the car.

My dad and I share an obsession with boats, so we spend most of the summers wrenching away at his 1980 Magnum and my 1977 Donzi Hornet. This has given me a ton of confidence in the build along with cram-studying the forums for the past 7 months. I probably could have built a car by now with how much time I've spent on here and can't offer enough thanks to those that help and share their experience.

We are doing the body work and paint (or I should say my dad mostly) since he considers fiberglass his "fancy" after he has spent thousands of hours repairing and building hulls.

I am incredibly grateful to be having this experience at such a young age and am thankful my dad enjoys loud engines and fast cars as much as I do.


Anyway, here is the build roughly, some things subject to change

From Factory Five:
Complete kit
IRS
Wilwood Brakes
Power Steering
Dual Rollbar
Carbon Fiber Dash
Vintage Guages
Standard Vinyl Seats
17" Halibrands
Hydraulic Clutch
Bare pipes

Drivetrain:
BPE 302 w/ T5

Mods/Aftermarket:
Replica Parts (Mike Everson): Radiator Aluminum, Steering Wheel Bezel, Roll Bar Trim, License Plate Bracket
Herb Fraser Door Cards
Breeze Radiator Supports
Footbox Vents
Cobra Engine Dress-Up Kit
Brake Bias Adjuster + Tilton Coupler
edwardb (Paul B.) E-Brake Mod
Many more non-vendor parts and many more micro-mods

Still debating (how many times more can we blow the budget?):
Mike Forte Mechanical Throttle Linkage (bought)
Boig Cool Tubes

Paint:
Guardsman Blue and Wimbledon White

I live in Scituate, Massachusetts, so I have Replica Parts, Breeze, Forte, the new manufacturer of Boig, and Factory Five all under an hour from me. Thanks to EVERYONE once again because I would be clueless without you all, let the build begin!
I am also running an Instagram page that will have more frequent posts: @sturdy_cobra_build

https://thefactoryfiveforum.com/attachment.php?attachmentid=163658&d=1646850700
https://thefactoryfiveforum.com/attachment.php?attachmentid=163648&d=1646840654
https://thefactoryfiveforum.com/attachment.php?attachmentid=163657&d=1646850700

[zee]

Congratulations, seems like it'll be an amazing build!


I live in Scituate, Massachusetts, so I have Replica Parts, Breeze, Forte, the new manufacturer of Boig, and Factory Five all under an hour from me.

Now I hate you :)

[Theshandman]

Can't wait to see the build progress. If its anything like that fabulous woodwork, it will be amazing sure enough!

[Ray from Long Island]

Sam & Dave,
Best of luck with the project! You have certainly picked the right company & the right "bling" :)
Ray

[Tooth]

I'm in MA as well. But, my kit doesn't come until the summer. What are you putting in for power?

[sam_sturdy]

Blueprint 302 carb with a T5, keeping it nice and simple for now. Will add that to the post above but I think it disappeared for some reason. Is this just on my end?

[txboiler]

Blueprint 302 carb with a T5, keeping it nice and simple for now. Will add that to the post above but I think it disappeared for some reason. Is this just on my end?

I don’t see the original post

[bil1024]

Nice plan! Have fun and welcome to the family!

[JohnnyB]

Can't wait to see the build progress. If its anything like that fabulous woodwork, it will be amazing sure enough!

Seriously, If the workmanship on the body buck and chassis dolly are any indication you are going to end up with a beautiful car. Enjoy the build and the time with your dad.

[cob427sc]

Ditto on the body buck! Most people either give these away (or throw then away) after the build. Yours should be converted into a piece of furniture. Good luck on the project and there are lots of us around in eastern Mass if you need assistance.

[Windsor]

Blueprint 302 carb with a T5, keeping it nice and simple for now.

Did BPE give you the option of adding EFI? (Or was that not even on your radar)

302 with T5 is what I'm considering.

[Springsyeti]

Congratulations. Ours kit is coming the first week of April.

[sam_sturdy]

I haven’t heard that they offer EFI from their factory. I talked with Mike D. at Factory Five and he said the option for EFI on a 302 was telling Blueprint your plan and they will leave the carburetor off and refund that chunk of money. Looks like BPE still only offers EFI from the 306 and up

[rthomas98]

BPE does offer EFI on the 302 you just need to ask. I decided not to do it. last year when I ordered my 302 it was a $900 option. But you had to talk to them to get it. Also as an FYI you can change the paint also. I went with black instead of blue on mine.

