Matt in MN's Roadster [Archive] - Factory Five Forums

mrglaeser

04-18-2022, 10:04 PM

Probably a little soon to start a build thread, but I'm bit excited. Just ordered a Base kit today, though I guess I could say started the build 3 years ago. I picked up a Foxbody pedal box in early 2019 and refurbed it that summer.

I've been picking up parts ever since. Wish I had ordered the kit and financed it back then with inflation and price increases the interest would have seemed like nothing! Oh well was trying to be responsible and save up a bit first.

Anyway if anyone cares here's my plan. At least until I modify it a 100 times.

-Base Kit
-Mostly New Parts (Some refurbished parts: Mustang Pedal Box and Spindles)
-Small Ford
-347 Shortblock from Ford Performance
-APR 185 Heads
-Trickflow TrackMaxx Cam,
-Trickflow Rockers
-Trickflow roller lifters
-TrickFlow True Roller double Timing chain
-Canton Racing 8qt Oil Pan
-Ford Performance High Volume Oil Pump
-Edelbrock Performer RPM Air-Gap Intake Manifold
-Holley Sniper 4150 Stealth EFI
-Holley HyperSpark Ignition
-LMR Shorty Headers (to be heat wrapped)
-TKX – Five Speed with 0.68:1 Overdrive
-Centerforce II Clutch Kit
-QuickTime Steel Bellhousing
-Cable Activated Clutch(don’t know why just want that feeling)

FFR Upgrades
1.) Powder Coating
2.) Cutouts Performed
3.) Tubular Front Lower Control Arms
4.) Power Steering
5.) Vintage Halibrand Replica Wheels, 17” X 9” Front and 17” X 10.5” Rear
6.) Front Sway bar - Original Plan after much advice I'm removing this from my order
7.) Passenger Side Black Powder-coated Roll-Bar
8.) Center Dash Support - After seeing this at build school decided against
9.) Trunk Gas Strut Kit
10.) Wind Wings
11.) Electrical System Completion Components(Maybe – may buy just the harness and source switches elsewhere)
12.) Moser 8.8 (probably 3.55) - Found a 89 Thunderbird Super Coupe Rear assembly to rebuild - same Gear Ratio

Other Upgrades/Modification
1.) Power Brakes
2.) Driveshaft Safety Loop
3.) Speedhut Gauges (GPS)
4.) Wilwood Brakes Front and Back
5.) Breeze Auto – Offset Powersteering
6.) Breeze Auto – Heavy Duty Radiator Support/Hinges
7.) Forte – Mechanical Throttle Linkage
8.) Forte – Windshield Release Brackets
9.) Oil Cooler
10.) Radiator Removable Protective Mesh
11.) Footbox Vents
12.) Jeg’s Hotrod heater/defroster (more BTUs than FFR for the MN Falls)
13.) Heater Electric Cutoff
14.) Drain holes in footwells with removable plugs
15.) Removable Headrests
16.) Russ Tompson Throttle Pedal
17.) Russ Tompson Dead Pedal
18.) Russ Tompson Pedal Covers
19.) 65 Mustang ignition, lights, and heater knobs (thought I came up with this on my own but just saw a posting using these parts)
20.) Some Kind of under coating
21.) Electric Line Lock
22.) Wheel Well Liners (maybe we’ll have to see once I get started)
23.) Cup holders of some kind
24.) Luggage Rack
25.) Koolmat
26.) Billet Brake Reservoir
27.) Electric Cooling fan(s) – Anyone ever try a contour fan like we do with Fox body and 69/70 Mustangs?
28.) E brake cable routing mod
29.) Side pipe covers

Styling
-Blackout as much chromes as possible
-Black Side pipes & covers (thinking of deleting from kit and ordering GasN Touring Pipes Ceramic Coated Black)
-Midnight Blue pearl, ghost racings stripes
-Tan custom interior
-Quilted Dash and Door Panels
-Contrasting Stitching
-Contrasting door pulls and ‘Oh S4!7!’ handle on the Dash
-Removable Tunnel Cover
-Marine materials to be weather resistant

Not sure when more posts will happen. I'm reading other build blogs daily now myself.
updated: 10/17/2022

165658165659165660

John Ibele

04-19-2022, 09:16 AM

Welcome to the fun! And yes, we care :) Your build plan looks like you've got experience with Mustangs and are unafraid of taking your own path to a distinctive roadster. Good for you. You also already know you'll change your plan at least 100 times before finishing, which puts you way ahead of the curve.

I've noticed that build plans over the past few years have featured a greater emphasis on styling, handling and convenience elements rather than horsepower, torque, and go-fast aspects. I think that's all in the direction of goodness, since its just about a given than any roadster built will have more power than you need for the street, and the styling and convenience items add more driving enjoyment and distinctive looks to these cars. All a lot of words to say ... I think you're focused on the right things. Best wishes for a delivery date that doesn't slip, and short POL! Cheers, John

mrglaeser

04-19-2022, 10:16 AM

mrglaeser

06-07-2022, 10:15 PM

Well - Still waiting for the kit to come next winter. But I'm trying to collect parts as best I can. Trying being the operative word. I ordered a Ford Racing Short Block in March, it we originally scheduled for delivery in April, then May, then June, then later in June, and finally I looked today and 1/12/2023.... more than 6 months from now and 9 months form the original order.

I hope it eventually comes because to reorder it today from someone else will cost another $1200. What a strange time. So I have Heads, Intake, Cam, Timing, Valve Train, Oil Pump, Valve covers, Oil Pan, Harmonic Balancers, Full Sniper Kit, Hyper Spark Ignition, Alternator, accessory serpentine kit, and most the bolt kits. but no block to it all on.

To be clear I'm not actually complaining. I wasn't planning to build it until winter anyway, but it's a sign I'm going to have to do a lot more planning and horse training to get the car built in a reasonable amount of time. I did find another supplier that said they could ship the same short block next week at a similar price (we shall see). So I ordered it. I can always cancel one of the orders or sell the the second one for a profit I guess.

Gizmosrcool

06-08-2022, 06:55 AM

Hi Matt. Welcome. I am in similar situation and have a 9 mont wait. The deal on parts is nuts and the time can be used to source and get the best deals u can. Plus read all the builds to keep it fresh and next thing u know it’s build time. Ur parts list should pop out a great roadster. Look forward to following your build. Tom

mrglaeser

10-16-2022, 08:39 PM

Well I suppose 4 months between posts is long enough right?

Still waiting on my my kit. 4 months to go. But with the holidays coming up I'm sure it will go fast. Still waiting on the engine short block. Still says 1/12/2023. But picking up a bunch of other parts. Got an axel assembly from a 1989 Cougar Souper Coupe (same as a Mustang GT just slightly longer axels). So this winters project will be rebuilding all that. Ordered a 31 Spline kit, install kit (all bearing and seals), and fancy aluminum cover from LMR hoping I can reuse the Ring and Pinion. Got a nice drop of black anodized bezels from Replicar, some cooling components from Breeze, and miscellaneous other bits as well. Also picked up all the components for foot vents using marine fans.

https://photos.smugmug.com/Home/9999-FFR-Roadster/i-tDHzdnk/0/b61a40c7/X3/20221009_154306-X3.jpg (https://mattglaeser.smugmug.com/Home/9999-FFR-Roadster/i-tDHzdnk/A)

Also in September a friend and I took a road trip to Flint to attend MOTT College's FFR Build School. What a hoot. I came away with pages of notes, had a ton of questions answered, and got to play in a shop for 3 full days without any honey-dos or responsibilities. I personally loved the experience. Is it necessary to build an FFR probably not. Most the activities we did I have done before, but it is nice to see the process, even if abbreviated, from start to finish. Just making me want my kit more and more. (I'm on the passenger side my buddy who is 6'8 wedged himself into the driver side).

https://photos.smugmug.com/Home/9999-FFR-Roadster/i-v6Gqsns/0/cfda8411/X3/20220918_165355-X3.jpg (https://mattglaeser.smugmug.com/Home/9999-FFR-Roadster/i-v6Gqsns/A)

Also purchased a shop space with my dad and friend so we can do these projects and take the home garage from our wives. Having it is great. I re-assembled a body buck a local builder gave to me last weekend, and this weekend I built a rolling chassis dolly. Now I need to build a work bench, build a mini paint booth for aluminum panels, and set up a shop press when I start to get at the Axel Dis-assembly/re-assembly.

https://photos.smugmug.com/Home/9999-FFR-Roadster/i-8CfkSrv/0/af24e1e4/X3/20221009_154320-X3.jpg (https://mattglaeser.smugmug.com/Home/9999-FFR-Roadster/i-8CfkSrv/A)
https://photos.smugmug.com/Home/9999-FFR-Roadster/i-MhGC46n/0/94974eae/X3/20221016_131855-X3.jpg (https://mattglaeser.smugmug.com/Home/9999-FFR-Roadster/i-MhGC46n/A)

I guess I also didn't mention that I actually started my first Roadster project 3 years go restoring a Foxbody footbox. But I might take it apart again as my build school instructor offer to lend me a tool to bend the pedals out to make more room for my feet.

https://photos.smugmug.com/Home/9999-FFR-Roadster/i-PkZ4qqB/0/866b9e11/X3/20200418_195357-X3.jpg (https://mattglaeser.smugmug.com/Home/9999-FFR-Roadster/i-PkZ4qqB/A)
https://photos.smugmug.com/Home/9999-FFR-Roadster/i-vcZGh9H/0/9ccb73c7/X3/20200418_195335-X3.jpg (https://mattglaeser.smugmug.com/Home/9999-FFR-Roadster/i-vcZGh9H/A)
https://photos.smugmug.com/Home/9999-FFR-Roadster/i-VnBwrgG/0/05cf7699/X3/20200620_124622-X3.jpg (https://mattglaeser.smugmug.com/Home/9999-FFR-Roadster/i-VnBwrgG/A)

Jeff Kleiner

10-17-2022, 09:25 AM

Mike.Bray

10-17-2022, 10:54 AM

A roadster in Minnesota, sounds like fun! Looks like a very solid plan. I'm far from an expert but happy to throw out a few FWIW comments.

Love the SBF, the Coyote is an amazing engine but I'm old school:)

I had a heck of a time finding a decent 351W block so I ended up just biting the bullet and buying a new aftermarket one. Found it in stock so was able to get it right to the machine shop. Bought a rotating assembly from Scat and made a 393.

You might want to check that 8qt oil pan, I think it's going to hang below the frame rails which is not good.

Everyone says the Ford clutch cable is far superior to the one FFR supplies so you might check it out.

As Jeff says the front sway bar will do more harm than good.

You're putting big Wilwood brakes on a relatively light car. You don't really need power brakes and installing the booster is not an easy job. Size the master cylinders correctly and you won't have any issues stopping other than hitting the steering wheel if you forget to cinch your belts tight.

Check out the seat heaters from Forte. Not very expensive and easy to install.
https://fortesparts.com/product/cobra-seat-heaters-waterproof-regular/

Electric line lock? Sounds like a way to get in trouble lol

You might check out this cooling fan and mate it to the Breeze shroud.
https://www.summitracing.com/parts/FLX-105390
https://breezeautomotive.com/shop/radiator-fan-shroud/

mrglaeser

10-17-2022, 08:47 PM

Missed your thread the firs time around Matt but just checked it out. Sounds like you're working on a solid plan but I'll offer a couple of thoughts.

Skip the front sway bar and put the money that you don't spend on it towards a set off FFR proprietary spindles for 2 reasons. With the standard FFR supplied spring rates the roadster has moderate understeer; if you stiffen the front either via a bar or higher spring rate without a corresponding change to the rear the car will push even worse. Second reason is that the Geometry of the FFR spindles is a great improvement over either Fox or SN95 spindles with the adapter in regards to spindle axis inclination as well as bump steer. The car will drive mush better with this setup and a bonus is that you can then use the 2 piston PBR calipers and larger discs than is possible with Fox and can't be accomplished on SN95 without modification.

What ratio is in the SC rear end? If you retain it do the math and let that be the determining factor on which version of the TKX you go with; either the 3.27 or 2.87 first and .68 or .72 fifth gear.

Good luck going forward!

Jeff

A roadster in Minnesota, sounds like fun! Looks like a very solid plan. I'm far from an expert but happy to throw out a few FWIW comments.

Love the SBF, the Coyote is an amazing engine but I'm old school:)

I had a heck of a time finding a decent 351W block so I ended up just biting the bullet and buying a new aftermarket one. Found it in stock so was able to get it right to the machine shop. Bought a rotating assembly from Scat and made a 393.

You might want to check that 8qt oil pan, I think it's going to hang below the frame rails which is not good.

Everyone says the Ford clutch cable is far superior to the one FFR supplies so you might check it out.

As Jeff says the front sway bar will do more harm than good.

You're putting big Wilwood brakes on a relatively light car. You don't really need power brakes and installing the booster is not an easy job. Size the master cylinders correctly and you won't have any issues stopping other than hitting the steering wheel if you forget to cinch your belts tight.

Check out the seat heaters from Forte. Not very expensive and easy to install.
https://fortesparts.com/product/cobra-seat-heaters-waterproof-regular/

Electric line lock? Sounds like a way to get in trouble lol

You might check out this cooling fan and mate it to the Breeze shroud.
https://www.summitracing.com/parts/FLX-105390
https://breezeautomotive.com/shop/radiator-fan-shroud/

Guys - Thanks for the post.

- My instructor at build school had mentioned that he didn't like the Roll Bar and I had just read up on them last night begrudgingly coming to the same conclusion as the two of you. So delete on the anti way bar.

- I already have a pair of SN95 Spindles on the shelf so I'll give them a go.

- As for the brakes - people here may not believe me but I actually ran the numbers and Wilwoods are not that much more money if you are doing a Base Kit and buying new parts yourself and skipping a donor. Which is probably the smallest minority of folks doing a Roadster. I tried Napa, Summit, OReilly's, LMR, and a few other places. If I buy all the components Rotors, Calipers, Brackets, Pads, etc the cost was surprisingly close to buying the Wilwoods on sale summer. And since I purchased the front brake kit over a year ago I got a pretty darn good deal on them. Are the over kill. Probably. But my other consideration is should I not enjoy the car as much and want to sell it after it is built - it's an option that some people will consider worth while. Boosting them may be over kill I'm still on the fence on that one.

-I've purchased the Ford Racing Clutch Cable and a Firewall adjuster, also I changed the quadrant on my footbox to an aluminum one (though the self adjusting feature would have been nice)

-Cooling I have a weird idea to use a Contour Fan Kit like the Foxbody crowd with DCC independent controller with soft start and post shutoff cooling. I have a fan on a Mustang I'm going to pull and test fit and see if I like it. I've had great luck with them - Probably overkill and not as pretty, but redundant (dual fans)

-The Super Coupe Gear Ratio should be a 3.55 just like the ones offered by Factory Five. But I actually already had plan to verify it later this month before disassembly. The TKX I'm looking at has a 2.87:1 first and 0.68:1 final - Cruising at 70s assuming I have the tire height in my model correct would be mid 2000 rpms.

-Will have to look at the heated seats. I was thinking with a good heater I could drive into the Fall most years.

Jeff Kleiner

10-18-2022, 08:19 AM

- I already have a pair of SN95 Spindles on the shelf so I'll give them a go.

-The Super Coupe Gear Ratio should be a 3.55 just like the ones offered by Factory Five. But I actually already had plan to verify it later this month before disassembly. The TKX I'm looking at has a 2.87:1 first and 0.68:1 final - Cruising at 70s assuming I have the tire height in my model correct would be mid 2000 rpms.

Which year are the SN95 spindles? 1994-1995 are preferred; they have the dogleg in the steering arm which is much better for bump steer geometry; !996 and later have a straight arm. Additionally, the 1996 and later spindles will move the wheel & tire out about 3/8' farther which although it doesn't seem like much often creates tire to body interference unless you dial in more aggressive negative camber.

That would be my choice on the TKX as well. The version with 3.27 first gear coupled with a 3.55 rear end winds up creating a really short first gear combination of 11.6:1 overall; 2.87 first with 3.55 rear winds up with a much more usable 10.2:1 overall.

Cheers!

Jeff

edwardb

10-18-2022, 10:23 AM

I'll just chime in and agree with Jeff regarding the spindles. I've had builds with both SN95 spindles (the "good" ones) and since then the Factory Five designed 2-piece spindles. The difference, especially when combined with power steering and the increased caster, is the difference between an OK driving car and one that is vastly improved. Really no comparison with the total lack of bump steer and how easily it cruises down the highway without feeling jumpy or darty. I get there are lots of builds with the Mustang spindles before the upgraded ones were available. And various mods to make them a bit better. But for new builds, really makes sense to figure out a way to use the newer spindles. As a percent of the total build cost, it's a minor percentage and the difference in the quality of how your car will drive and how you'll enjoy it is dramatic. Figure out a way to save money somewhere else if budget is the issue. Something you can change later if you have to. But whatever spindles you install now will likely stay there as there are other dependencies.

mrglaeser

10-18-2022, 10:41 AM

Which year are the SN95 spindles? 1994-1995 are preferred; they have the dogleg in the steering arm which is much better for bump steer geometry; !996 and later have a straight arm. Additionally, the 1996 and later spindles will move the wheel & tire out about 3/8' farther which although it doesn't seem like much often creates tire to body interference unless you dial in more aggressive negative camber.

That would be my choice on the TKX as well. The version with 3.27 first gear coupled with a 3.55 rear end winds up creating a really short first gear combination of 11.6:1 overall; 2.87 first with 3.55 rear winds up with a much more usable 10.2:1 overall.

Cheers!

Jeff

I'll just chime in and agree with Jeff regarding the spindles. I've had builds with both SN95 spindles (the "good" ones) and since then the Factory Five designed 2-piece spindles. The difference, especially when combined with power steering and the increased caster, is the difference between an OK driving car and one that is vastly improved. Really no comparison with the total lack of bump steer and how easily it cruises down the highway without feeling jumpy or darty. I get there are lots of builds with the Mustang spindles before the upgraded ones were available. And various mods to make them a bit better. But for new builds, really makes sense to figure out a way to use the newer spindles. As a percent of the total build cost, it's a minor percentage and the difference in the quality of how your car will drive and how you'll enjoy it is dramatic. Figure out a way to save money somewhere else if budget is the issue. Something you can change later if you have to. But whatever spindles you install now will likely stay there as there are other dependencies.

Jeff they are 95 spindles. I was originally thinking of going with 95 Front Brakes so when I saw a good pair at a decent price 3 years ago I grabbed them

Edward I'll have to have a think on all of that. It isn't so much the budget as that I already have them, but I could probably ebay them. I do have Breeze Power Steering centering kit which I think is supposed to help. I have until Jan to make my final decision. I appreciate the input.

mrglaeser

01-20-2023, 11:31 PM

Ok Only three months between posts this time. I think that is a little better. Just received an email from Factory Five today. I have one week to finalize my order! So it is getting close.

Only 2 Roadster Activities have been going on in the last couple months.

1st I built a little collapsible and moveable 'paint booth' so I can paint all the panels as I go year round. We have an ok amount of space, but there are several other cars in the shop that I share and I have no desire to overspray on my wife's Mustang, or my Friends M2. I can say this though. I hate working with 2x2s they get real wonky real fast. But I think the end result will work. I'll put a paint cloth down, move the 'booth' on top of it and then cover the top with some 2 mil plastic. The front doors can be open to any angle so I can close it off while thing dry to keep out any thing floating around the shop. There are also 3 levels I can hang the dowl to attach items to paint depending on how big they are.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-P7nNd2H/0/f19fb48e/X2/20230103_104947-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-P7nNd2H/A)
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Drxbnr2/0/a972b471/X2/20230103_105019-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Drxbnr2/A)

Second next I build at 30"x96" work bench with a vise and table grinder.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-6FZnHR8/0/4bfef3c2/XL/20221023_174444-XL.jpg

If anyone is curious it's w4' x d4'6" x h8'4"

(original post broken up because of too many pictures)

mrglaeser

01-20-2023, 11:42 PM

Finally I got to work on the rear end. I purchased a 89 1989 t bird super coupe rear end for a couple hundred bucks. You can see it in my post above sitting next to the shelves of parts. I wish I had taken a close up of it before starting work. here is a shot after I removed all the extra suspension bits.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Kq3Mjjj/1/8392f401/XL/20221202_125636-XL.jpg

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-6kxTxqP/0/38a35341/X2/20221202_131415-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-6kxTxqP/A)

I stripped all the lines, bushings, suspension bits off of it, and cut the extra brackets they weld on for the Disc Brakes (I've got Wilwood rears). I also found the ring gear was rusted and un-usable. Bummer. So I order a new ring and pinion set from LMR. I've seen housing go for more than what I picked this up for so I guess I'm still ahead. After that I pulled the gears/spool, pinion, knocked out the races, removed all seals, and pulled the axel bearings. I have a new 31 spline kit to put in from LMR which includes Axles, Spool, bearings, seals, crush sleeve, flange nut, and fluids. I also got a nice aluminum cover.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-w3J7g2F/0/f22c79a8/X2/20221202_141434-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-w3J7g2F/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rstfX6X/0/cfb75e00/X2/20221210_154407-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rstfX6X/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-VxJZCzL/0/93409e87/X2/20221210_154418-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-VxJZCzL/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-RNSFrmt/0/5a6c2f93/X2/20221210_154423-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-RNSFrmt/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Kn359Ww/0/6b0400e1/X2/20221210_154431-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Kn359Ww/A)

mrglaeser

01-20-2023, 11:43 PM

After that off to sandblasting and powder coating.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-SWTtHss/0/8f88170c/X2/20230120_154235-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-SWTtHss/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pvfqj3h/0/e7a8eb83/X2/20230120_154245-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pvfqj3h/A)

So maybe this weekend I'll start to put parts back in.

Also look what the kids got me for Christmas!

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-WNj8L8r/0/8181b68a/X2/20221231_120325-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-WNj8L8r/A)

Hopefully in a month I'll have some delivery photos and maybe I be ambition and get a video too.

Hopefully in a month I'll have some delivery photos and maybe I be ambition and get a video too.

mrglaeser

01-26-2023, 12:13 PM

It's starting to happen.
- I got an email from Factory Five on Friday that this Friday is my deadline for changes!
- Still on track for 2/11.
- Sent my changes on Monday morning, received the updated invoice last night.
- Got ahold of Stewart Transportation and got on their list.

Now I just need to pay.

More axel assembly
building tomorrow and maybe Sunday.

mrglaeser

02-10-2023, 02:54 PM

More Excitement!

1.) Just got off the phone with Stewart Transport and they are picking up my kit from FFR next Friday 2/17 and it should be delivered 2/21-2/23.

2.) Also my Ford Racing short block did not show up and I have a new delivery date of the first week of April, but I think this date is more reliable because a backup order I have at another supplier was changed to 1 week after that where before it said unknown.

Maybe this weekend I can finish the rear assembly build. I have the backlash where it needs to be but the pinon depth reads a little shallow. The new flange is pretty tight on the new pinion and I didn't have my puller at the shop so I could only go so far a couple weeks ago (Delay since for a Hockey tournament) Though once that is done I'll have a slight delay in completely finishing the complete rear setup as I'm waiting for the rear Wilwood kit to show up. Ordered in early December no news of when it will get shipped.

mrglaeser

02-10-2023, 03:09 PM

A couple of photos
1.) Pressing the old bearing off the old pinion to get at the spacer and do measurements
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-SPWbQnw/0/ac7fab88/X3/20230122_123500-X3.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-SPWbQnw/A)

2.)New Limited Slip 31 Spline Spool from Ford Racing
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-q2GWdxd/0/a52ee3e0/X3/20230124_202402-X3.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-q2GWdxd/A)

3.)New Ring Gear and Pinion Kit from Ford racing
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-CFW27Pq/0/7c705b37/X3/20230122_113257-X3.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-CFW27Pq/A)

4.)New Cover from LMR
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-68Qs5QS/0/188f5b5c/X3/20230122_113311-X3.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-68Qs5QS/A)

5.)Pressing the new bearings on the new spool
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7KndgRM/0/176ac2fc/X3/20230128_143837-X3.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7KndgRM/A)

6.)Hello Pinion Gear
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-txWTNPk/0/3abc951f/X3/20230128_150048-X3.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-txWTNPk/A)

7.)Assembled Spool with Ring Gear and Bearings
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nZsPzdR/0/f02b9e40/X3/20230128_150057-X3.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nZsPzdR/A)

DanQ

02-10-2023, 09:49 PM

Hi from another Minnesota builder. My 33 Hot Rod should arrive sometime in June (via Stewart Transportation) I live in Chaska, SW metro area of the TC.

mrglaeser

02-19-2023, 11:37 PM

I got a call from the Stewart Transport driver.... My kit arrives tomorrow! Can not wait.

mrglaeser

02-21-2023, 09:07 AM

Kit was delivered yesterday. Even though we got a little snow in the morning and it was a bit cold unloading the truck. Mark from Stewart Transport was awesome and everything went smoothly. Took less than an hour. I guess this weekend I'll be going through dozens of boxes to verify inventory.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-HhLfdr4/0/f457c788/XL/20230220_154511-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-HhLfdr4/A)
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-VRJBLC7/0/6db3acab/XL/DSC_9835-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-VRJBLC7/A)
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rpDVPzZ/0/8b863cf2/XL/DSC_9841-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rpDVPzZ/A)
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gwS4z52/0/cdb724f2/XL/DSC_9847-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gwS4z52/A)
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-6jbfnz2/0/3d0ec043/XL/DSC_9851-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-6jbfnz2/A)
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4vGrZzh/0/518f67b2/XL/DSC_9853-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4vGrZzh/A)

mrglaeser

02-21-2023, 09:09 AM

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-XQCFJcV/0/e3f9aab5/XL/DSC_9856-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-XQCFJcV/A)
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-MmrQxJ8/0/2753d55f/XL/DSC_9857-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-MmrQxJ8/A)

mrglaeser

02-21-2023, 09:11 AM

In other news. My short block is further delayed. From April 5 now to September 5 at Summit or from April 8 to June 7 with Jegs. I don't really believe either supplier at this point. I don't really need it that soon, but it would be nice to have a realistic timeline.

Blitzboy54

02-21-2023, 12:06 PM

This is a great thread!

A couple thoughts from my experience. 1st, that steering wheel is beautiful. 2nd I rebuilt a fox body rear end and left the quad shocks on as well as I assumed they would really be in the way. I ended up grinding them off because once in the car I didn't like the look, to each his own on that. I just wanted to give you a heads up I had a change of heart after it was installed.

I look forward to following along

Scneal

02-21-2023, 03:25 PM

Congrats on your kit arriving Matt. Scott

cc2Arider

02-21-2023, 03:53 PM

Awesome! I noticed you were able to use your own dolly to offload from the truck :)

Craig C

Mike.Bray

02-21-2023, 06:19 PM

What an exciting day! Why is your grass white?

John Ibele

02-21-2023, 11:26 PM

What an exciting day! Why is your grass white?

... and just watch how fast it grows in the next two days.

mrglaeser

02-22-2023, 12:57 PM

... and just watch how fast it grows in the next two days.

Funny Guy John! It already grew a couple inches yesterday but tonight it's supposed to be 10 times worse. Thanks for stopping by for the delivery it was great to have someone with a little experience with FFR Roadsters to help!

mrglaeser

02-22-2023, 12:59 PM

Awesome! I noticed you were able to use your own dolly to offload from the truck :)

Craig C

One of the first things I built. I pulled the designs off this forum somewhere and it fits like a glove! My only change was to use the really tall pneumatic wheels. So it sits a foot or so taller than the specs. But I like that easier to get at the suspension work and under the frame.

mrglaeser

02-22-2023, 01:01 PM

Congrats on your kit arriving Matt. Scott

Thanks Scott. You'll have to swing by sometime. John and I were talking about the late April/Early May get together you and I had discussed last fall. Keep an Eye open in the next couple weeks I'll be putting your body buck to good use. This weekend is of course inventory time.

mrglaeser

02-22-2023, 01:04 PM

John Ibele

02-22-2023, 01:18 PM

Funny Guy John! It already grew a couple inches yesterday but tonight it's supposed to be 10 times worse. Thanks for stopping by for the delivery it was great to have someone with a little experience with FFR Roadsters to help!

Thanks for inviting me to join in! It was great seeing the awesome car condo, and delivery days are always fun.

One of the first things I built. I pulled the designs off this forum somewhere and it fits like a glove! My only change was to use the really tall pneumatic wheels. So it sits a foot or so taller than the specs. But I like that easier to get at the suspension work and under the frame.

... and handy for getting over that 'tall white grass' Mike noted ...

mrglaeser

02-22-2023, 01:19 PM

In addition to kit delivery on Monday I also pretty much finished the rear axel assembly. The only thing left is to torque down the cover(I had to order a 5.5 mm Hex socket which is a weird size) and install the wheel studs. The rear brakes have been on order since the first week of December. Who knows when those will show. But I have plenty of other things to do now anyway.
Axel and Seals installed
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-KJWbtkq/0/f547c668/XL/20230219_111520-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-KJWbtkq/A)

Fuzzy shot of side by side comparison of 28 v 31 Spline Axels. 1.23 cs 1.35 inch thickness
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ThNsR2N/0/2146612a/XL/20230219_111744-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ThNsR2N/A)

Axel's Slipped in
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-5Jbr8bN/0/7ca93e22/XL/20230219_112211-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-5Jbr8bN/A)

C-Clips Installed
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-BmkW7BF/0/fe11445c/XL/20230219_112558-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-BmkW7BF/A)

Retaining pin and securing bolt installed
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-M75zSNW/0/d3cc63b2/XL/20230219_112615-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-M75zSNW/A)

Gasket and cover hand tight (waiting on correct tool to torque)
https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nWmVtmc/A

Forgot to take a pick of the upper bushings being installed but that is done too
I used this tool and it worked great

https://lmr.com/item/MM-MMT1/79-04-Mustang-Maximum-Motorsport-Rear-Upper-Control-Arm-Bushing-Tool

mrglaeser

02-26-2023, 12:10 AM

https://www.youtube.com/watch?v=sVoZBCwftb4

ok 5 hours and 40 minutes later and inventory is done.

Still to be delivered:
Certificate of Origin
Nameplate
Aluminum Center Section (steering component)
Steering Wheel Boss
1/2 Rollbar Box (4 link parts)
10' 3/4 Wire Loom
Rivet Package this is the biggest surprise these things are pretty common you think they'd have many suppliers for something so basic. Good thing i bought extras from Replicar So i can still get started right away.
4' 16 GA Blue Wire - again something pretty basic so surprising they don't have it
Ground Strap - again very common thing to be out of
5 PT Seat Harness, Black
Door Latch Fasteners
latch striker - though I did get all the other door latch parts
Engine Harness Block off plate
Dash Box
Outer Tie Rod Ends - this is a bummer as these will come up early in the build
Carriage Bolts for the Hood Hinge - Again pretty basic thing to be out of
185 Degree Theromostat Swtich

One thing I was surprised at is how nice the basic gauges are. I already have a set from Speethut and the GPS Speedo is going to be nice, but these are pretty good. Everything was packaged really well I didn't find anything damaged. I'm just glad the bookkeeping is over and next weekend we can pull the body and get going.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fWJXdwC/0/6f74e563/X2/20230224_185507-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fWJXdwC/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-W9DtDnm/0/9f1a1e70/X2/20230224_185517-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-W9DtDnm/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-NdmRsnD/0/49373023/X2/20230225_171543-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-NdmRsnD/A)

Junbug

02-26-2023, 12:23 AM

mladen

02-26-2023, 12:38 AM

You don't have to block your build on the tie rods, and many other things. I just started the engine this week, and I technically still don't need them until I'm ready to test drive. So don't worry about it :)

mrglaeser

02-27-2023, 12:01 AM

mladen

02-27-2023, 09:02 AM

I ended up buying a bunch of Amazon when I bought the rivet gun, even before my kit arrived, so I mostly used those :D

mrglaeser

03-05-2023, 12:56 AM

Lots of work to get to the starting point!

Put some padding on the body buck
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pzRTTXt/0/5ffd9b21/XL/20230304_141512-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pzRTTXt/A)

Created a body support
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-spWtbFq/0/18806088/XL/20230304_141505-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-spWtbFq/A)

Took the doors off
https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nh96D4R/A

Took the trunk off
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-X65cxn6/0/5ce21801/XL/20230304_144348-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-X65cxn6/A)

Took the Body off and moved it to the body buck
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-BWNbBNB/0/6b429423/XL/20230304_153813-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-BWNbBNB/A)

Labeled, photo'd, took notes, and removed all the aluminum panels
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-xhgMKTb/0/97055acb/XL/20230304_170038-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-xhgMKTb/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pj64vk6/0/f3552dc6/XL/20230304_170042-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pj64vk6/A)

Ready for step 1 - started to look at the F-panels and the drivers side doesn't line up so well. This lead to some measuring and it looks like the bar that runs the length of the engine compartment was welded in 1/4-1/2 inch further to the rear of the car than the passenger side. This means the radiator support and dash hoop are both at a very slight angle. Not sure if I should worry about this or not.

https://thefactoryfiveforum.com/showthread.php?45448-Manufacturing-tolerances-F-Panel-not-lining-up

John Ibele

03-08-2023, 02:38 PM

Ready for step 1 - started to look at the F-panels and the drivers side doesn't line up so well. This lead to some measuring and it looks like the bar that runs the length of the engine compartment was welded in 1/4-1/2 inch further to the rear of the car than the passenger side. This means the radiator support and dash hoop are both at a very slight angle. Not sure if I should worry about this or not.

https://thefactoryfiveforum.com/showthread.php?45448-Manufacturing-tolerances-F-Panel-not-lining-up

Hey Matt, saw your associated thread and responses. Good to post, and good feedback received. It's a typical hump to get over with the first panel or two. A recurring theme through the build is questions like these ... is it 'typical', or is there something off with what FFR sent me? You'll get dialed in pretty quickly. If something needs minor tweaking (and this one was fairly minor, actually), I'd typically have at it. But if anything was off in a major way, in retrospect ... it was me that was off, not any of the parts.

As for raised welds keeping aluminum from sitting flush: I would hit the aluminum over the weld with a rubber hammer, and with one or two blows have a panel which fit around the weld perfectly. Could always grind down the weld and recoat it for protection from rust, but the way I used was quick, easy, and turned in a perfectly acceptable result (which wouldn't been seen in the end anyway).

mrglaeser

03-12-2023, 09:26 PM

Pretty Good week.