[CraigS]

Looks like a great plan to me. One comment is move the Forte throttle linkage out of the 'Still debating' list and into the 'mods' list. It is really, really worth the $.

[Theshandman]

BPE does offer EFI on the 302 you just need to ask.

That’s right. When I ordered the 302 (347) from BPE last summer, I requested the FI option. Stephanie there got it done.

[sam_sturdy]

Just stopped by Forte’s and picked it up so one less item to ponder. Just needed a little boost to pull the trigger I guess

[sam_sturdy]

Delivery Day of Chassis 10325

My dad and I picked the kit up at the end of the day on Friday (3/11). The entire process was extremely easy and very uneventful. We put the frame on top of blankets on the trailer, and that became an adventure once home. After 2 hours getting it off the trailer, we began inventory and discovered what was on the POL list. The list is 38 lines long and includes some important things like the IRS center section, front upper arms/ball joints, wheels, and fuel tank. I was told at Factory Five that most parts would be in relatively soon and the parts situation is getting much better.

https://thefactoryfiveforum.com/attachment.php?attachmentid=163848&d=1647113390
https://thefactoryfiveforum.com/attachment.php?attachmentid=163849&d=1647113409

We soon got to the inventory and left the car outside for the night until inventory was complete. We took around 4 hours to complete it and were done by 10 Saturday morning. Some of the missing parts marked as packed are springs, pedal box, accelerator pedal, and master cylinders. Seems like large items to miss but still plenty to begin working on in the meantime.

https://thefactoryfiveforum.com/attachment.php?attachmentid=163850&d=1647113422
https://thefactoryfiveforum.com/attachment.php?attachmentid=163851&d=1647113440

Later in the morning after inventory and a dump run we got the body off the frame and put it in its position. Now the drilling begins!

https://thefactoryfiveforum.com/attachment.php?attachmentid=163852&d=1647113463

[egchewy79]

Looks like you're off to a good start. My brother-in-law is from Scituate, so I've been there a few times in summer. Must be nice to be so close to all the vendors.

[BadAsp427]

Congratulations... you seem to have a great grasp on your plans... I see you are not 100% on the mechanical carb linkage... I'd like to throw the suggestion out that you will NOT be sorry if you go that way. I started with the factory cable option... then while I had the engine out for some warranty work, I put in my own mechanical linkage and LOVE it... I'm so glad I made the change... Here is a link to my build thread page for the linkage and parts that I used. CLICK HERE (https://thefactoryfiveforum.com/showthread.php?29472-Carl-s-20th-Anniversary-8690-Graduated-12-000-miles&p=393511&viewfull=1#post393511)

[Ted G]

Hey Sam! Looks like a good build and you and I have the same completion date (3/12/22), so we will have very close numbers I'm sure! Unfortunately, I have to wait two or three weeks for delivery here on the west coast.

Good luck and I will sure follow along with your build. Here is a pic of mine in the cradle:

163945

Ted

[JeffP]

Congrats! I was just in your shoes a week ago. Your MIK list sounds as bad as mine. Sadly I think I got everything you're missing but I'm missing a bunch of different stuff - Transmission bracket? Quick jacks? you would think it would at least be consistent:)

I'm sure we'll be running pretty close and look forward to watching your build.

[sam_sturdy]

I have the all transmission parts and all quick jacks. Really would like the pedal box (non-POL) at least to finish up the driver's foot box. I kept re-reading your posts a few days before my delivery to try to guess what the inventory situation looked like. Keep up the updates!