Trimmed and fitted the F-panels.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-jn6wrTd/0/2c809337/XL/20230308_192100-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-jn6wrTd/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-CkJ9KP5/0/65bb8284/XL/20230308_192109-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-CkJ9KP5/A)

A couple coats of self etching primer
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gTxfDRD/0/7acb9818/XL/20230308_203153-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gTxfDRD/A)

Some black on the Engine side and bed liner on the wheel side
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-dN2fSLs/0/d1eef613/XL/20230309_125851-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-dN2fSLs/A)

Then on to the car
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gs8hH2t/0/13250ac1/XL/20230312_105334-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gs8hH2t/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Dmx5kqz/0/c759b724/XL/20230312_113854-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Dmx5kqz/A)

mrglaeser

03-12-2023, 09:37 PM

Next we put the front upper and lower control arms on. One thing I found to be a PIA is on the upper arm on the holes toward the rear of the car there is literally no way to get a wrench or socket on the stop nut. I ended up cramming a washer in one case and a medium flat screw driver in the other - in between the mount and the nut to get it to stop spinning. Seems to have worked out ok.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-QLc3b9Q/0/61e219b8/XL/20230312_123153-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-QLc3b9Q/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wTTJTqr/0/aef02cd3/XL/20230312_123218-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-wTTJTqr/A)

Then on to the front coil overs.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3TKvFCx/0/eb641ba9/XL/20230312_123342-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3TKvFCx/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-NBB9rh6/0/99577cbb/XL/20230312_125639-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-NBB9rh6/A)

I didn't see any instructions on the set screw so I just put them in loose so I don't lose them. I'm assuming there will be adjustments to make in the future and then tighten them. No real issue getting them onto the car. Not sure it would have been much fun if I didn't have some help. All those spacers, nuts, bolts, and arms to old in addition to the coil over.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rfgKgPH/0/a2687636/XL/20230312_133158-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rfgKgPH/A)

mrglaeser

03-12-2023, 09:37 PM

Was going to move onto Spindles, hubs, and front brakes, but I didn't know I needed spindle to strut bolts if using SN95 spindles and didn't have them. So those are on order. Also thought about doing the rear axel but I didn't have the right torque wrench with me to install the new aluminum cover so I could fill it. I figured doing the final prep of the rear axel would be easier out of the car. But I did get the spindle brackets painted.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-sCVT2Sm/0/27e6b68d/XL/20230312_143750-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-sCVT2Sm/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-zNGHsDr/0/83b5b593/XL/20230311_135905-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-zNGHsDr/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Qf44Lhj/0/e4e5dc45/XL/20230311_145655-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Qf44Lhj/A)

One bummer for the day was the powder coat flaked when I torqued the lower control arm down. I'll have to cut it and do a little touch up later.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-cPNmBV4/0/e4ae6ea5/XL/20230311_140629-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-cPNmBV4/A)

mrglaeser

03-12-2023, 09:41 PM

Hey Matt, saw your associated thread and responses. Good to post, and good feedback received. It's a typical hump to get over with the first panel or two. A recurring theme through the build is questions like these ... is it 'typical', or is there something off with what FFR sent me? You'll get dialed in pretty quickly. If something needs minor tweaking (and this one was fairly minor, actually), I'd typically have at it. But if anything was off in a major way, in retrospect ... it was me that was off, not any of the parts.

As for raised welds keeping aluminum from sitting flush: I would hit the aluminum over the weld with a rubber hammer, and with one or two blows have a panel which fit around the weld perfectly. Could always grind down the weld and recoat it for protection from rust, but the way I used was quick, easy, and turned in a perfectly acceptable result (which wouldn't been seen in the end anyway).

Hey John thanks for the reply. Wish I had seen this earlier this week. Yeah I did a little trimming and I'm decently happy with the fitting.

John Ibele

03-12-2023, 11:16 PM

Your post #43 ... I can't remember if this was it, but I know I found some of these (https://www.amazon.com/RamPro-Drive-Crowfoot-Wrench-Standard/dp/B0719BLYH3/ref=asc_df_B0719BLYH3/?tag=hyprod-20&linkCode=df0&hvadid=309813767497&hvpos=&hvnetw=g&hvrand=4844681651854755735&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9019670&hvtargid=pla-568081655239&psc=1) to be handy at some point during the suspension installation.

Coilovers ... I'm pretty sure most folks don't ever tighten the set screw. From what I've read for the most part they don't move. My challenge was getting them to move enough ... little space to work in, and the friction was hard for me to overcome. I picked up some of this stuff, which I had read about in setup recommendations (https://raceland.com/news/how-to-take-care-of-coilovers/) on another site (didn't find much on Koni's site). The stuff is sold in bike stores, and is supposed to work well in lubricating without picking up debris when on the road. I wanted something to reduce friction, and sure couldn't picture gooping up my shocks with anti-seize.

Looks like you're having fun out there in the car palace!

Windsor

03-13-2023, 08:14 PM

Then on to the front coil overs.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3TKvFCx/0/eb641ba9/XL/20230312_123342-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3TKvFCx/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-NBB9rh6/0/99577cbb/XL/20230312_125639-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-NBB9rh6/A)

I didn't see any instructions on the set screw so I just put them in loose so I don't lose them. I'm assuming there will be adjustments to make in the future and then tighten them. No real issue getting them onto the car. Not sure it would have been much fun if I didn't have some help. All those spacers, nuts, bolts, and arms to old in addition to the coil over.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rfgKgPH/0/a2687636/XL/20230312_133158-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rfgKgPH/A)

Before you get too deep into the front-end build, did you verify the rebound setting on the Koni reds? Several builders have noted that the settings aren't consistent from the factory. Setting it while installed is unpleasant if not impossible.

Frank (i.e.427) has a great video on this:

https://www.youtube.com/watch?v=JOCEEYdNYOI&t=18m58s

mrglaeser

03-19-2023, 08:17 PM

Before you get too deep into the front-end build, did you verify the rebound setting on the Koni reds? Several builders have noted that the settings aren't consistent from the factory. Setting it while installed is unpleasant if not impossible.

Frank (i.e.427) has a great video on this:

https://www.youtube.com/watch?v=JOCEEYdNYOI&t=18m58s

Hi Rob - Thank for the note. I actually watched that video mid-week and when I worked the car today I pulled out the Coilovers off and checked them before moving on. Wish that little note was in the manual. They did tell us about this in build school but I didn't write it down. So when I saw video it was a head slapper!

mrglaeser

03-19-2023, 08:30 PM

Ok pretty decent weekend in shop. Last one i'm going to have until mid-April.

First as noted above I pulled the front Coil overs and verified the Konis were set correctly. Over the week I got several parts deliveries. Included were the SN95 strut bolts and nuts. So I installed the spindles and brackets.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-xTMv8XK/0/db6a52e1/X2/20230318_160132-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-xTMv8XK/A)

Then I torqued the differential cover down, set the bearing cap supports, and filled the dif. Once some help got to the shop we put on the brackets on the axle. I did need to bend one out to get it to fit, and there was persuading with mallets and dead-blows involved.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DfPxszX/0/03885b53/X2/20230319_125528-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DfPxszX/A)

On to the lower and upper control arms:
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-cLzV23r/0/5ed03e74/X2/20230319_133955-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-cLzV23r/A)

We checked the settings on the rear coil overs and assembled them. Then bolted it all to the frame. That was a lot more physical effort than I thought. I'm glad I had a hand it's probably not something that should be tackled alone.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-CJv32pr/0/29722994/X2/20230319_154742-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-CJv32pr/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pbSRSqX/0/f188f87f/X2/20230319_154757-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pbSRSqX/A)

I really like the way the QA1 control arms look. Especially the uppers:
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-F8zQvZ8/0/1f70bfbf/X2/20230319_154817-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-F8zQvZ8/A)

mrglaeser

03-19-2023, 08:37 PM

Also spent some time working on the front rotors (well the drivers side). It took me about six times to finally get a decent safety wire setup between two of the bolts on the Wilwoods. By the sixth pair of bolts I felt I was getting decent at them.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ttbkH8R/0/5893ab35/X2/20230318_171812-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ttbkH8R/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-r6RTmFW/0/bf7b5ad0/X2/20230319_162336-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-r6RTmFW/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wwjcV5Q/0/f4382aaf/X2/20230319_162718-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-wwjcV5Q/A)

One down one to go.

Fixit

03-20-2023, 05:31 AM

mrglaeser

03-20-2023, 10:57 AM

Just caught your thread...
A belated "Welcome to the Asylum!"

I'm also in MN (Mound). If you're on FB, we have a group, MN-WI Cobra Builders. I also know Mr. Ibele - he helped me unload #9365 a few years ago.

Hey John! I'm out in Maple Grove. I am on the FB Group. Watch the FB group in a couple of weeks - I was hoping to invite everyone to a Grill Out end of April or Early May. Scott up in North Oaks and I talked about last fall. My shop space is in Corcoran and there are some pretty nice twisty roads out there for people to drive if they are willing to come out.

mrglaeser

03-30-2023, 11:03 AM

Another fun weekend working on the roadster last weekend. Didn't get quite as much done as previous weeks. First I finished the safety wire for both rotors and put them on the care using some spare lug nuts. I was then able to install the Driver's side caliper. I have to wait on the pass. side as I need some different shims.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wwjcV5Q/0/f4382aaf/X2/20230319_162718-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-wwjcV5Q/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kWWRxx2/0/c193a464/X2/20230325_120847-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kWWRxx2/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-HQqFrRq/0/53c4b7c3/X2/20230325_120854-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-HQqFrRq/A)

I think is funny that in the front brake kit Wilwood tells you 11 times that you should hire a professional so you don't kill yourself.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nF2gmf6/0/df43fded/X2/20230325_120757-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nF2gmf6/A)

mrglaeser

03-30-2023, 11:09 AM

Next was to mock up the Firewall, Dash, and heater.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-VFMzwRS/0/d88ad8ba/X2/20230319_170423-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-VFMzwRS/A)

Should Fit
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-tqcP75k/0/09b3058f/X2/20230325_124720-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-tqcP75k/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-vb8wMhm/0/5627b701/X2/20230325_124731-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-vb8wMhm/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7MJWDc9/0/a7434918/X2/20230325_124741-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7MJWDc9/A)

I bought a kit from Jegs rather than FFR because it is 28,000 BTU v 16,000. I like to drive in the fall and I hope this buys me a few weeks each year.... I should also note that I'm using an FFMetal extended firewall. What a nice piece that is. Twice as think as the FFR piece and nicely fabb'd.

Time to cut...

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-q6xZDdT/0/7eb17763/X2/20230326_154805-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-q6xZDdT/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2BMQTsp/0/1febc948/X2/20230326_160234-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2BMQTsp/A)

The older one took to filing burrs the younger not so thrilled.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-9b77Jwj/0/0ff9303b/X2/20230326_162418-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-9b77Jwj/A)

mrglaeser

03-30-2023, 11:11 AM

I originally thought I'd cut the blower motor and pipes separately but with this unit that doesn't really work.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-N564F6q/0/a2337777/X2/20230326_174832-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-N564F6q/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-LG7KHL5/0/fde94130/X2/20230326_174838-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-LG7KHL5/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gjvGs78/0/d619d9d1/X2/20230326_175935-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gjvGs78/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-w93D83W/0/ac2355df/X2/20230326_180405-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-w93D83W/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-sztnMBM/0/84bbd76f/X2/20230326_180410-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-sztnMBM/A)

mrglaeser

03-30-2023, 11:14 AM

On to Drilling holes and some paint

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4hjRbv7/0/32a179f0/X2/20230327_123300-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4hjRbv7/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-s24tZgd/0/5b1dd936/X2/20230327_131758-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-s24tZgd/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-96XgrnN/0/c25ccfa9/X2/20230328_122050-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-96XgrnN/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rSXkh8F/0/0320d776/X2/20230328_123426-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rSXkh8F/A)

Fortunately/unfortunately I'm heading off for a two week vacation so it will be at least 3 before I can install the firewall and move on to the drivers foot box/Pedal box/steering

cc2Arider

03-30-2023, 05:56 PM

Nice progress! :)

Craig C

mrglaeser

05-01-2023, 02:28 PM

Ok I got back from Vacation a week and 1/2 ago and have been making some progress again. First riveted the Firewall in place and installed the Heater box.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-QRk5dqp/0/54e5f9f5/X2/20230416_160332-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-QRk5dqp/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4ZWrKgk/0/eb78e0ed/X2/20230416_160340-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4ZWrKgk/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-VPBChpD/0/2457a15b/X2/20230422_175046-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-VPBChpD/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-246sKTh/0/525a44e5/X2/20230430_192734-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-246sKTh/A)

mrglaeser

05-01-2023, 02:38 PM

Next I fit the drivers footbox front panel to the car and trimmed it. Right before I started drilling I realized I fit the wrong panel. I'm using a Foxbody pedal box. DOH!!
https://media.giphy.com/media/xT5LMzIK1AdZJ4cYW4/giphy.gif (https://media.giphy.com/media/xT5LMzIK1AdZJ4cYW4/giphy.gif)

So I did it again with the correct panel. Then I painted it and had a horrible run. DOH!!. So I stripped it and did it again. You know the ole saying' make it nice by doin' it twice!

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-TRf9cQn/0/a915f388/X2/20230426_115228-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-TRf9cQn/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DQKHMsH/0/055dfe73/X2/20230427_212531-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DQKHMsH/A)

I'll get that installed tomorrow I think. While I was messing that panel up several times I also worked on the pedal box.

First I took it apart and cut all the bit off the manual says to.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-V3F7WH5/0/6accdaf6/X2/20230426_142037-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-V3F7WH5/A)

Then I fit it to the car - sorry no picks here. But I will say it is a lot easier getting the box in and out with no pedals installed.
After that I bent the pedals to the left to add some clearance for my feet. I found this a bit nerve racking as I didn't want to mess it up.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-prq5gdw/0/f589199c/X2/20230430_155342-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-prq5gdw/A)

Assembled everything and installed loosely in the car. Once the front panel is riveted I'll come back and tighten everything.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kRtQVM4/0/a9d73e28/X2/20230430_192656-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kRtQVM4/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-vzPWrn4/0/78099ae7/X2/20230430_192709-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-vzPWrn4/A)

After the photo above I took the speed control and bracket off as it caused interference with the Russ Thompson throttle pedal.

mrglaeser

05-01-2023, 02:51 PM

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZpcTt4G/0/51853077/X2/20230430_192647-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZpcTt4G/A)

Now I'm prepping to install the power steering rack. I purchased the Breeze centering kit. What super nice hardware that is . To bad it will be hidden by the install.

https://media.giphy.com/media/j8TqCNLk6BIwtETx2x/giphy.gif (https://media.giphy.com/media/j8TqCNLk6BIwtETx2x/giphy.gif)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-sZXGSKB/0/295cdb31/X2/20230427_205809-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-sZXGSKB/A)

I also purchased the Moog Ends for more adjustability

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fBnSnHf/0/240765de/X2/20230427_205825-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fBnSnHf/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rfr6Mqx/0/6c20f860/X2/20230430_192742-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rfr6Mqx/A)

cc2Arider

05-01-2023, 03:50 PM

mrglaeser

05-01-2023, 07:35 PM

Hi Matt,

I've heard others use the Breeze centering kit...what's in the kit? Simply offset sleeves?

And at the risk of getting flamed ('cause I'm sure this has been asked many times before), why does the rack need to be centered?

Thanks in advance :)

Craig C

The main benefit of the kit is to reduce bump steer. This mostly needed for donor parts. The foxbody or sn95 spindles. I don't think it as much of an issue with the FFR spindles. The second benefit is that the rack as is slightly off center and mounted a little low. This kit changes that too. Finally there some rigdity added froming to solid bushings.

https://breezeautomotive.com/shop/offset-rack-mounting-kit-for-ffr-roadster-and-coupe/

mrglaeser

05-08-2023, 07:53 PM

The last week feels productive.. Though I'm not 100% happy with the results. 95%. I'll have to touch up some paint and fill in some gaps I created during fitment. But still happy to have the frame start looking more like go-kart.

I got the lower and middle steering shafts installed. Found out they didn't send me the upper shaft. Email FFR and one came today will put it in later this week.

Then most of the time was spend fitting the passenger foot box and floor, painting, and installing.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-JSHpgjR/0/24eb937f/X2/20230504_142654-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-JSHpgjR/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nDXhJdW/0/e24f4185/X2/20230504_142658-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nDXhJdW/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gSnZNM2/0/242f6e11/X2/20230504_142707-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gSnZNM2/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rZDX9sF/0/e90efa36/X2/20230504_142714-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rZDX9sF/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2bLmqQB/0/38c043aa/X2/20230504_154102-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2bLmqQB/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-KRFgf7m/0/22dd965f/X2/20230506_135922-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-KRFgf7m/A)

a

mrglaeser

05-08-2023, 08:00 PM

This next part was probably a mistake. I fit the floor without the footbox. Which I found out later was not the way to do it.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-dNfvF49/0/1aa28751/X2/20230507_102920-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-dNfvF49/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-vbHXBCD/0/742f8b31/X2/20230507_113627-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-vbHXBCD/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-xKZ7LFK/0/81c039b3/X2/20230507_130920-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-xKZ7LFK/A)

You can see that I scraped the heck out of the front corner of the footbox/tunnel junction. Also had to trim more of the floor after paint. Still also not happy with the fit in general in that area. Going to trim some and maybe create a patch panel. After that I can touch the paint with a brush. Good news is it will all end up under the carpet.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Dp3C569/0/ab35def2/X2/20230508_113850-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Dp3C569/A)

mrglaeser

05-08-2023, 08:03 PM

While waiting for paint to dry I also pulled out all the fuel tank parts and put them together so I'll be ready to install them once I get some more sheet metal work completed.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-PcFgJbf/0/70a264d2/X2/20230506_121747-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-PcFgJbf/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7t9pWVK/0/6653fc7e/X2/20230506_130250-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7t9pWVK/A)

Here are a couple shoots of the outside of the Foot Box

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-tBt3fhq/0/1037b8e8/X2/20230508_113831-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-tBt3fhq/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Gb2qc2B/0/bb93812a/X2/20230508_113842-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Gb2qc2B/A)

mrglaeser

05-17-2023, 07:39 PM

OK Lots of sheet metal is in the car after the last week and 1/2.

- Passenger Side/under door metal
- Driver Inner Foot box panels
- Driver Foot box Floor
- Driver Floor
- Driver Side/Under Door metal
- Driver & Passenger rear cockpit outside panels
- Driver & Passenger rear inner cockpit panels
- Rear Transmission tunnel

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-BSZqcCj/0/8f83ba92/X2/20230515_144715-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-BSZqcCj/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-22TQ7MS/0/5bbefe43/X2/20230515_144724-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-22TQ7MS/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-L4ZmFnx/0/0384d6ac/X2/20230515_144731-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-L4ZmFnx/A)

Created a little bracket to mount the fuel filter too, painted, and installed.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nQr2mDR/0/cd93a340/X2/20230513_092102-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nQr2mDR/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-8dG3h7X/0/1141dfe8/X2/20230515_144708-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-8dG3h7X/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nnghkX4/0/770c5051/X2/20230517_092639-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nnghkX4/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-97GdfLN/0/d5a08db6/X2/20230517_093814-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-97GdfLN/A)

mrglaeser

05-17-2023, 07:44 PM

Also installed the gas tank. it was a little bit of a pain because I had to bend some metal down. Maybe this is in the donor prep section but I didn't see this noted - I did by a new fox gas tank from LMR maybe the FFR ones don't need this. Also had to trim just a bit of metal on the front passenger side of the tank and even then the strap barely cleared.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-CPfQ3t2/0/2a103bba/X2/20230517_095649-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-CPfQ3t2/A)

The jack could not lift the tank high enough... so ratchet straps to the rescue. here is where the tank is bent up creating an issue getting it to sit against the metal support.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-BbczvLJ/0/736752fb/X2/20230517_100457-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-BbczvLJ/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-CFv5s84/0/c919066a/X2/20230517_101214-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-CFv5s84/A)

20 minutes of additional messing around and the tank was in.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-cnjNQNL/0/cf85a961/X2/20230517_105639-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-cnjNQNL/A)

mrglaeser

05-17-2023, 07:47 PM

Additionally I installed the fuel pressure regulator and used some string to measure the lines. I'm going to use braided nylon -6AN lines. hope I did leave too much or too little slack in the string.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-phj23bn/0/e1f89a90/X2/20230517_142414-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-phj23bn/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-KgNjZP8/0/bba075e5/X2/20230517_142401-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-KgNjZP8/A)

Next will be fitting the brake power booster. So it might be a while until I get that figured out.

mrglaeser

06-10-2023, 12:03 AM

OK been a minute since I was on the site again. A little slower on progress. I ordered and installed the fuel lines:
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fwHLkkh/0/2a5fe545/X2/20230531_193054-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fwHLkkh/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-bQhRfM7/0/c683838d/X2/20230531_193050-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-bQhRfM7/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-bQhRfM7/0/c683838d/X2/20230531_193050-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-bQhRfM7/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-PtpHZmP/0/9bbc4f18/X2/20230608_121426-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-PtpHZmP/A)

mrglaeser

06-10-2023, 12:06 AM

After the Fuel lines I installed a Charcoal canister from a Yamaha motor Cycle and ran the hoses for it

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-qCX5rKG/0/e6b0eb2f/X2/20230531_194153-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-qCX5rKG/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3mLMwr2/0/367e8173/X2/20230531_194203-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3mLMwr2/A)

Chopped the frame up a little to make room for the power booster:
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kTDbgH5/0/f5246b02/X2/20230608_100118-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kTDbgH5/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-R757TvF/0/b23ce2ff/X2/20230608_100200-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-R757TvF/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-qK5gCNC/0/7edf5d47/X2/20230608_100107-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-qK5gCNC/A)

And now I'm prepping to enlarge the hole for the brake push rod.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-vrWBhN3/0/4dbcbab8/X2/20230606_160705-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-vrWBhN3/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-QXRL4bX/0/c871a380/X2/20230606_160712-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-QXRL4bX/A)

I also fit the drop battery box for the truck. Just a touch of grinding. Plus marked the rivet holes, disassembled it, and painted it. But I didn't take photos. So those will come next once it's also installed.

mrglaeser

06-20-2023, 12:06 AM

Ok making slow progress.

I honed out the hole for the power brake booster using a Harbor Freight dye grinder that was lent to me. Our tiny air compressor allowed me to grind 20-40 seconds then a minute to recharge, grind 30-50 seconds, then a minute to re-charge. Rinse and repeat for 90 min. But it did the job very well. I guess a bigger tank and more powerful compressor are on the x-mas list.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-MrJC8ML/0/76e444fd/X2/20230611_145021-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-MrJC8ML/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Z2kTTrk/0/c51c5b13/X2/20230611_145016-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Z2kTTrk/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-KMqqN7G/0/55f865e7/X2/20230611_145025-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-KMqqN7G/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3ZRwXB6/0/0c1e6c05/X2/20230611_145030-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3ZRwXB6/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-SJJMsCn/0/d12941c3/X2/20230611_151952-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-SJJMsCn/A)

If I do another kit someday. Along with doing all the panel fitting at one time and sending it out to powder coat, I'm also going to cut this hole before installing parts. After cleaning everything up I tried installing the booster.. No-Go. I had purchased a 93 Cobra Brake booster and it was just to large. The steering kept hitting it. I ended up needing to get a standard V8 Brake Booster which fit pretty well.

More on this here: https://thefactoryfiveforum.com/showthread.php?46389-Mark-IV-Power-Brake-Booster-Steering-Clearance-issue

mrglaeser

06-20-2023, 12:16 AM

Once the booster was sorted out I was able to install it and the Whitby Frame Mod.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-8kmzhKf/0/4af12371/X2/20230617_144037-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-8kmzhKf/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-SzhXHqn/0/af5ca0a0/X2/20230619_191849-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-SzhXHqn/A)

Once done with that I installed the Wilwood rear brakes.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-bN7zP2R/0/daa67860/X2/20230619_182824-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-bN7zP2R/A)

I do need to call/contact Wilwood as the centering rig doesn't line up with the 'hub' on my axle. So not sure if I should use it get a different one or what.

I also painted, assembled, and installed the FFmetal rear battery box. That is a real nice piece of kit.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-frjhfjH/0/b954a422/X2/20230610_133638-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-frjhfjH/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7hWTDm9/0/f41cdc12/X2/20230614_164455-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7hWTDm9/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-CpZF36Z/0/81280371/X2/20230614_165924-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-CpZF36Z/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-svVJRdJ/0/d2173b52/X2/20230614_165927-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-svVJRdJ/A)

Seems the trick to getting my girls to help is letting them use the power rivet gun. They seem to enjoy the metal work the most so far.

mrglaeser

07-03-2023, 09:57 PM

Whelp.... Sometimes $hI7 happens. The dolly under my roadster gave out in one corner and collapsed the back half of the rig. I was luckily not under it and the total damages are some scratches to the gas tank over and the tube frame (mostly from jacking the car up when the front was quite high and the back was on the floor).

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-twDPGdj/0/f39afdee/X2/20230703_180535-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-twDPGdj/A)

Everything is on jack stands now. I think the fix is to make the dolly a little longer to change where the weight is centered, center the 2 x 6s the wheels are mounted on the 4x4s, pre-drill the screws to keep the wood from cracking.

Meh. Time for fireworks tomorrow. Worry about the dolly next weekend.

mrglaeser

07-03-2023, 10:32 PM

Before my dolly broke I had gotten most of the brake lines run.

First I set the pushrod depth and bolted the MC down to the power booster. I also installed the line lock and proportioning valve.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mDGqTts/0/8cb2f451/X2/20230623_152520-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mDGqTts/A)

Because I purchased a base kit the brake line brackets don't work with the Wilwood's and I only got them for the front - I guess donors use brackets from the car. So I made 4 new brackets and orders some c/spring clips.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DtXWPhD/0/a8569886/X2/20230625_125912-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DtXWPhD/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-VZsMDhw/0/3fce10cf/X2/20230625_125854-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-VZsMDhw/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-sCSm3gF/0/d3e414bd/X2/20230625_125859-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-sCSm3gF/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-QNxPHTH/0/4ac7fe24/X2/20230625_125907-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-QNxPHTH/A)

mrglaeser

07-03-2023, 10:47 PM

Then I started running the lines. It was the first time I worked with nickel - copper lines. It was pretty nice compared to bending the steel lines. Plus I didn't have to use any of the junctions so a few less places to cause links. I also tried this new flaring tool which worked great. I broke the 3/16 die on my 30 year old Napa kit on like the 3rd flare.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZSRJGjG/0/d886b11e/X2/20230701_173744-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZSRJGjG/A)

I find it funny how crazy lines look off the car.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-NkzGKst/0/97abfd65/X2/20230701_173023-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-NkzGKst/A)

Additionally I'm tapping holes and using 1/4" screws for the retainers just in case I need to pull things apart again. Did the same with the fuel lines.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7mS7jJb/0/28993083/X2/20230702_115732-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7mS7jJb/A)

Anyway I pretty happy with the end results.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4RPtrD6/0/adbb4963/X2/20230701_171253-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4RPtrD6/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-LRmgKvS/0/5b428d8d/X2/20230702_113248-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-LRmgKvS/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-xBsmkjM/0/b7928e46/X2/20230702_121044-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-xBsmkjM/A)

danmas

07-03-2023, 11:46 PM

mrglaeser

07-04-2023, 12:03 AM

Your lines look fabulous. Your right wheel in the last picture is creeping me out.

Thanks danmas - if you go up a couple posts there is a picture of a broken dolly! It gave out today. No real damage to the car or people. The 2x6 the wheel was mounted to cracked right down the middle. I saw the wheel when I did the line to the rear and was planning my next move. But I guess I took a day to long. I was actually testing the stability of the setup today and it gave way. Took me an hour and half to get the frame on jack stands. What a PIA.

mrglaeser

07-09-2023, 10:37 PM

Small update to my dolly giving way. Found the grease fitting for my rear lower control arm broke. So I'll have to find an extractor to get that out and replace it.

Finished the brakes. Not sure if I mentioned before but I had to make my own brake brackets.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-TBcRgbm/0/0a583ea3/X2/20230707_165022-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-TBcRgbm/A)

I also put a quick polish and Everbright on the lines.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-qRNpMD7/0/0ef18cdd/X2/20230707_165112-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-qRNpMD7/A)

My oldest drilled and tapped the holes to mount the final line.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-W7MgVmw/0/827a6bb4/X2/20230709_115955-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-W7MgVmw/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fV8fmFG/0/38ff7fa3/X2/20230709_120549-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fV8fmFG/A)

I will admit I had a few do-overs and bad starts creating the lines.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-npJ4g9Z/0/90afc52a/X2/20230709_130656-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-npJ4g9Z/A)

And that pretty much completed this phase of the build
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2MQSbXP/0/28e04c6e/X2/20230709_125317-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2MQSbXP/A)

F500guy

07-09-2023, 10:43 PM

Love the white board! I just use a note book...Which is pretty boring

mrglaeser

07-09-2023, 10:48 PM

I also fit two of the trunk panels thinking I would fit all of that and build my drop tank while waiting for the wiring kit to show up.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-SKX9wdr/0/701cef45/X2/20230707_165215-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-SKX9wdr/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3PZr46b/0/9b012eef/X2/20230707_165223-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3PZr46b/A)

But then I received this box on Saturday afternoon.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-vH44zKH/0/a9d1751c/X2/20230708_155316-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-vH44zKH/A)

So now I'm reading the guide, painting the fuse panel bracket, pulling out the interior insulation kit, and digging out the gauges and Sniper manuals so I can start a plan.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-M8hT4Vj/0/576bf2f6/X2/20230709_125406-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-M8hT4Vj/A)

Also I watch i.e.427's video https://www.youtube.com/watch?v=YiJKIfkhAOQ&t=1439s so we went a head and cut 3 brackets to lower the dash mounting screws and primed them.

mrglaeser

07-09-2023, 10:50 PM

Love the white board! I just use a note book...Which is pretty boring

It's my consulting background. Way to many planning/brainstorming sessions.
https://www.amazon.com/gp/product/B09YY85XY8/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

mrglaeser

07-20-2023, 06:42 PM

Ok well since my dolly had collapsed a couple weeks ago I thought I should rebuild it. This time I made it 10 inches longer, changed the rear support so I could place it closer to the rear, centered the 2x6s on the 4x4 rather than having it offset to the outside, and pre-drilled the holes for the lag bolts. Should I ever build one again it will be by stacking 2 2x6 and 1 2x4 and using longer bolts. The car is much better balanced, is easier to push around, and seems to be all around in better shape. It did take little extra to get the rebuilt dolly back under the car.

https://photos.smugmug.com/photos/i-fX9LHVK/0/X2/i-fX9LHVK-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fX9LHVK/A)

Started on the harness next. I painted the fuse panel - panel and installed it. I used some small hinges to hold it on the Cab side and I'm looking for some way to latch the side in the foot box.

https://photos.smugmug.com/photos/i-B5P9h2s/0/X2/i-B5P9h2s-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-B5P9h2s/A)

https://photos.smugmug.com/photos/i-7fRfmJz/0/X2/i-7fRfmJz-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7fRfmJz/A)

https://photos.smugmug.com/photos/i-38C5GGw/0/X2/i-38C5GGw-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-38C5GGw/A)

I didn't take a photo, but I also installed the brake switch, ground, inertia switch, and ran the Alt/Starter wires through the firewall. Next I plan to run the front and rear harnesses. I'm going to wait a little while on the dash.

I also had purchased some switches I thought looked cool and tested plati-dipping them black. But I don't like the results so I think I will probably end up a couple additional swtiches from FFR.
https://photos.smugmug.com/photos/i-P8qzSLk/0/X2/i-P8qzSLk-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-P8qzSLk/A)

Notice the holes get filled in. Additionally the plasti-dip makes it impossible to get the retaining ring on an off (switch is too big coated) - so impossible to install.

https://photos.smugmug.com/photos/i-rpqv97Z/0/X2/i-rpqv97Z-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rpqv97Z/A)

I plan on having switches for 2 vent fans, Radiator fan override, line lock, and hazards (though I'm not sure how I would do this one - maybe jumper the wires off the turn signal?). Also I'll have a blower motor rotary switch and a rotary switch to set how open the valve is to let heat flow to the heater core. The plan is just to extend the dash in the center to house these switches.

mrglaeser

07-20-2023, 06:43 PM

I also moved the fuel lines a little this week - after looking at John Ibele's (John thanks for the loan of some tools) car I realized there was no way the lines wouldn't rub the bellhousing and need a small re-route behind the 3/4 bar.

https://photos.smugmug.com/photos/i-8q4P6PJ/0/X2/i-8q4P6PJ-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-8q4P6PJ/A)

Additionally I picked up some poster board to mock up a drop trunk. And I fit two more trunk panels.

https://photos.smugmug.com/photos/i-zJF5PP7/0/X2/i-zJF5PP7-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-zJF5PP7/A)

https://photos.smugmug.com/photos/i-KdQL8gr/0/X2/i-KdQL8gr-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-KdQL8gr/A)

mrglaeser

07-29-2023, 02:34 PM

Well chipping away at different areas of the car at the same time. Must be a ADHD kicking in. I ran the rear harness through the transmission tunnel and the trunk area. It took awhile as I'm planning a drop kit and the normal installation guide says to run everything through the middle, but I won't have that area as the plan for the drop trunk is about 26 inches and get close to the fuel pump area of the tank.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mZmTMgJ/0/1098a9cb/XL/20230721_144507-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mZmTMgJ/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-WtLWDSG/0/371a51a5/XL/20230725_194246-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-WtLWDSG/A)

Then I ran the headlight part of the harness, installing the bilge fans so I could run the wire in the loom.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-bD4t2j8/0/b276c5d3/XL/20230721_144443-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-bD4t2j8/A)

I found these large plugs on amazon and cut holes for the loom.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-F4SKhTG/0/a4a31599/XL/20230725_194220-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-F4SKhTG/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-r99xhcb/0/82c76953/XL/20230728_165949-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-r99xhcb/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-hxR2sgs/0/5d7ffe0f/XL/20230728_165956-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-hxR2sgs/A)

mrglaeser

07-29-2023, 02:43 PM

Between electrical components I also started prepping for the drop tank. I fit the upper trunk aluminum. I had to cut out the FFMetal battery box cover, cut a couple groves for the screws that hold the battery box together, and trim out some metal for the drop trunk.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-TWmTZcV/0/0732c42b/XL/20230728_165757-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-TWmTZcV/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-R9rGjdn/0/82a63ae3/XL/20230728_101003-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-R9rGjdn/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mQT88hm/0/c9ae6a9d/XL/20230728_100951-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mQT88hm/A)

Next I decided to take out the DS angled 3/4 square tube. I'll cut around the PS side 3/4 square tube for the box, but I wanted most of the area to be easier to get in and out.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-6cwnvBc/0/e2c924fb/XL/20230728_165751-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-6cwnvBc/A)

Finally I made a bracket to secure the DS footbox inner sidewall to the Round tube/fram. It was driving me crazy that it didn't attach to anything.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-8DnhT3G/0/2de30d81/XL/20230728_150858-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-8DnhT3G/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-xsktFMV/0/49e087e1/XL/20230728_150851-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-xsktFMV/A)

Now I'm working on building a power harness. The Holley Sniper wants a direct connection and I'm adding Engine bay light, trunk lights, 2 power ports, 2 USB plug in ports, a powered valve to control the hotness of the heater, 2 bilge fans, and line lock. So quite few items not provisioned for on the Harness that need power. At the same time I will be templating an under dash switch panel, templating the drop tank, and cutting some heat insulation for the dash(before I can't get at it anymore). So lots to do.

mrglaeser

08-11-2023, 06:48 PM

Just some small stuff going on.