[sam_sturdy]

Day 5 Update

The past five days have been almost non-stop working in anticipation of going back to school next week. I'm having too much fun on the kit so far besides the panel drilling and have put in around 62 hours total. I have been working as in-order as possible but have now been skipping everywhere and putting in bolts where I'm waiting on parts. Several more days left and my engine order shipment got moved from May to this week so that should be very exciting. anyway, here's where the build is currently:

Since the IRS center section is on the POL, I can't complete the rear suspension, but I have done as much as I can without getting in the way of that install for later. I had some small gaps between the bushings and tabs for the control arms and added some .04" washers in to prevent any wiggle once there is weight on the assembly. Most likely overkill, but it can't hurt.

https://thefactoryfiveforum.com/attachment.php?attachmentid=164056&d=1647491461

I fitted and drilled the driver and passenger side foot boxes on Sunday despite not having the pedal box. I installed the passenger side mostly with ease and will be going back later to do a final seal of all gaps later. I used Sharkhide on every panel that would not be in contact with the carpet and so far it seems great. They recommend using diaper cloths to apply, but I noticed little pieces of fuzz come off after coming in contact with rivet holes or edges, so I resorted to paint-prep wipes from DeVilbiss. The fuzz does not come off of the panels so these wipes have worked well.

https://thefactoryfiveforum.com/attachment.php?attachmentid=164058&d=1647491461

It had to be done at some point, so I tackled all of the aluminum for the car over the next three days. I had to bend a few of the pieces for better fitment, but overall went well. Only had two harbor freight drill bits break, so I'd consider that alright. The passenger floor got riveted in as I can work around all of the other assemblies with it installed. Everything else is just drilled and clecoed in place for now or off of the frame.

https://thefactoryfiveforum.com/attachment.php?attachmentid=164054&d=1647491461

The largest research area in anticipation of the build has got to be the e-brake handle/cable connection. I mostly copied edwardb's solution but used a different clevis. I planned to modify it to match the Lokar stock part since it isn't sold any longer separately, but all seems okay for now. I used some nylon spacers where the stock FFR parts would normally be to get it closer to the transmission and more inline with the pulleys further back.

https://thefactoryfiveforum.com/attachment.php?attachmentid=164055&d=1647491461

Skipping around a little more, I installed as much front suspension as I have, steering rack minus the bushings, steering components, horns, and the beginning of the front brake components.

https://thefactoryfiveforum.com/attachment.php?attachmentid=164057&d=1647491461

Tomorrow will probably be a day of planning in terms of what's next while I wait for missing and POL parts. The garage needs a little space made for the engine as it waits for its time to be installed. The countless hours of research seems to be paying off so far and has gotten me through everything with confidence as of now. Looking what I have left, maybe harness is next. Should be fun

[zee]

All of that in 5 days???

Amazing!

[Ted G]

Nice Job!

[sam_sturdy]

One Month Update

After being away at school for the past few weeks, I finally got back to working on the car. Everything I have has been started so now I just need to tie up loose ends to some minor/major extent. The front suspension is as complete as it can be, fuel line run, all panels drilled, electrical run, pedal box complete, radiator fitted, and some more little details. I finally got my center section in yesterday and installed it after using a ream to enlarge the holes.
Next challenge was dropping the engine. I was waiting on my slave cylinder and had to modify the bracket to fit in the bell housing. Same cylinder as most use, just different bracket. I have it all adjusted with a little play as the clutch wears.

The engine leveler did not end up working out great so we used some force getting the transmission through with a lifting plate. No issues besides forgetting to put the adapter plate on the transmission mount at first, but all sorted out now. The driveshaft install was interesting to say the least, but I now know how to take one apart at least. Waiting on a coil to begin wiring the engine next.

https://thefactoryfiveforum.com/attachment.php?attachmentid=165313&d=1649642316

https://thefactoryfiveforum.com/attachment.php?attachmentid=165314&d=1649642344

Still waiting on my Wilwoods and wheels to arrive so I can get the car on wheels.
Has anyone received their brakes ordered through FFR recently?

[sam_sturdy]

Two Month Update

It has been almost two months since delivery day. A lot has come in and we made some changes to the original plans. We decided to switch from the 17" Halibrands to the 15" Halibrands. I am using Gordon Levy's Wilwood brake kit and am going with the pinion parking brake. Those should be in shortly along with the 15" wheels from FFR. Still waiting on a gas tank but may source one myself once I have brakes and wheels. I ordered a blank dash to use in substitute of the carbon fiber until it gets here to keep the project rolling. Here's what the car looks like for now. Going to try to clean up the wiring behind the dash a little and then body work begins.