I wired in the LED Trailer Converter.
Put some lava mat along the firewall and used some trim adhesive to mount the heater valve servo control and LED trailer converter.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-CBfVHCr/0/32011b9b/X2/20230730_140845-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-CBfVHCr/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-f9p5LBQ/0/89a743a9/X2/20230730_140852-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-f9p5LBQ/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Xc9BCTM/0/f0e1725c/X2/20230730_142215-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Xc9BCTM/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-zKjW7s9/0/e301da46/X2/20230730_142224-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-zKjW7s9/A)

Yes I mix Blade and Bullet connectors... Ran out of one kind and didn't want to take 1/2 hour to go get more.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZQ5sFNv/0/448e75c0/X2/20230730_144335-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZQ5sFNv/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-S7RwhJC/0/92410f96/X2/20230730_151206-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-S7RwhJC/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-CzdpkwV/0/83a19bb7/X2/20230730_151221-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-CzdpkwV/A)

mrglaeser

08-11-2023, 06:52 PM

Next I tackled creating a power run. A single four gauge to run to the starter/relay and two ten gauges. One ten gauge for the Sniper EFI directly to the battery and one for the USB power, normal power ports, bilge fans, line lock, and heater valve servo.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-B64JX54/0/50ea5d6f/X2/20230803_132232-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-B64JX54/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fQz2rvw/0/dcdf58cf/X2/20230803_132243-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fQz2rvw/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-XWQGH2c/0/4bdc162a/X2/20230804_160239-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-XWQGH2c/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kQVZLBH/0/40b8b291/X2/20230804_160246-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kQVZLBH/A)

mrglaeser

08-11-2023, 06:55 PM

Additionally I fed a black ten gauge wire into the main hardness and ran it from the battery to the engine bay for the Sniper EFI
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-P3SRz4W/0/e8a02905/X2/20230803_142002-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-P3SRz4W/A)

Ran the main Ground from the battery
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-PtsX66m/0/4c040c1d/X2/20230803_141958-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-PtsX66m/A)

And installed tabs on the dash hoop to move the mounting screws down an inch or so to make them more easily accessed with the body on.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-qv5qQPp/0/383d88bf/X2/20230804_165112-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-qv5qQPp/A)
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Lt635c2/0/4e050c7e/X2/20230804_165106-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Lt635c2/A)
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-87smQ2D/0/680894e0/X2/20230804_165109-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-87smQ2D/A)

Finally I installed the rear USB and 12v Power ports
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-M6c2xRm/0/1ef69214/X2/20230804_165117-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-M6c2xRm/A)

zee

08-11-2023, 07:48 PM

The power port / USB port there is a great idea I never thought of. Passengers would rather have the port close to them to charge their phones! I shall copy this :).

mrglaeser

08-11-2023, 09:02 PM

The power port / USB port there is a great idea I never thought of. Passengers would rather have the port close to them to charge their phones! I shall copy this :).

Yeah I think now days you can't have enough power ports!

Blitzboy54

08-14-2023, 11:24 AM

mrglaeser

09-07-2023, 10:59 PM

FYI, it looks like you are running the LED converter for LED lights. I noticed on your picture of the fuse box you are using non grounded relays that look like for standard lights. If you run LED lights you will need an LED relay like this one.

https://www.amazon.com/gp/product/B07P4QLLL9/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

Like I said I was only looking at a picture, you may have an LED compatible relay already but just a heads up to take a look.

Thanks for the note Blitzboy54 - I actually do have the LED flashers I just didn't put them in yet. I installed the fuse box as it came in the wire harness kit. I ran most the wiring but haven't done the connections yet as I'm doing a drop truck mod. But since the kits aren't available at the moment I'm fabbing my own. Hoping to get back to wiring in a couple weeks.

mrglaeser

09-07-2023, 11:20 PM

Working pretty slowly lately. A lot of 'Life' and 'Work' going on keeping me out of the shop. But still got a few things done.
First I put in an LED light for the trunk and ran power for it. I'll add a switch once the body is on. I also wired the power to the rear power ports.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-X8Tfxnz/0/4101e815/X2/20230814_203908-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-X8Tfxnz/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-hHXKdvw/0/0bbca7bd/X2/20230814_204629-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-hHXKdvw/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-djp2nGd/0/3a7cb9ef/X2/20230814_204638-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-djp2nGd/A)

Now on to the drop Trunk

First I fit the lower trunk floor section and drilled for rivets
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-M6GjF9C/0/22263435/X2/20230814_203838-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-M6GjF9C/A)

Then I pulled the passenger side fuel tank strap using a ratchet strap to keep the tank in place.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Qkfd9WN/0/673eee81/X2/20230814_204650-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Qkfd9WN/A)

Next I cut the panel and one of the cross members out for a drop trunk
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-5MSBBTP/0/863a2899/X2/20230815_204136-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-5MSBBTP/A)

mrglaeser

09-07-2023, 11:27 PM

Next I modeled the panels with poster board. A little harder than I expected because it sagged so much. Next time I'll stick with cardboard.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mzmZwtb/0/e4439328/X2/20230817_211036-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mzmZwtb/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-cWxPgQk/0/885a1bef/X2/20230818_212459-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-cWxPgQk/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Bt24HnV/0/45f3f203/X2/20230820_121250-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Bt24HnV/A)

yeap that is scrap brake line trying to take the sag out of the new floor.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DLkhNtg/0/2d4cb8bc/X2/20230820_123043-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DLkhNtg/A)

I bought 3 sheets of aluminum just in case. I haven't done much fab and I'm sure I'll find uses for the aluminum sometime anyway. I was able to layout all the templates on a single sheet.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-jqJB6Pv/0/025613f9/X2/20230820_135218-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-jqJB6Pv/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kfHp7Qs/0/8becc3bc/X2/20230820_141025-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kfHp7Qs/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-MSppKm8/0/ddc1f8b0/X2/20230821_193508-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-MSppKm8/A)

mrglaeser

09-07-2023, 11:32 PM

John Ibele was nice enough to lend me his 36inch sheet metal brake
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Jk7J92L/0/32b7a6ec/X2/20230904_104546-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Jk7J92L/A)

I picked up a lot of deep clamps from harbor freight after completely botching a bend with cheaper plastic ones (remember I bought 3 sheets of aluminum. Whelp it came in handy when I needed to recut a new piece)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-J2CPX3T/0/7024c744/X2/20230904_104552-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-J2CPX3T/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-59XGbd9/0/c58d91f3/X2/20230904_104802-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-59XGbd9/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-FNhm95B/0/d64d821b/X2/20230904_110303-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-FNhm95B/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-xdCw5mc/0/df396a7d/X2/20230907_195143-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-xdCw5mc/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-jpTFmWh/0/541ba628/X2/20230907_195154-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-jpTFmWh/A)

mrglaeser

09-07-2023, 11:35 PM

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-jVKJg5H/0/78f866f4/X2/20230907_195124-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-jVKJg5H/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-vhXdT6G/0/f39dd5db/X2/20230907_195233-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-vhXdT6G/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-QKv5nZp/0/79a75429/X2/20230904_121735-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-QKv5nZp/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3WNLQ8q/0/e6154ded/X2/20230904_121740-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3WNLQ8q/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-GfTWgBP/0/176f42c9/X2/20230907_191710-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-GfTWgBP/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nRkQDGj/0/4675b674/X2/20230904_114210-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nRkQDGj/A)

mrglaeser

09-07-2023, 11:50 PM

So not sure I would design the drop trunk the same way again. I was trying to maximize space, and because I have a solid axle and 4 link setup I could cut further back. I also cut all the way over to the 3/4 tube on the drivers side. This required a lot of weird shapes and extra bending. Should I do one again I think a simple box will suffice.

Anyway hopefully this weekend I can cut the hole for the access panel. Do all the drilling for rivets and move on to the Breeze cubby modification. Once that is fitted I can start painting and installing it all. Hopefully it won't take all month to get there.

F500guy

09-08-2023, 08:15 AM

Very nice work!

mrglaeser

09-17-2023, 04:50 PM

Still working on the trunk. A lot of painting. Will have the assembled photos probably next week. Here is a shot of the weird little corner cover I needed to create for the drop trunk - one of the reasons I would make it different next time.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-BsQbWgZ/0/8739d10a/XL/20230916_211346-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-BsQbWgZ/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-MbLRfjM/0/f744a58c/XL/20230916_211352-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-MbLRfjM/A)

Besides that started to mock up and fit the dash
Knocked out the little tabs to increase the size of the two gauge holes and temporarily put some gauges in to see (They are not in the order I want them in for the final assembly)
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pxbjSbN/0/cd2fc6d1/XL/20230911_144520-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pxbjSbN/A)

I drilled the holes bigger for the horn, ignition, light switch, and heater controls. Plus added a hole for the turn signal left of the gauges and indicator light above the wheel.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-SMhfD7x/0/5a5ab954/XL/20230914_150327-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-SMhfD7x/A)

mrglaeser

09-17-2023, 04:52 PM

I'm using 66 Mustang ignition switch and light switches and wanted to use two similar knobs for the heater controls. So i ground down the shaft on the fan speed switch to test fit a Mustang knob and it worked.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-5vGTQsd/0/0b34af84/XL/20230914_141832-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-5vGTQsd/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-GrzFdB6/0/0c24c155/XL/20230914_142015-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-GrzFdB6/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-c3nBzJv/0/7f25f646/XL/20230914_142034-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-c3nBzJv/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-JffTX7Z/0/9f565508/XL/20230914_142040-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-JffTX7Z/A)

Will do the same for the hot-cold solenoid control next. Finally I played with cardboard and modelled out a switch panel for all the accessories (foot box fans, hazard lights, radiator fan override, and line lock).

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gHp7RS2/0/e59b8c66/XL/20230914_132759-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gHp7RS2/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-dxKrVPD/0/f2004240/XL/20230914_132810-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-dxKrVPD/A)

I should be able to knock out the aluminum version next week.

John Ibele

09-18-2023, 10:39 AM

mrglaeser

09-21-2023, 11:18 PM

Great progress, Matt! Drop trunk looks great - structural impacts aside (not sure about the impact of removing the one brace but I’m sure you considered it carefully), you’re going to have some nice additional storage space there. And you provided a good example for all those folks who want the space, and don’t have Russ’s fine product to purchase.

And the switch panel comes to life! I love seeing builders’ design sense become a reality. So cool to watch it take shape.

Thanks John! I've been having a time with your metal break. Now I see places for additional brackets and changes everywhere! I'm really pleased with how it's coming out.

We talked about that support in Build School for a while and the consensus there was that it should be ok. But if comes out of square or causes issues I'll let everyone know.

mrglaeser

09-21-2023, 11:31 PM

Now for some fun... well its all fun really. Making the swtich panel. Step one draw out the template onto some metal.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nwmdjgs/0/c85a2fc4/X2/20230917_192951-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nwmdjgs/A)

Then cut the shape out little by little
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-WGhvK8G/0/944b6bd7/X2/20230917_201522-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-WGhvK8G/A)

Drill holes
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-RbgHjsT/0/e75e1dcc/X2/20230918_102700-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-RbgHjsT/A)

and bend
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4hbkNs3/0/bbdae53d/X2/20230918_111249-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4hbkNs3/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-P3kbJBc/0/70732be0/X2/20230918_111253-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-P3kbJBc/A)

put the goodies in for a test fit
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-QfhTTTg/0/d02eff95/X2/20230918_114229-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-QfhTTTg/A)

I plan to cover the panel in the same material as the dash otherwise the rivets would be lined up better.

mrglaeser

09-21-2023, 11:36 PM

Here is a more complete dash mock up.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fxbnP8v/0/2657c8a0/X2/20230918_122408-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fxbnP8v/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-p2Lkvtk/0/50c0b123/X2/20230918_122416-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-p2Lkvtk/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-t8d5BNr/0/5c47aa9a/X2/20230918_122424-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-t8d5BNr/A)

mrglaeser

09-21-2023, 11:40 PM

Additionally I put in 500 or so rivets and attached all the trunk paneling.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-X69HT7g/0/f41d7135/X2/20230919_104358-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-X69HT7g/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-K4Z6T2s/0/f25a3fa3/X2/20230919_104405-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-K4Z6T2s/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-b99Btjw/0/62ba7b7b/X2/20230919_104412-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-b99Btjw/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-vT3DwXP/0/89109b7b/X2/20230919_104420-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-vT3DwXP/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-WFwvF27/0/285a9f66/X2/20230919_104426-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-WFwvF27/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-f5NL36q/0/01bc1f4b/X2/20230919_104432-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-f5NL36q/A)

Fixit

09-22-2023, 05:42 PM

Looking good! Great progress!
This may give you some ideas about your trunk illumination (https://thefactoryfiveforum.com/showthread.php?27544-40-Watt-Garage-amp-9365&p=347762&viewfull=1#post347762)

mrglaeser

10-05-2023, 03:02 PM

Looking good! Great progress!
This may give you some ideas about your trunk illumination (https://thefactoryfiveforum.com/showthread.php?27544-40-Watt-Garage-amp-9365&p=347762&viewfull=1#post347762)

Thanks Fixit. I didn't even think about illuminating the cubby. (Slap to forehead). I bough two roles of LEDs so I can go crazy if need be. As for wiring I was running a 10ga always hot for other accessories and just tapped that for my trunk (possibly cubbie) light, USB power, and standard power port in the back. The front end of the circuit will get it's own fuse and run engine bay lighting, footbox vent fans, linelock, another USB powerport, and an additional standard power port. I did think of using the radio wiring but incase everything was running at once decided on a larger dedicated power supply. I also ran a 10ga for the Holley Sniper setup, so lots of direct battery power.

mrglaeser

10-05-2023, 03:14 PM

So the last two weeks have been mostly making brackets and fitting the dash. Hopefully next week I can the dash rapped the I can start that part of the wiring.
-built some brackets similar to IE427 recommendations to screw the dash into hopefully lowering the screws so if need by I can remove the dash with body on.
-modified the heater register brackets that came in my generic Jegs kit
-created fire wall support brackets so I can mount the brake reservoirs on the firewall as I am running a Mustang pedal box and power brakes
-created custom slimmer brackets than come in the kit to tie the dash in at the bottom as my switch panel was adding some weight and I felt might make the dash do funny things.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fSRnXCf/0/bd9dc46c/X2/20230928_135751-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fSRnXCf/A)

Two brakets rivet to the outside of the hoop that supports the dash, then I tapped them for some M5 bolts because I found some bucket washers I liked.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-dFqJngH/0/f420c3dd/X2/20231001_114202-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-dFqJngH/A)

3 Brakets under the hoop
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pGg2Wfx/0/d8fc922d/X2/20231001_114209-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pGg2Wfx/A)

here is the bolt and washer combo.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mhNKBzt/0/ef6ee6ae/X2/20231001_131039-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mhNKBzt/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-NmPm2L5/0/03c9b701/X2/20231001_131048-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-NmPm2L5/A)

I also installed rivet nuts so I could attach the switch panel. Here everything is screwed in rather than being held by clamps
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ccw8LQ4/0/2e518e94/X2/20231001_131100-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ccw8LQ4/A)

mrglaeser

10-05-2023, 03:20 PM

Here are the heat registers and brackets under the dash

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-5Tqcdqr/0/6e400609/X2/20231001_134914-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-5Tqcdqr/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wKcqrng/0/ed6cdde9/X2/20231001_134929-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-wKcqrng/A)

please ignore the extra hole where the switches are mounted those were to reduce weight not a bad measurement I promise.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-dQR3rDr/0/5ec8142b/X2/20231001_151614-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-dQR3rDr/A)

and finally the Firewall support
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-StWp8SS/0/3b9af453/X2/20231001_145112-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-StWp8SS/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-GpvWWP2/0/1b8f870b/X2/20231001_145122-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-GpvWWP2/A)

I also mocked up an Oh---Sheesh handle on the passenger side but need to make those brackets now. Good news is the same M5s fit the 4 screw holes for the handle. So I got that going for me which is nice.

mrglaeser

10-17-2023, 10:53 PM

No onto the most important part of any build. Cup Holders

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-RnHJhJ9/0/9dcd1c4d/X2/20231006_084804-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-RnHJhJ9/A)

nothing surprising in the this work. Marked everything from the underside and cut some holes.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fmQdxRN/0/90a0855d/X2/20231006_134705-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fmQdxRN/A)

I did decide to take some of the tunnel and mount it fixed and make part of it removable. The fixed part will host a power port, a USB Power port, and the power shutoff.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-FZrHck9/0/5d5289e3/X2/20231006_134718-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-FZrHck9/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4PGJSBR/0/364f5b1d/X2/20231006_151036-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4PGJSBR/A)

mrglaeser

10-17-2023, 10:59 PM

After watching some more i.e.427 (https://thefactoryfiveforum.com/member.php?22850-i-e-427) videos I decided I wanted some brackets for the dash OH SH!7 handle. I made them out of steel to give the best reinforcement

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-f37PtNm/0/b653f8e7/X2/20231006_161015-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-f37PtNm/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pjmhqTX/0/630c6099/X2/20231006_113053-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pjmhqTX/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-MDvR6hc/0/d8668d76/X2/20231006_113047-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-MDvR6hc/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rvP695q/0/18f4d84f/X2/20231006_113040-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rvP695q/A)

mrglaeser

10-17-2023, 11:01 PM

Couple of shots of the cockpit mocked up.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-WbBhR5b/0/f71fb4c1/X2/20231006_151338-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-WbBhR5b/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gCd3Q9v/0/0431b3a5/X2/20231006_151350-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gCd3Q9v/A)

mrglaeser

10-17-2023, 11:09 PM

For some heat mitigation I purchased some Basalt based heat shielding. Made some templates, cut it out, and stuck it to the footboxes.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-p2Z7PrD/0/d4a257f8/X2/20231016_133816-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-p2Z7PrD/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-zjFcLFK/0/32339066/X2/20231016_145835-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-zjFcLFK/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kRSvXCW/0/2abfb240/X2/20231016_145842-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kRSvXCW/A)

I've also heard from some local builders that a lot of sand and junk gets into their trunk. So I used some aluminum tape and covered any place I saw light through.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-84W3x4g/0/2365e948/X2/20231017_140751-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-84W3x4g/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DH5Cnr9/0/e4d4f37e/X2/20231017_140803-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DH5Cnr9/A)

Additionally I mocked up the air ducting... there isn't much room left now. The longer line (the part sagging in this photo) that goes across will actually be zip tied toward the firewall.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-bt4pdGG/0/48d624d4/X2/20231017_105431-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-bt4pdGG/A)

Fixit

10-18-2023, 06:19 AM

mrglaeser

10-18-2023, 09:09 AM

Looking very nice... lotsa progress!