https://thefactoryfiveforum.com/attachment.php?attachmentid=166287&d=1651804766

Installed the brake bias adjuster from Wildwood with the Tilton part and all seems to be good so far.
https://thefactoryfiveforum.com/attachment.php?attachmentid=166288&d=1651804766

We installed Forte's linkage above the tube and added this stainless bracket with tapped holes into the frame to eliminate flex in the firewall. I would probably go through the frame if I were to do it again to avoid height issues in the footbox.
https://thefactoryfiveforum.com/attachment.php?attachmentid=166290&d=1651804766

I finalized all engine connections minus power steering a few weeks back and also installed the bulkhead battery cables which I think look great.
https://thefactoryfiveforum.com/attachment.php?attachmentid=166289&d=1651804766

And finally we have begun constructing the paint booth. It is 13x20 so it will be a little tight when walking around while spraying but should be fine. Pictured behind is our crush car thanks to Massachusetts. It is a 1969 Buick LeSabre and runs and drives minus brakes. Found on the Cape from someone who has an ERA 289 in the Heritage Museum and a split window Corvette to die for. He had bought it as a crusher for a Factory Five but backed out. Extremely lucky find.
https://thefactoryfiveforum.com/attachment.php?attachmentid=166293&d=1651805552

Hope to have a driving car in time for the open house. More to come.

[Ted G]

Moving fast! WOW !!!!


Looking great. Keep it up!

[JeffP]

I learned yesterday the only access (at least that I could determine) to the windshield bracket bolts are through those very small openings above the footbox. Keep in mind you'll need to reach up through there and over to those two angled holes on the chassis bracket to bolt in the windshield. You can always remove those plates (brake bias and/or fuse panel) to gain access, but just passing along something I'm not looking forward to.

If you're looking for a gas tank they aren't too bad in the grand scheme price wise. I ordered one a while ago. Although, I have more POL items coming today and one is the right size/weight for a fuel tank so they may be shipping them.

here is the correct one on amazon: https://www.amazon.com/gp/product/B000IZ9R06/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

you'll still be missing the cover, which you can also order seperatly, skip it, or just put it on when it eventually arrives from FF (Which i'm planning on)

[sam_sturdy]

I will definitely keep that in mind Jeff. I received the windshield this week and plan to put the body on tomorrow.

I’m curious about the current POL and am afraid I missed the wood steering wheel order this time around. Also expecting side pipes to be in very soon so looking forward the the next few weeks.

[Ted G]

I have apparently 3 POL deliveries on the way. One is definitely the windshield (not really needed for a while), I was told the UCA's are coming, and no clue what the 3rd will be. I'm hoping its the fuel tank or my missing IRS stuff.

[Ted G]

Day 5 Update

The past five days have been almost non-stop working in anticipation of going back to school next week. I'm having too much fun on the kit so far besides the panel drilling and have put in around 62 hours total. I have been working as in-order as possible but have now been skipping everywhere and putting in bolts where I'm waiting on parts. Several more days left and my engine order shipment got moved from May to this week so that should be very exciting. anyway, here's where the build is currently:

Since the IRS center section is on the POL, I can't complete the rear suspension, but I have done as much as I can without getting in the way of that install for later. I had some small gaps between the bushings and tabs for the control arms and added some .04" washers in to prevent any wiggle once there is weight on the assembly. Most likely overkill, but it can't hurt.

https://thefactoryfiveforum.com/attachment.php?attachmentid=164056&d=1647491461

I fitted and drilled the driver and passenger side foot boxes on Sunday despite not having the pedal box. I installed the passenger side mostly with ease and will be going back later to do a final seal of all gaps later. I used Sharkhide on every panel that would not be in contact with the carpet and so far it seems great. They recommend using diaper cloths to apply, but I noticed little pieces of fuzz come off after coming in contact with rivet holes or edges, so I resorted to paint-prep wipes from DeVilbiss. The fuzz does not come off of the panels so these wipes have worked well.

https://thefactoryfiveforum.com/attachment.php?attachmentid=164058&d=1647491461

It had to be done at some point, so I tackled all of the aluminum for the car over the next three days. I had to bend a few of the pieces for better fitment, but overall went well. Only had two harbor freight drill bits break, so I'd consider that alright. The passenger floor got riveted in as I can work around all of the other assemblies with it installed. Everything else is just drilled and clecoed in place for now or off of the frame.