Thinking about the tape on the trunk seams... It probably won't live too long in the environment of the wheelhouses. Invert your idea. Tape the seams inside the trunk (assuming it will be covered by carpet), and squooge a bead of silicone or seam sealer into the gaps/grooves on the wheelhouse side.
Here's something to think about as well. (https://thefactoryfiveforum.com/showthread.php?27544-40-Watt-Garage-amp-9365&p=365744&viewfull=1#post365744)
I had to slightly massage them (heat gun) after the car was Kleinerized, but it didn't take much.

Thanks Fixit. I am doing some on the inside as well, there are places though it's not sticking that I need to give a good scrub to. I wasn't sure or not if it will last but figured it can't hurt. As for the rubber covers. Yes great idea. John I just did that as well. But I'm far enough away from the body going on that it will be a while. I had also seen these in the past https://vraptorspeedworks.com/mk-4-wheel-well-liner-kit/. So once I have the body on I'll stick my head in there and decide how I want to proceed.

mrglaeser

10-28-2023, 09:56 PM

Moving On....

After watching another I.E.427 video where he forgot to put in the brackets for the trunk support I figured I better get after now whilst the body is off. I then realized I had not cut holes for the air shocks to pass through in the cubby hole wall. So I cut them out.

Measure 100x cut once
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-P7xsVBM/0/61aae055/XL/20231016_145925-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-P7xsVBM/A)

two hole saw cuts to start for each side
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nLNFQkb/0/ffbcc936/XL/20231016_150355-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nLNFQkb/A)

yay glad to use this bit again. I thought I would only need it 4 times, now I'm up to 8
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-5pjM8ch/0/33ee670b/XL/20231016_150359-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-5pjM8ch/A)

here's the driver side all worked out
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-xHFc2g7/0/20c40362/XL/20231016_151932-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-xHFc2g7/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-HH6sqrJ/0/bd172c52/XL/20231016_151943-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-HH6sqrJ/A)

I also tried to figure out everything I need powder coated. Took apart the indicator lights, tail lights, leman's cap, hood/trunk latches, trunk hinges, and pulled a bunch of other stuff out of boxes. Sent the current list to get an estimate.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-z5B5kFb/0/5ce3d412/XL/20231020_135352-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-z5B5kFb/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-GtWgNpV/0/41d8ce65/XL/20231017_135816-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-GtWgNpV/A)

mrglaeser

10-28-2023, 10:06 PM

I also put in the courtesy lights and a light in the cubby. I used some specially designed crimps for LED light strips. Much easier than soldering like what I did for the trunk.

Here is a close up of the crimp
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-tdJFdrD/0/6763b943/XL/20231027_105734-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-tdJFdrD/A)

Just cutaway the rubber on the LED to expose the copper contacts as if you were going to solder.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nx46mLL/0/9aa3db76/XL/20231027_105823-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nx46mLL/A)

Slide the clip over the contacts, strip your wires slide them in, and press the two metal strips down into the plastic retainer.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-SDTF63Z/0/67d3e5f2/XL/20231027_110938-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-SDTF63Z/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gtQwCJk/0/6259cfde/XL/20231027_114456-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gtQwCJk/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7rJMcg4/0/0bc86218/XL/20231027_114541-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7rJMcg4/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-VQdb8BS/0/e2749d13/XL/20231027_114554-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-VQdb8BS/A)

The cubby hole uses the same power supply as the trunk and has it's own switch installed on the bottom of the 3/4 bar. The front I wired to the circuit in the Ron Francis Harness.
I'm not sure what they were thinking with that part of the harness it reaches all the way to the passanger door practically. I pulled the Courtsey light wires and cut them down to clean things up a bit. Not sure but I'll probably cut the other wires down. I'll use the heater power for sure, maybe the wipers power side can be repurposed for the footbox vents, the radio line looks to small for the line lock but I'll have to look up the amp requirements.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-sk9dLVD/0/33f59416/XL/20231027_122757-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-sk9dLVD/A)

mrglaeser

11-03-2023, 05:07 PM

ooofda - Spent the last few hours in the shop working on covering the trunk area. I went a little different than most people. I tend to like to do longer drives and rallies so I normally have spare parts and fluid in the trunk. Because I'm a clutz I also tend to spill said fluids. So in stead of carpet I went with vinyl similar to what a mid 60's Chevy might have. I got lucky and a friend of mine gave me some tips and trips on upholstery, but I still made a few mistakes.

-First I only spayed the trunk and not the back of the material, and I used too much adhesive on the first piece. After a few minutes the piece was not really adhering. So I got out some boards and clamps and forced it to stay in place for 24 hours. This fixed the mistake.
-Then I had a learning curve on spraying the 3M adhesive and made quite a mess.
- I have a couple gaps I'd rather not have, but once the body is on they'll disappear
- I realized the complicated drop trunk shape caused an extra seem I could have avoided with a simple box
- I need to get a little better with a utility knife.

That said I'm actually very pleased with how it came out. I still need to do the cubby and cover the fuel pump access panel.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-BKDQwCS/0/b3db8992/X2/20231027_084451-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-BKDQwCS/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kcrTXzZ/0/fd7e208b/X2/20231031_162802-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kcrTXzZ/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4VgqRfr/0/117e6e99/X2/20231031_162804-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4VgqRfr/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-W3LzNF3/0/cc907c2d/X2/20231101_120134-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-W3LzNF3/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZQt6Rtf/0/902c3b35/X2/20231101_142012-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZQt6Rtf/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-p4K4ZBN/0/8fe4fccc/X2/20231103_125859-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-p4K4ZBN/A)

mrglaeser

11-03-2023, 05:09 PM

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pQVDMP4/0/e6e8a787/X2/20231103_125903-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pQVDMP4/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-8SFcQhN/0/a7c2a248/X2/20231103_125908-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-8SFcQhN/A)

I also put sound deadening on the rear wall. Next week I'll put the pre-cut breeze pieces in the passenger side.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-cbPc6pD/0/cfbf4cf0/X2/20231103_134849-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-cbPc6pD/A)

I'm also really excited as my short block should ship on Monday. I've only been waiting 19 months.

Railroad

11-04-2023, 04:00 PM

Check your cubby hole opening trim. It might not fit over the sound deadening and carpet too. It's easier to trim back the area now.
Nice work.

mrglaeser

11-06-2023, 11:57 AM

Check your cubby hole opening trim. It might not fit over the sound deadening and carpet too. It's easier to trim back the area now.
Nice work.

Thanks Railroad. I will double check prior to carper. Great advice.

mrglaeser

11-24-2023, 10:50 PM

Well the shipping date for my Ford Performance Short Block came and went. Looks like they have revised the ship date to Feb 5 2024. So I'm trying to find things I can continue to do without a drive train.

For Starters I closed all the gaps in the foot boxes with some 3M Strip - Caulk I've had on the shelf for ages. It's pretty much made for this purpose so I hope it holds up.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-WcpP2dJ/0/027d40a6/X2/20231124_132011-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-WcpP2dJ/A)

Probably could have smoothed it out better but the Koolmats going to cover it up anyway.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-K3t7rGx/0/0d96a3f4/X2/20231124_133117-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-K3t7rGx/A)

Next I put in 3/4 of the Breeze Koolmat kit. I have to wait on the last driver's side foot box and driver's side tunnel wall, but I got the rest of the pieces in. I hope the material does a really good job because I didn't save a ton of time as most pieces needed trimming to get them to fit.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4dQjQdH/0/3060b9b3/X2/20231124_132025-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4dQjQdH/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-FtC8qFB/0/5677f2b9/X2/20231124_132033-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-FtC8qFB/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-sgLQ96H/0/2bb3af51/X2/20231124_152409-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-sgLQ96H/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-BGvPX7j/0/584ca55a/X2/20231124_152417-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-BGvPX7j/A)

Other Items I think I can work on while waiting for the Drive train are:
1.) The fresh air vents for the foot boxs
2.) Get the radiator setup ready. As I have both the Breeze Hinge kit and lower support, plus fan/shroud with Controller, there is going to be some time needed there.
3.) Soon I should have my Dash covered and then can install and wire all the gauges and switches.
4.) Mock up the seat tracks
5.) Create a wiring cover for the trunk lid
6.) Install the parking break

Maybe this will keep me busy until Feb. Any other ideas?

mrglaeser

11-30-2023, 02:17 PM

I picked up most of the interior today from the upholstery shop, Knish Kustomz in Kilkerny, MN. An amazing shops that does a lot of small and big builds every year, including a few SEMA projects.
https://www.facebook.com/KnishKustomz/?fbclid=IwAR0YSlKZjrNfmnHl9raldt0n6G_9UdLFwzp333mL m-FK9GPY9LGvmvkJDn8
https://www.instagram.com/knishkustomz/

Another of Knish's cars was a much more customized Mark IV.
https://thefactoryfiveforum.com/showthread.php?29445-Please-Graduate-FFR-8352&fbclid=IwAR1TpZvWcdRNYfn5hN5rdyg-O0tynO3f9doz4KbP9CFjjEBzE_VagbVhxQY
https://www.ffcars.com/threads/please-graduate-ffr-8352.634090/
https://www.ffcars.com/attachments/cobra-5-8-18-18-jpg.326178/

Anyway I am so happy at well it came out. I didn't go full custom but I wanted to do a saddle interior rather than the standard black and I am stoked to see everything together (probably in a year or so)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-733CnWq/0/dae3ef66/X2/20231130_114556-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-733CnWq/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-VCw7cFZ/0/2458793f/XL/20231130_114532-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-VCw7cFZ/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gGf8rRJ/0/1af44044/L/20231130_114525-L.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gGf8rRJ/A)

Latter once I get the drive train put in I'll get the tunnel cover done too, but with a double stick up the center and single stitching along the corners. I like quilting but having looked at some back draft cars feel it can be over done. Will have to pick out some dark tan or brown carpet to compliment the great job Knish did.

mrglaeser

12-07-2023, 05:56 PM

Exciting week this week. Though I didn't get any shop time in.

First after an 18 month wait my short block from Ford Performance Parts came. Which allowed me to borrow and drive our facilities fork lift. Which is always fun - though it's been 25 years since I've needed to drive one. Doesn't look like a motor now but it will in the next couple months. Need to get my hoist out to the shop next.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-JXWqGgW/0/f2b7d5d7/X2/20231204_141429-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-JXWqGgW/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Kw2JVn5/0/a540e0ad/X2/20231207_120706-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Kw2JVn5/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-XgfPzLv/0/b543a9bf/X2/20231207_121606-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-XgfPzLv/A)

Next the machine shop called and my steering boss is complete. I had them machine it so an NRG slim quick release can be mounted to it. Turned out pretty good.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Wt7Wrtk/0/936b2013/X2/20231207_121932-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Wt7Wrtk/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-KwHJvxL/0/7d064c6f/X2/20231207_121936-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-KwHJvxL/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-LFsq7MK/0/8c86ecb5/X2/20231207_121939-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-LFsq7MK/A)

zarnold

12-07-2023, 10:51 PM

Ooh!! Very very nice block. And ordering it directly for Dearborn, MI is cool too.

mrglaeser

12-21-2023, 07:21 PM

Well the last couple of weeks have been pretty slow. Mostly just working on some wiring odds and ends and getting the dash ready. Once that is done I'll turn my attention to the engine build.

I spent a couple hours putting most of the components in the dash. Then I could not wait to see it mocked up on the car.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-K66B4VX/0/0a083f3c/X2/20231215_162540-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-K66B4VX/A)

Another day I wire up the headlight switch, heater fan switch, heater cut off servo control, and the dash side connector for the foot box fans/radiator manual fan/Line Lock.

I'm using a 1965 Mustang Headlight Switch. I got a pigtail from Midlife wiring harnesses (he restores Mustang Harness and resells them http://midlifeharness.com/) and replaced the RF harness connector with it.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mFZVrLq/0/e57b6c7f/X2/20231216_173644-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mFZVrLq/A)

It took a few wiring Diagrams to hopefully have sorted it out
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gR3Q8qC/0/ac73bf2d/XL/20231216_173710-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gR3Q8qC/A)

Here are the connectors for the Fan Switch all wired up. Again wired into the RF Harness - at least for the heater power lead.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nb4M3kN/0/24ae2ce5/XL/20231217_132211-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nb4M3kN/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-th5PDLD/0/de60f1e4/XL/20231217_132224-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-th5PDLD/A)

and finally the very exciting connector for Footbox vents/line lock/radiator fan override - the other side will get put together once I get the switch gaurds powder coated and the accessory switch panel together.
https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7tgVHvv/A

Today I did 90% of the harness to gauges/dash wiring. Still need to sort out the hazard switch and dimmer switch. I also need to run the GPS speed sensor wiring and the Speedhut oil pressure sensor. Since it needs 3 leads and the RF harness only has 2 I'll just run it and tape off the RF wires.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-XJqvTsw/0/3b092369/X2/20231221_151808-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-XJqvTsw/A)

mrglaeser

01-15-2024, 09:59 AM

Well after a lot of back and forth and some re-wiring I finished the dash wiring. Not much to see but the pic below the add on switches are now wired. Not shown is I dieted the harness of the sensor wires in the engine bay and replaced them with the Speedhut leads. Also I wired and rewired the ignition switch.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kLvn3Cv/0/958cd9b4/X2/20240101_113143-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kLvn3Cv/A)

Now that the wiring in the car is mostly done (minus the Sniper/Hyper Spark/Engine bay) we're moving on to building the motor.

As mentioned in the above link the short block from Ford Racing Final came in December. This last week we unwrapped the turkey and got it mounted to the engine stand. We had to clean and test the engine hoist since it has just been sitting in the corner of the garage for over a decade without being used. Still worked fine so that was nice. But of course we needed to run to the store to get some additional bolts and washers.

We also had planned to do the timing component install but I misplaced the assembly lube. I was surprised to find that none of the Napas, O'Reilys, or AutoZones had any. I finally found an Advanced Auto with a single bottle. So we'll get back to the assembly this week as I ran out of time on Sunday.

Here are some unbocking photos. My friend said we should have gone full Gen Z and done a youtube unboxing.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-CTXKsMK/0/b0f10569/X2/20240113_133727-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-CTXKsMK/A)

I thought it looked like a turkey or ham in the frozen food section.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-c5FwNLh/0/9c542c0e/X2/20240113_133730-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-c5FwNLh/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-W9JMfhz/0/eff0ffa2/X2/20240113_134018-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-W9JMfhz/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gxRFnGb/0/8889e2f0/X2/20240113_134023-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gxRFnGb/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2TJthQD/0/7099b10d/X2/20240113_134031-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2TJthQD/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-8xT7hSP/0/4f244924/X2/20240113_134043-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-8xT7hSP/A)

mrglaeser

01-15-2024, 10:01 AM

And onto the lift it goes

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ngpKT9x/0/2476fce6/X2/20240113_150341-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ngpKT9x/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Kvs8mTH/0/f65647e6/X2/20240113_150350-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Kvs8mTH/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-8nr87bR/0/df040a32/X2/20240113_150515-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-8nr87bR/A)

It's home for the next month or so

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-L6Svf44/0/1c14dd8b/X2/20240113_151052-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-L6Svf44/A)

mrglaeser

01-28-2024, 10:24 PM

Well now that it's time to work drive train it's time to update the task board.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-PF765qN/0/223f614a/X2/20240128_134111-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-PF765qN/A)

5 tasks carried over. Which is better the last time I cleared the board.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2v5mbfg/0/eb9b7e67/X2/20240128_134414-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2v5mbfg/A)

Ok most of the new tasks are on the board, I'll keep adding to it for a bit.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-VxrZhGj/0/cd1758bc/X2/20240128_135433-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-VxrZhGj/A)

Not much progress to report at the moment. Because I decided to build a short block up rather purchase a completed engine I'm learning slowly what does and does come in the various kits you buy (short block, top end kit, bolt kits, gasket kits, etc). I'm also learning there are few more differences between a 1969 302 and 5.0 based 347. Mostly I'm just missing things. Like the spider tray and lifter retainers, random bolts and nuts, etc. Since I'm busy at work right now I only have a few hours to work on the project each week and I find that I spend more than 1/2 that time figure out the next step, what is missing, and how to get it. That said, like everything else in this build, the next build would/will go much faster based on my learnings(probably should dream of the next project when this one is so far from the finish line).

So basically in the last 2 weeks I have... Drum roll please... Installed the Cam, Timing Gear, and Timing Chain. I also degreed the Cam.

I got to buy this nifty sprocket that allows me to degree the cam without installing the balancer or put torque on the Crank Shaft bolt.

It slips over the crank shaft and engages with the key to turn the motor. It has a knurl bolt to tighten against the Degree wheel. Pretty cool - I recommend. I got it on Amazon - it's made by Comp Cams.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nqT94D7/0/8197245a/X2/20240128_130958-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nqT94D7/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-SxmFP6t/0/6682ba7a/X2/20240128_131002-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-SxmFP6t/A)

Here it is in use. I'm not as happy with my cylinder bridge. There is no way to secure it to the block so I ended up just turning the block 90 degrees.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-VmPjmQ6/0/5d1eb15b/X2/20240128_122556-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-VmPjmQ6/A)

mrglaeser

01-28-2024, 10:31 PM

I also inspected the heads, the lifters, push rods, rockers, oil pan, harmonic balancer and timing cover and made sure I have all the bolts I need, valve guides and rocker studs. So once I get a new spider tray and lifter retainers I should be able to get most of the engine build done. Though I should probably pull out the water pump, oil pump, and intake manifold as well.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-FXWf2L8/0/df7fe1ed/X2/20240128_123937-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-FXWf2L8/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4wNtVnF/0/aabe4e56/X2/20240128_123946-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4wNtVnF/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZHVSJwX/0/2c950631/X2/20240128_123718-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZHVSJwX/A)

mrglaeser

02-01-2024, 10:34 AM

Not sure if I have to have a Fuel Eccentric. But I decided it is probably better to install one and not use then want to use the motor with a Carb + Mechanical pump and not have it. But continuing the theme of parts that don't come in kits when building up a short block here is another to add to the list.

zarnold

02-01-2024, 10:19 PM

Yep, better to have it and not need it than visa-versa :)

mrglaeser

02-11-2024, 12:11 AM

Got a new fuel pump eccentric and installed it today, plus torqued down the cam bolt.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-vJgTnP9/0/79e70c65/XL/20240210_145716-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-vJgTnP9/A)

Then I had some help putting the lifters, dog bones, and spider tray in.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-6D4pSpv/0/f0ebf253/XL/20240210_145734-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-6D4pSpv/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7BjTbqH/0/55002670/XL/20240210_145852-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7BjTbqH/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-JnMdD3B/0/0ce2f589/XL/20240210_150124-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-JnMdD3B/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-RQwMfch/0/3ce5f627/XL/20240210_153108-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-RQwMfch/A)

The rest of the plan today was to check the valve to head clearance and hopefully bolt the heads down and install the rocker studs, push rods, push rod guides, and rockers today... So we put some clay in the first pistons recesses. bolted the head down. Set up the studs and guides for cylinder one...

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-C5X34PZ/0/a1eaf511/XL/20240210_155010-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-C5X34PZ/A)

and...

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DBr9znb/0/cb5812b0/XL/20240210_160718-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DBr9znb/A)

The push rods are too long. It looks like I was sent 351 pushrods by the supplier. I'm thinking this happened because their tech support said I need the 351 ARP head bolts for the boss block (and they seemed to fit fine) and when I ordered just ask for the swap. My guess is they saw 351 head bolts and also swapped in the 351 push rods which are 1.5 inches longer. So again I'll be waiting for parts as this becomes a very drawn out engine build.

mrglaeser

02-11-2024, 12:12 AM

One more shot of the long push rods.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DMmbbQP/0/3bab82d9/XL/20240210_160705-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DMmbbQP/A)

mrglaeser

02-11-2024, 12:17 AM

Last weekend my younger daughter and I visited John Ibele (https://thefactoryfiveforum.com/member.php?5170-John-Ibele) and he gave us a nice tutorial on home powder coating, while also doing some sample parts for us. It was as usual great to hang out and learn something knew. Plus see some of the finishing work he is doing on his car.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-PKzdqrM/0/03c84e51/X2/20240204_151411-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-PKzdqrM/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-5zGKsCB/0/1eb9af34/X2/20240204_151713-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-5zGKsCB/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-TKRNnKP/0/78345fce/X2/20240204_155732-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-TKRNnKP/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Pq4cwT9/0/030862cd/X2/20240204_155740-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Pq4cwT9/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-htgnZSG/0/e804c326/X2/20240204_161836-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-htgnZSG/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZQmT35k/0/8acc4ed8/X2/20240204_162851-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZQmT35k/A)

Thanks again John!!!

Mike.Bray

02-11-2024, 11:34 AM

mrglaeser

02-11-2024, 03:15 PM

Nice looking engine so far! You're going to have to measure the pushrod length with all of those aftermarket parts. Use something like one of these (https://www.summitracing.com/search/product-line/trick-flow-adjustable-pushrod-length-checkers/part-type/pushrod-length-checkers?fr=part-type&SortBy=Default&SortOrder=Ascending).

You're looking for a particular position and pattern on the valve tip, I'll let you Google & YouTube that part so you have nice visuals. This one (https://www.youtube.com/watch?v=oeLWK0LpTc4) from Summit is okay, I've seen better.

Mike

Thanks for the information Mike. The top end kit was supposed to take that all into account. I think the guys who packed up my order saw 351 head bolts which the Boss Block needs and thought I was building a 351 and sent the push rods for that. But after watching the video I think I will confirm the length when I get the ones that are supposed to be in the kit using the technique in the video above. Then if I don't see the pattern expected like in the video I'll stop get the checker and figure out the length.

mrglaeser

02-26-2024, 03:24 PM

Received replacement push rods from my supplier. They didn't make any fuss just said send them back and we'll swap them. That is after I had them nearly 2 years. So I proceeded to install them on a cylinder and complete a Valve to Piston clearance check and verify the push rod length.

Here is a fun pic showing the difference in length. Also I realize I didn't send a pushrod back so I'll have to package it up and mail it back.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-jjRpbG5/0/VS6qKP4MXJfTWTtmxfXtr8SzWdwSXkZVj2TKQFfv/XL/20240225_105657-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-jjRpbG5/A)

Here is the pushrod length test. Looks like the rockers are contacting the middle of the valve stem as expects so I'm calling this a pass.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nvfrmwh/0/C38mCm72BzrdPf3rCm2xZWJCwcXzfvkNFsvSkMkw7/XL/20240225_111258-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nvfrmwh/A)

Here is the Valve to Cylinder results. There is plenty of room so another pass.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pxx9Z3W/0/DpCqx57tStf8Mg9T4PWT4tqNj2F5rwBBn38zZpmJC/XL/20240225_112604-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pxx9Z3W/A)
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-JXtBWbj/0/DQdD7CzdBS5ckw7KJHJRqSRD3Vkj5nX8T7Sk4K2vr/XL/20240225_112611-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-JXtBWbj/A)

And the heads go on..
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-zzxBcNv/0/Fc6w2wFxzX6GcT3jrdwhx83HF3V35mh42f85n8kM7/XL/20240225_113907-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-zzxBcNv/A)
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-9xbNLVj/0/C5tpVGthTV5PHVg3nvt2Qg2wDKccrj5MVJbcpnvMN/XL/20240225_122234-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-9xbNLVj/A)

on to the valve train
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-jvcHnKH/0/x8HMgvXjBNdS9xzSVKvB96pzDPxcnsWCF6Q279Dp/XL/20240225_142743-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-jvcHnKH/A)

I did initially set the valve lash but felt I was over tightening so I backed everything off for now and plan to review the proper procedure and start over again next time I get out there. But it's starting to look like a engine.

Justin

02-26-2024, 03:40 PM

Here it is in use. I'm not as happy with my cylinder bridge. There is no way to secure it to the block so I ended up just turning the block 90 degrees.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-VmPjmQ6/0/5d1eb15b/X2/20240128_122556-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-VmPjmQ6/A)

I was just catching up on your build. Just thought I'd ask. Did you degree your cam off the number 5 cylinder? Ford small blocks engine firing order are Right(Passenger side) bank 1-2-3-4, left bank 5-6-7-8. Right bank closest to the front is #1. 302HO/351W Firing order is 1-3-7-2-6-5-4-8. I you try to set your dizzy up to fire #1 at the #5TDC I'm sure it won't work out.

mrglaeser

02-26-2024, 04:42 PM

I was just catching up on your build. Just thought I'd ask. Did you degree your cam off the number 5 cylinder? Ford small blocks engine firing order are Right(Passenger side) bank 1-2-3-4, left bank 5-6-7-8. Right bank closest to the front is #1. 302HO/351W Firing order is 1-3-7-2-6-5-4-8. I you try to set your dizzy up to fire #1 at the #5TDC I'm sure it won't work out.

Degreeing the cam is just measuring that cam lift happens at the correct time in the rotation of the engine and if not changing the timing by a couple degrees if necessary. It doesn't affect the firing order as far as I know. The timing is hard to mess up, in this case simply line up dot to dot on the timing gears. The timing set I had wouldn't even install until I had the gears, chain, dots, cam dowl, and chuck lined up perfectly. Additionally the hyper spark distributor I'm going to use has a tool to help set the timing when installing it. So as long as I wire the plugs correctly I should be good.

As for the Cam Degree -

Yes I did use number 5. I honestly don't know it matters as the lift/duration should be the same for each cylinder. It was also pretty much right on to what the card said it should be which gives me confidence.

I watched 1/2 dozen videos and they all used the front right cylinder. I don't remember them calling out the Number 1 cylinder but could have missed it. I mimicked the videos pretty much step for step. I guess next time I would do it on the other side but I'm not super worried that I would get a different outcome.

All of that said now I just did a search on videos to degree a cam including Ford and the three I found do show it on the #1 Cylinder. Wish they had been higher in the list I didn't think made a difference what engine the procedure is done on.

If anyone out there knows for sure that using the number 5 cylinder would give me a bad reading please let me know. It's not too late to start over, just a set of new gaskets.

BUDFIVE

02-26-2024, 11:03 PM

If you are using the #5 cylinder and setting the degree wheel to #5 TDC then you need to be sure you are using the #5 intake lobe for Intake Centerline, Intake Open Angle and Intake Close Angle.

BUDFIVE

02-26-2024, 11:15 PM

I’m trying to paste the right picture from my 347 build last summer to show #5 intake is the fourth lobe.196160

Justin

02-26-2024, 11:56 PM

I'm sure the cam timing will be just fine.

Just looking at the picture, my mind goes to setting the pointer on the balancer at TDC off the #1. Plug wire location doesn't matter too much (as long as they are in the correct order) however different EFI setups use various pick ups to fire the injectors at the right time (some being in the dizzy). I have confidence that you'll have it sorted just right at the time of the first start.

mrglaeser

02-27-2024, 09:04 AM

If you are using the #5 cylinder and setting the degree wheel to #5 TDC then you need to be sure you are using the #5 intake lobe for Intake Centerline, Intake Open Angle and Intake Close Angle.

Thanks BUDFIVE. Yes I did use the corresponding intake lobe for Cylinder #5. I had not counted lobes front to back but it was the one you point out in your photo.

mrglaeser

03-10-2024, 08:11 PM

Continuing the fun adventure of learning as I go I attempted to install the Timing Cover a couple weeks ago only to find out that Ford Performance changed the bolt size for the lower 4 bolt's on the Boss Block. So the ARP kit I purchased from LMR didn't cover everything I needed. This was mentioned in the Bock's documentation but just barely. Nearly fine print. So i purchased a lot of different 3/8-16 in various lengths. If this happens to anyone else I think (2) 2 and 1/8 and 2 2 inch bolts will do the trick. I ended up using 2 1/4 bolts, 1 2 inch bolt, and one 1 3/4 bolt. They engaged with plenty of threads, and should work fine but "next" I'll have bolts that match a little better.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-z77MHwD/0/QSP2qSmmXZLgdrHGfHrkXGnCvWJpjN5SB2whRBJJ/X2/20240310_151200-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-z77MHwD/A)

And yes I know the block is not the same 'Ford' blue as the timing cover, water pump, and oil pan. I painted them at home instead of at the shop. Had I realized I need to paint the block too I would have sprayed it all together. But a little brush on paint will make it all match.

The water pump went on pretty Easy next.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-6Px8G7g/0/CXrJ8vNrxCWcW9JTsB792gC2L97qFzG39VsGSdVw5/X2/20240310_151920-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-6Px8G7g/A)

On to the fuel pump. Though I'm going to post this pick of the bottom end. Looks like who ever put the short block together took their time.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-srs7rn5/0/CZbtcXSwr6qHksPJbvRs5LzJpVcwvnzGfvCtpqPKT/X2/20240310_152115-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-srs7rn5/A)

Looks like good clearance.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3P9W3jb/0/C8jHXFZX84c8wjncQp7s7qR4GKkvPPNm8ZZttmcD/X2/20240310_154250-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3P9W3jb/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-6PJMCHt/0/LvjtcbwcgqPP6CDLwzgvNhhTgd5jmst5LJKq5kg2/X2/20240310_154300-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-6PJMCHt/A)

Finally having checking the clearance to for the crank, rods, and pick up I put on the oil pan. Everything seems to fit well, I turned the engine over and didn't here anything run or feel additional friction anywhere. I pulled the pan and looked at the interior none of the baffles were scuffed or scratched.

Not bad for a days work. I did have to chase some threads for the bigger oil pan bolts. But other than that this was a smooth day.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-s8JZ4km/0/DcvrTxSQtb8MjqdtSppvHmXHN3SGsBpCsns4SGCqr/X2/20240310_174850-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-s8JZ4km/A)

Smooth except when I was fitting the intake I found another bolt that needs the hole's threads dealt with. That will have to wait till later this week. Also the valve covers are really just on to keep junk out of the motor. I want to take them off when I prime the engine to make sure I see oil come up on both sides.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-V5fhJV8/0/FS8XR7fLTFPvPWWn2BHJX2dhnR5MhTCD5MsWjhD3/X2/20240310_174836-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-V5fhJV8/A)

mrglaeser

03-18-2024, 10:38 AM

Not sure if this is a normal milestone but I'm calling engine assembly done after this weekend.

First I brush painted the block in the correct blue to match the tins. Then I clear coated the aluminum and bare steel parts. I know things won't look new forever but the longer the better.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Z8J6r76/0/DvNJzFf5tjZkf5PmpDWqrJQrfD8QLSnKQ5m9jZS9j/X2/20240316_092723-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Z8J6r76/A)

I know on anther project this bit of steel was a bit problematic.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Jqbdw3v/0/q7Xm7RzhnfbMCW9NSMBjLh8KZdBgJH5JVDFtrXrw/X2/20240316_092737-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Jqbdw3v/A)

Then I did a little baking. Pretty Simple Recipe, 1 Harmonic Balancer for 30 min at 225 f:
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-786mqzF/0/DvQTgHJwWd3LQLgFRRCx9s9K3GT75fGWnN7Dw2vQm/X2/20240317_113632-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-786mqzF/A)

Pressed on/installed the balancer, installed the intake manifold and a finished motor. Here is the Glamor Shot (my friend said I should take the photo in portrait mode for affect what do you think).
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Qqb8tPN/0/D5MvZLzBzFbXKG2ppWz9ZKnsFHSqMhrDrb3SktLhr/X2/20240317_134712-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Qqb8tPN/A)

While cooking the Balancer we decided to install the bracket and press on the pulley for the Power Steering. This took WAY longer than I expected. It went smoothly it just took forever.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-B9b65mH/0/DgjjH525cfsdzQDHgQZd9SgqZc337V7GgbtTCrrhb/X2/20240317_134731-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-B9b65mH/A)

Used a kit from Harbor Freight and off the vehicle it was a little hard to secure everything. Next week I'm hoping to get the engine off the engine stand and then install the flywheel, start to mock up the accessories, and fit the Bellhousing.

zarnold

03-18-2024, 11:17 PM

Looks Great! Awesome work!

John Ibele

03-19-2024, 09:34 AM

mrglaeser

04-18-2024, 11:56 PM

Ufffda it's been a month since my last post. I've been out of town a lot for work and spring break and the kids have had a lot of spring hockey. So one month later I finally got an evening in the garage. No major changes. But it was nice to get out there.

First I picked up the wheels from the powder coater. Can't wait to get tire's mounted.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-hp25hsM/0/C4cMK88RMgkzhWCppfgGtD5jrqXT9XLGW5hxX7Lsh/X2/20240418_165715-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-hp25hsM/A)

I put the frost plug in the dipstick hole as the oil pan has one.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2KwqBC9/0/DFZLtNrbG7wwvjRww6mfqpcmxnPPwDSCtmbvGg9vB/X2/20240418_211739-1713501769396-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2KwqBC9/A)

Temporarily installed the flywheel and steel separation plate.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DBdhbr6/0/DcrLD78B8bf39F6kJBCDMcqdrt6kzJvHKHj5SsH9g/X2/20240418_190433-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DBdhbr6/A)

Next I installed the bellhousing and measured it to confirm alignment.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-cmS9JPx/0/CfLjM6wvWTL3Xzm27CtFHrjV637rjggCdtptfDfX9/X2/20240418_193202-1713501773938-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-cmS9JPx/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-JZBsXHs/0/TqWF4wgcLDkkPVG3ZmwRh8dBWxvr6xs8zzgQDwjw/X2/20240418_211731-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-JZBsXHs/A)

Sure enough I need the offset dowels. So that's as far as I'm getting on that this week. If I can get back to the shop the list is still pretty long to get me to first start.

mrglaeser

04-18-2024, 11:59 PM

Matt, that just looks like an awesome motor and great progress. Wish I had your skills! Someday maybe I'll take the dive and build one up, at least from a short block. Until then I'll enjoy keeping tabs on your progress. Would like to be there when you fire it up!

Thanks John. You will be welcome to come by and I'll let you know when. It's going to be mid summer I think at this point. I just paid the Tax man and it will be at least a month before I can order the transmission. Also I'm sure you have the skills to assemble a motor. You already did something as complicated as a rear end and some of you fabrication is really nice.

mrglaeser

05-04-2024, 10:46 PM

I guess 3 weeks between posts is better than a month. Lots keeping me away from the shop, but finally got some time in.

I got the Offset dowels. Installed them facing opposite from where I was off. But I had a time getting the factory dowels out. A friend showed me a cool trick though. Apparently you can take the adjusting bolt out of a vise grip and slide hammers have an adapter that replaces it.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-KG55qmB/0/CDx8nFb7BqkGJKJSbtzJqq8MvZjt7vP58PL7p4cjn/X2/20240424_200405-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-KG55qmB/A)

Now with the new pins in, the Fly Wheel installed and torqued, and the bell housing installed and torqued I could take readings again. To my surprise the new readings didn't make any sense. I was actually more out of alignment than before. It was very strange. I remeasured 1/2 dozen times. I purchased a different magnetic base to get a better angle. But still got the weird readings.