https://thefactoryfiveforum.com/attachment.php?attachmentid=164054&d=1647491461

The largest research area in anticipation of the build has got to be the e-brake handle/cable connection. I mostly copied edwardb's solution but used a different clevis. I planned to modify it to match the Lokar stock part since it isn't sold any longer separately, but all seems okay for now. I used some nylon spacers where the stock FFR parts would normally be to get it closer to the transmission and more inline with the pulleys further back.

https://thefactoryfiveforum.com/attachment.php?attachmentid=164055&d=1647491461

Skipping around a little more, I installed as much front suspension as I have, steering rack minus the bushings, steering components, horns, and the beginning of the front brake components.

https://thefactoryfiveforum.com/attachment.php?attachmentid=164057&d=1647491461

Tomorrow will probably be a day of planning in terms of what's next while I wait for missing and POL parts. The garage needs a little space made for the engine as it waits for its time to be installed. The countless hours of research seems to be paying off so far and has gotten me through everything with confidence as of now. Looking what I have left, maybe harness is next. Should be fun

Just curious where you got that part (cable block?) that attaches to the clevis? Did you have to fabricate that? I'm struggling with my e-brake set up at the moment. I see you mounted both of your L brackets on top and ignored the "notch" of the ratcheted part.

Ted

[sam_sturdy]

Just curious where you got that part (cable block?) that attaches to the clevis? Did you have to fabricate that? I'm struggling with my e-brake set up at the moment. I see you mounted both of your L brackets on top and ignored the "notch" of the ratcheted part.

Ted

The block I think you're referring to is a Lokar part (S-8070) that I'll link below. I'm no longer using this setup since I am changing to a single pinion brake instead of the conventional 1 brake per rear rotor parking brake, but what is pictured worked well.

https://www.speedwaymotors.com/Lokar-S-8070-Parking-Brake-Connector-Block,274778.html

As for mounting the e-brake, I tried several different ways including the way the manual instructed and was not getting the clearance of the aluminum that I wanted. The way I have mounted gave complete clearance and complete travel perfectly. The front L-bracket is below and the rear is on top.

Sam

[sam_sturdy]

Temporary Dashboard Install

While I wait for the carbon fiber dashboard to come in, I bought a blank dash just to keep the project rolling. I picked the dash up yesterday and have full power to everything now. A massive thanks to Dave Lindsay and team for their quickness in getting it to me and in email responses. Now time to clean up behind the dash and hope the brakes are on their way!

https://thefactoryfiveforum.com/attachment.php?attachmentid=166390&d=1651970827

[JeffP]

Nothing too exciting - driver roll bar (wrong one sent), gas shocks for either the hood or trunk, lca’s for a 3 link and some other random stuff. No tank:(

[WILUMD]

"And finally we have begun constructing the paint booth. It is 13x20 so it will be a little tight when walking around while spraying but should be fine. Pictured behind is our crush car thanks to Massachusetts. It is a 1969 Buick LeSabre and runs and drives minus brakes. Found on the Cape from someone who has an ERA 289 in the Heritage Museum and a split window Corvette to die for. He had bought it as a crusher for a Factory Five but backed out. Extremely lucky find."

can you explain "crusher car for Mass"?
I'm probably not going to like the answer :)

[sam_sturdy]

In Massachusetts, if you aren’t using a donor engine or an emission compliant engine, you need to buy a car and send it to the junkyard to get an exemption for your Factory Five. You must find a car with similar or larger engine displacement than what will be in your Factory Five that is pre 1972. The car must have papers and be registered in MA in the past five years for at least one. After you get your car to the inspection station and fail emissions, you will scrap your car, get the junkyard to sign a paper, then bring that paper to a MAC center. From there, an employee will put an emissions exemption on your Factory Five’s VIN forever and you “pass” the emissions test without a complaint engine. Hope that help. I’ll be going through this in 2 weeks so I will go more in depth as some Massachusetts registers things have changed from what other threads state from the past.

[drewr]

In Massachusetts, if you aren’t using a donor engine or an emission compliant engine, you need to buy a car and send it to the junkyard to get an exemption for your Factory Five. You must find a car with similar or larger engine displacement than what will be in your Factory Five that is pre 1972. The car must have papers and be registered in MA in the past five years for at least one. After you get your car to the inspection station and fail emissions, you will scrap your car, get the junkyard to sign a paper, then bring that paper to a MAC center. From there, an employee will put an emissions exemption on your Factory Five’s VIN forever and you “pass” the emissions test without a complaint engine. Hope that help. I’ll be going through this in 2 weeks so I will go more in depth as some Massachusetts registers things have changed from what other threads state from the past.

Wow, that's super interesting. You have to kill one car so another can live.

[sam_sturdy]

Day 107 Update: First Drive

I've not provided many updates for the build but plan to do so detailing my Wilwoods with IRS and 15" Halibrands and some more adventures I took on. After 107 days since delivery and trying to find time between school and a full time job, I got the car to the go-cart stage. Here's a video of the first drive beyond the driveway.

https://www.youtube.com/watch?v=Q_g1lDNU7KE

Big thanks to Mad Dog (Dave L) at Factory Five and his team, Chris (460.465USMC) for the side pipes, and all for the collective knowledge to be able to get the car to this stage in a short manner. Massachusetts VIN inspection is in 10 days so that should be fun. Lots to update on soon.

[Nigel Allen]

Looks and sounds great. Excellent achievement for 107 days. Took me about 3 1/2 years to get to that point.

Cheers,

Nigel

[MB750]

Who's the maker of that slave cylinder for your clutch?

[sam_sturdy]

Who's the maker of that slave cylinder for your clutch?

It’s the same size and make as the one Forte supplies. Here’s the link

https://www.moderndriveline.com/shop/hydraulic-clutch-kits/slave-cylinders/ford-slave/external-hydraulic-slave-kit-t-5-for-94-95-5-0l-94-04-3-8l/

[sam_sturdy]

Wilwoods for 15" Halibrands and IRS

It has been a while since someone posted photos of Levy's brake kit making it possible to have Wilwoods with the 15" Halibrands and IRS. In terms of the knuckle modification, the upper caliper arm gets cut off and a new bracket is installed in its place. Very easy to do but definitely do it before assembling the rear end if possible.

As for the parking brake, I chose to go with the pinion brake. A rotor is added in between the driveshaft and center section and a floating caliper is used shown below.

https://thefactoryfiveforum.com/attachment.php?attachmentid=168791&d=1656553695

https://thefactoryfiveforum.com/attachment.php?attachmentid=168794&d=1656553712

I used a Lokar parking cable that works very well and tapped the frame to accommodate it.

https://thefactoryfiveforum.com/attachment.php?attachmentid=168790&d=1656553695

A lot of extra work to do if you make the change later in the build like us but I think it will definitely be worth it in terms of brake performance.

[sam_sturdy]

Body Work

Dave has been plugging away at the body for several weeks and we are getting a few days away from high build. We are using Awl Grip products for everything besides paint and clear. We are using PPG Deltron base for the Guardsman Blue and Wimbledon White. According to PPG, one of the tints has been discontinued so the color is a little off of what it was several years ago. This is what it looks like out of the can, so praying that it looks the way it does in my head.

https://thefactoryfiveforum.com/attachment.php?attachmentid=168788&d=1656553695

And here's Dave hard at work on the body. We are going to shrink-wrap our building tomorrow and move the body in there to spray primer.

https://thefactoryfiveforum.com/attachment.php?attachmentid=168792&d=1656553695

[sam_sturdy]

Random Updates: Carpeting, Clutch, & Fuel Pump

As we reach the home stretch, I thought I'd point out some of the other things we did that weren't out of the manual or just some things I thought are cool.

When it was time to install the drivetrain, Forte did not have a hydraulic clutch setup in stock so I decided to make my own by modifying a bracket and using the same slave cylinder in his kits. The bracket had to be cut away quite a bit and some reinforcing of the bell housing inside along with trimming the opening back. The setup seems to work very well and is linked a few posts above.

https://thefactoryfiveforum.com/attachment.php?attachmentid=168793&d=1656553712

To my surprise, the Blueprint 302 came with an electrical fuel pump, so we weren't ready to find room for one. We eventually included to put it behind the passenger on a stainless bracket. It doesn't seem too noisy yet and seems clear of everything.

https://thefactoryfiveforum.com/attachment.php?attachmentid=168789&d=1656553695

And lastly for this update is the trunk carpeting. I became obsessed with Papa's carpeting job and went the same approach as he did. The carpeting is typically used for wrapping speakers so it is very workable. I used 3 pieces for the entire trunk with Super 77. I wrapped the service covers as well and think all turned out great. Some minor trimming to do still but there's still some time before the VIN inspection.

https://thefactoryfiveforum.com/attachment.php?attachmentid=168795&d=1656553712

https://thefactoryfiveforum.com/attachment.php?attachmentid=168796&d=1656553712

[Fman]

Congratulations on the 107 day go-kart, wow that is really quick took me seven months and I thought I was moving along at good pace. That e-brake is really unique as well let us know how that works out for you.

Build is looking great, keep it up!

[sam_sturdy]

Painting Begins

https://thefactoryfiveforum.com/attachment.php?attachmentid=168962&d=1656951203

After 113 days from delivery, Dave (my father) began the Awlgrip high build on the body. We have our Massachusetts inspection on Friday and have decided to leave the body in high build after blocking it for the inspection. We would rather not rush the sealer and base coats just to get it glanced at for a few seconds during VIN assignment. We will put the car back together tomorrow and then take everything apart again over the weekend if all goes well. We will get the base on most likely mid next week to try to have it ready for a car show in town that happens once a month.

https://thefactoryfiveforum.com/attachment.php?attachmentid=168963&d=1656951203

I started on the carpeting for the cockpit yesterday and am pleased so far with the progress. Still many spots to touch up but all seems to be good.

https://thefactoryfiveforum.com/attachment.php?attachmentid=168964&d=1656951203

[sam_sturdy]

1 Day Until Massachusetts VIN Inspection

After making the decision not to paint the car before the inspection, I got right to work on finishing an unfinished car. I am glad I did this because there are a few more things I want to tweak before base like exhaust cutouts and another tweak at the doors. I grinned off the entire door striker tab and am going to put a new single piece in instead of FFR's suggestion of adding a piece on top.

https://thefactoryfiveforum.com/attachment.php?attachmentid=169046&d=1657150156

In more good news, I got Cincinnati Insurance to insure the car for an agreed upon value at 4,000 miles a year (not complaining since they're letting a 19 year-old drive it). Power on to Friday morning and I'll pray for the best with the state troopers.

[WILUMD]

Sam,
any update on the inspection?
How did it go?

[sam_sturdy]

I got the VIN with ease and am going to do an updated MA post on registering a car. Currently in line at the RMV to try again at getting a plate after being turned away for not having proof of FFR paying sales to the state. Trying a new registry

[sam_sturdy]

Paint!

Despite having to do almost all body work outside or in a garage with 2 feet on either side, my dad (Dave) has done an incredible job to get a near perfect body. We used AWLGRIP filler, high build, and primer and had great success with all. For the base, we used PPG Deltron and then PPG Shopline for the clear. I'll go more into detail about using AWLGRIP and how to manage painting outside later but I just wanted to do a quick update to show the pre-cut & buff body.

https://thefactoryfiveforum.com/attachment.php?attachmentid=170566&d=1659577759

[CaptB]

Looks awesome.

[CraigS]

I am surprised that more people don't paint outside. Admittedly we were not going for show car but my brother and I painted several cars outside. The last couple I did, I didn't even have a tent like yours. Pushed the car out as soon as it was light onto the grass, did a final tack cloth wipe down and started spraying. The doo on everything keeps dust to a minimum so my biggest problem as a few tiny bugs in the paint. Of course weather is the huge factor so getting up 30 minutes before sunrise to check wind etc was kind a pain on a couple of days. It is nice to be able to paint w/ just a good quality mask and no worries about breathing in chemicals like most diy'ers have.

[sam_sturdy]

The area I am in is in a “severe drought” with fines for using any water so dust was a bit of an issue but we tried to keep the area wet. The tent made it nice to be able to still work on the body on hot days outside. There’s some dirt and a few bugs in the clear but it looks perfect from 10 feet away.