So I decided to start over. I took everything apart again and replaced the stock dowels. I started to recheck the mating surface on the block, looked good. Rechecked the mating service on the bell housing that looked good. So I went to recheck the separator plate and I noticed a perfect circle pressed in.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wVkbgns/0/2QHJfFKF8wTP8dmvs2nHfJHFGzHwz33sdctLDZp5/X2/20240504_163456-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-wVkbgns/A)

So I looked at the block and found a screw in freeze plug that sticks out past the mating surfaces. It was pushing on the separator plate. Not the best photo but you can see the straight edge cannot lay flat.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gDqTBbL/0/FPgf65x9c3TZt2qnnZ77kDKVJNLDqrQkQWjkhJdLj/X2/20240504_163514-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gDqTBbL/A)

As I was getting super frustrated I took a little break. I Just wanted some forward progress so i did a couple other tasks. I repaired the treads on a wheel stud that had gotten cross treaded. Then I decided to put the pilot bearing in. I had seen a neat trick online to use a steering wheel puller as a press. Worked perfectly.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-J6pvSr5/0/2S9WFhZC9LkBrfLds2D9h5rbpjJ89XSwzRDVD6Ds/X2/20240504_181227-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-J6pvSr5/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-M5rjZ9g/0/CqWLc6TmsrDX2B6c3wqbDhNWKTTDdXvx7skdXhkKk/X2/20240504_181230-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-M5rjZ9g/A)

Next I thought about the separator plate. I tried screwing the frost plug in more with no luck. I pulled it out checked and there was noting in the treads and they were in good shape so that is as far in as it will go. I talked to a friend and he said to face the frost plug, but I didn't think this was a good idea because it seemed it would be too thin to hold the o-ring in place. Looking at the Summit and Ford Racing Plate and they have holes right where the indent is.

https://static.summitracing.com/global/images/prod/xlarge/sum-700601_xl.jpg (https://static.summitracing.com/global/images/prod/xlarge/sum-700601_xl.jpg)

So I cut a whole in mine.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-8CZbMbT/0/MGKcN2XZHqmdWVxVp7WJL3NQDnCSxR8WX4g9DQVt/X2/20240504_194749-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-8CZbMbT/A)

I put everything back together and torqued the bolts. Setup the dial indicator and remeasured. Sure enough everything is in line now; .00225 off less than 1/2 the .005 tolerance.

So the bell housing and separator plate are sorted out. It all has to come apart at least one more time to install the clutch. I also need to re-install the flywheel bolts with some sealer.

I'm really glad I took the time to go by the book though and do this check because in the future either the transmission would not have gone in or it would have and then wear out in a couple thousand miles.

zarnold

05-06-2024, 09:00 PM

Nice find, albeit very frustrating for you.

mrglaeser

05-12-2024, 09:45 PM

Now that the Bellhousing centerline has been checked it was time to do final install on the Flywheel.
I recleaned all the surfaces, threads on the bolts, and bolt holes. Then I pressed in the clutch locating dowels.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DMqQ3KR/0/FRgZ8LNJdBk957F5HCxrH9gPrJbn5FjPg85M76rPV/X2/20240512_135439-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DMqQ3KR/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gRqsCFS/0/FCX5cGwTNzDZBSXFhQNBTcq8xPJkCWZgvStpZRJmq/X2/20240512_135445-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gRqsCFS/A)

Then I lined up the holes in the flywheel to the crank, dabbed some sealer on the bolts, and torqued them down for hopefully the last time.

Next I used the locating tool that came with the clutch to set the disk. Making sure the side that said toward the fly wheel - was toward the flywheel.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2N6dWTF/0/CgTSgNDwMjjS6V4Kvw2cj6rxM8zzZnWB3CZnsDnCq/X2/20240512_143534-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2N6dWTF/A)

Next I set the clutch over the disk. Then started to bolt down the clutch while holding the centering tool in place. It seems to wiggle a little and I didn't like that. And there we go an installed clutch.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-HSWj9WM/0/CPhqtDMpqB35sHF8frR4kMXkJNVKXsGfHdFD2kCkH/X2/20240512_144739-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-HSWj9WM/A)

After that I installed my coil to the bracket and did a quick mock up of what that might look like.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-NZRP65D/0/CCfxd9GMkdLZrcXFkSXxBGV3wQz5XSsRR6dmGrVL6/XL/20240512_110804-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-NZRP65D/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3k6nbp6/0/FRcCDndwhZnKWtHGLqZ7VrZFZh9bxxpqzWrxwPBjF/XL/20240512_134047-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3k6nbp6/A)

it might be a little low and rub the power steering pump. We'll see later this week when I try to mock up the power steering pump. This bracket is not exactly for the Holly Hyper spark coil. So I might have to order a newer version specific to that coil that didn't exist 2 years ago when I ordered this one. But fingers crossed I don't have to.

I also was going to test out my powder coating kit, but need some connectors. So it's mostly setup but will have to wait.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mqMpqr2/0/CjxHhJpHjZRnbJx9t8WPpdnGtqGs3zW3ttxJg4nJ5/XL/20240512_110951-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mqMpqr2/A)

mrglaeser

05-20-2024, 01:57 PM

Got the powder coating setup running. It's a lot of fun. Tested a piece of scrap with minimal prep. It came out ok.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-v5Gx7Pd/0/FBkBTkLwkqRrLbMqGv6cpBFSQFXDp4X7RntjBNGxC/XL/20240518_141912-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-v5Gx7Pd/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-d7GVwgK/0/CX5RBzJZXW3SmWr4mFr93svVSPZSrc9bVMKpntGDN/XL/20240518_142157-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-d7GVwgK/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Stxjkb4/0/DLS6RgnHTCKC6xKdHLs44QwBMmdsrXJT8Vz4dZT2Q/XL/20240518_142208-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Stxjkb4/A)

Then I moved on to some switch guards.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-77pMv8c/0/nMGGj9KHjDBz5zmW8nZ3rNHTPLj6HRFv6zxr2j6b/X2/20240518_141840-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-77pMv8c/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kR7v7Sk/0/LJxMTcxkLMFKMfVCzHF9L2JWnw9TkTSjzmw2fStX/X2/20240518_143429-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kR7v7Sk/A)

They came out perfect thought the phono doesn't show detail

https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-R3x6RLg/A

mrglaeser

05-20-2024, 02:02 PM

After playing a couple hours to learn powder coating I moved on and installed for the final time the bellhousing and clutch fork.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wS2LPrh/0/DzRf9sBw3qwxbp3PPLwSWK3KVFKx2ScSNQX2K9W2r/XL/20240518_153552-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-wS2LPrh/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-f7tBn73/0/MRLx3BMvHgfSV7JtQRjpRLvxS733h464JztGf5pr/XL/20240518_153604-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-f7tBn73/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ftCWmsL/0/DtJMfwJDSLTz446CpjxVFK6GxV8fzWrR32bFnZ4rF/XL/20240518_153608-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ftCWmsL/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Wzfmbvm/0/DkN26KbvZVdxqZSxZRs5VzFdJBqcmFjmx3m7PDsp6/XL/20240518_153702-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Wzfmbvm/A)

mrglaeser

05-31-2024, 10:12 PM

Received my TKX this week. Got it to the shop today and un-boxed it. I thought about making an unboxing video for all the kids but didn't have the time. Only really did a quick visual inspection I'll double check it goes through all the gears next time I'm out there per the instructions.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3dTz52d/0/CjbSWMmx8pfX872bCKFWFdwQ7DCt4H2xxMGzSCm4Q/X2/20240528_171155-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3dTz52d/A)

First thing in the box... a Warning Label - test your transmission prior to install

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wkhMtbx/0/CgWMwTDxXCVNVHNRQGGsMNxf9BF947bdP5tb35DQf/X2/20240531_085533-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-wkhMtbx/A)

Lots of good packing

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rZD3B8H/0/FXwWGNBfJwpXFB4NLPzVFCJDSqD6FsWQk5B72m4Wj/X2/20240531_085942-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rZD3B8H/A)

and there she is in all her new transmission goodness

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mM8PWwf/0/NWmQpvNrGCJtz9z4kwmztdsLHzmJwsQMhLGMBtDh/X2/20240531_104817-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mM8PWwf/A)

It was a bit of a nesting doll type of situation with boxes within boxes

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wPsFg7J/0/FTCcLKcXBLvw6fZnKXTqtcMknfHrJNzCXQ8wFLNKg/X2/20240531_122748-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-wPsFg7J/A)

Out of the box and ready to be tested and installed

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3S8LPFp/0/CsBWv39Ls8tkqrTt3sP55F6NwvD5T8pWx9RJbGFfH/X2/20240531_122800-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3S8LPFp/A)

It was basically Christmas morning for me.

gbranham

06-01-2024, 03:26 PM

Question:

When you checked your p-v clearance, what did you do to ensure your hydraulic lifters didn't compress? I'm nearly at this stage with my 427 BOSS. I have a short block and valvetrain combo set from summit, so I'm sure the pushrods, hydraulic lifters, roller rockers and heads that came in the combo kit will play nice together, but I want to make sure. Haven't sorted out the best way to ensure my lifter doesn't compress when I check, and I don't really want to remove the pre-installed valve springs on my TFS heads.

Greg

Mike.Bray

06-01-2024, 04:13 PM

mrglaeser

06-02-2024, 12:08 AM

I used valvetrain checking springs like these (https://www.summitracing.com/parts/cca-4758-2?seid=srese1&ppckw=pmax-tools&gclid=CjwKCAjwjeuyBhBuEiwAJ3vuoaoW6kOkMxf_yVdfVS27 v4LB0jQfDT9lP_ru21vxK63mYsqvf7QToxoC4HUQAvD_BwE).

Pretty much all the advice is to use test springs. In fact you could take it a step further and also use a solid lifter as well (though it need to have the same length from the bottom to the bottom of the cup as those you plan to use).

mrglaeser

06-02-2024, 12:11 AM

This is pretty similar to a photo I posted before but I finally got all of the switches, gauges, switch guards, oh **** handle, etc into the dash. Nothing is connected on the back side but I really wanted to see what it looks like. Pretty much exactly how I planned it. I could not be happier with how it came out.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-9NCkZcT/0/ZgMqbzv5fxPjQLX2T9zBHK3fsZhQhRVw2NZ7gt2n/X2/20240527_175908-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-9NCkZcT/A)

mrglaeser

06-15-2024, 09:04 PM

Last Winter John Ibele was good enough to give my daughter and I a quick lesson in powder coating(thanks again John!). I really was intrigued with the process and ordered up an Eastwood kit, some powder (black in flat, semi, and gloss) and started playing around with it. I would say about 80% of the items come out right the first time 10% need a touch of paint to cover some small nook, and 10% need to be stripped and coated again. Those numbers are improving but I'm pretty happy with the results. But there has been a bit of learning.

First... Acid. I tried using Muriatic Acid to strip the chrome from parts. It worked in some cases. In others it dissolved the pot metal that was under a thin layer of some other metal. So for anyone else out there the Lemans cap (I did not ruin), the mirror post, and the lock bases are pot metal... Don't use Muriatic Acid to clean or un-coat them.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-r8HHbLG/0/C7qZTBkKQhbwzfBxbW6k9GDNWpJQCZ49SdqjpcRpP/X2/20240531_143433-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-r8HHbLG/A)

The bubbles mean something is happening it if looks like it's boiling pull out whatever is in there.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-XLS7QB8/0/CwBKQK7b67WmHDFW9qfcQsKTvtgVvRXTxJx5vsCmS/X2/20240531_143438-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-XLS7QB8/A)

Actual Metal parts come out great
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-stbN9f5/0/D43hzkhq2LVfZndzqgKJ6wbm6Hf4c5fTpfnC9QqhD/X2/20240531_143441-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-stbN9f5/A)

Pot metal... Yikes
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-bNjBP3C/0/C97wJcjR7SXrgJJKqKCmXsQbDVrZfVq9ddRVLFmXk/X2/20240602_130410-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-bNjBP3C/A)

One of the skills I'm getting better at is making funking hooks to haning the parts on. Here is a front turn signal bezel.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-28MjBjt/0/FDpbwZxHKDjGXt6hPcNm2LXfRMTcJqMcMTDZ5zBFC/X2/20240614_162954-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-28MjBjt/A)

Anyway I have about 10 more parts to do and 1 to re-do and then on to the next thing. The Windshield and headlight bezels are to big for my oven so those will get sent out.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kqxLKx4/0/DP37Q9LzVFT9wSd9BJ3nXdsMd2PZZJzh8hCcgFmJn/X2/20240615_181446-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kqxLKx4/A)

mrglaeser

07-22-2024, 08:49 PM

Well 5 weeks since I wrote an update. Not a lot of progress at the moment. A lot of life keeping me out of the shop. I'm sure a lot of folks here know what that's like.

I did get the tire tires install on the wheels. Nitto NT555 G2s. For some reason I didn't take a photo of them out, but the shop wrapped the tire/wheels in bags and I thought it looked funny in the back of the truck.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-TmmVrcs/0/KbFLt2M8XxFSXTKXsWjVLPJNCZZTwPJSwV3qrpv4N/X2/20240622_101450-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-TmmVrcs/A)

I also fitted all the accessories, plugs, and sensors to the engine. Later I also got the belt installed again I forgot the photo.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-khWWr6r/0/KxMHbPnnm7FgVGcR57bqcBvnTHxSJ4ZDXmVZsRH9b/X2/20240704_105439-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-khWWr6r/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Mqbbnx5/0/Ks4jMHBRtv3RWxRMzgzDW6Kq9RPfNF5D6d9N47PW9/X2/20240704_105445-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Mqbbnx5/A)

Also I had an issue thinking 3 dimensionally and cut the hole for my dimmer switch in the dead pedal I made on the bottom.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3MRcX57/0/MQTHtxn2fXFsttFxv8vMQ4V8kdrLCHKT2rQ3bTCmj/X2/20240720_101607-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3MRcX57/A)

mrglaeser

07-22-2024, 08:51 PM

I guess that lets me say that I make'm nice because I make them twice.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-h3S5xtN/0/K5BZ66nJJjCjfLZ38dp7VQN5KVLmH3VQT6GXvGwFm/X2/20240720_103007-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-h3S5xtN/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-v8D8kwC/0/Mg9d5Pd9sqFqtWmKWSbQ2QM8hvHD3FFwCsZNz2HcG/X2/20240720_103014-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-v8D8kwC/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-G4FhT5W/0/KMK8FTNvsZ6BKxssRFQCh478GCnTXNQ2XhFtdBq4F/X2/20240720_122839-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-G4FhT5W/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-tpvZzLD/0/LHrL567g8vDkmszX7mfcqZxF6rKS45RFMrW9hNwCC/X2/20240720_130047-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-tpvZzLD/A)

Unfortunately my Black and Decker rotary tool gave up and died. And they don't make it any more. It was my 3rd one in 24 years bummer. The Harbor freight one was 20 bucks so I picked on up. So far so good. I bought an actual Dremel a few years ago and it was the worst of the lot and lasted just a few months.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2SDV5Dz/0/KGQsxc2GB5DgzVgsCHZQfWC2shtDpQVxrLWPtQLWc/X2/20240720_122842-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2SDV5Dz/A)

mrglaeser

07-22-2024, 08:57 PM

Finally we made one attempt to marry the Engine and the transmission. And by attempt I mean 2 hours of wrangling. We had a gap of less than 1/16th of an inch but couldn't push it in any further. The instructions say not to draw it in with the bolts so we pulled it a part to try again another day. I looks like the centering ring might have some imperfections so I'm thinking of polishing the inside of the ring and looking for any imperfections on the TKX where the ring/transmission should slide onto. It was so close to being on I am pretty sure that the splines line up. So the other think was going to look at was maybe the pilot bearing.

mrglaeser

08-03-2024, 09:53 PM

Pretty good day on the roadster. Finally got the engine and transmission bolted together. Took quite a bit of effort. Gave up on using the floor jack and suspended it from the engine hoist. Way easier. Also putting the motor on dolly was nice for moving it around and lining things up.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-B45W73J/0/Kr9cDkvCXMm3BbZNRLqhBJnqxQm3tzKJ9fVDwVF5v/X2/20240803_105923-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-B45W73J/A)

And bolted together

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-NTbsMpS/0/LrRfB5QG7TgSb7Q9FnCkd8gP896Sz3C74ncwzkc8Z/X2/20240803_123808-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-NTbsMpS/A)

I also cut out 6 1/8 steel spacers for the transmission. I've read that to get the pinion angle folks are using 5/8-3/4 inch spacers. So no I just need to drill a few holes and coat them and they are ready to use when we drop the motor and trans in.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DQSr655/0/NFRbrSZdcW6jbbkwjsZc7F7HXMTCXqSHQ4rzfvTdn/X2/20240803_151112-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DQSr655/A)

Also a few weeks ago I got all the brackets, accessories, belt, and thermostat housing lined up and installed but I didn't take a snap. So here it is now.

https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DPcvsd7/A

I also did a bunch of small things as well.
-Fixed a Zerk Fitting on the lower control Arm (Drivers side not that it matters)
-Powder coated one of the headlight trim rings
-Powder coated the dead pedal
-Fixed the Koolmat on the driver's footbox
-Reinstalled the now powder coated trunk brackets

I also broke a couple banjo bolts.. oops.

JMD

08-04-2024, 02:43 PM

I'm enjoying reading through your build. Some great work done and I'm definitely stealing the 3M strip caulk idea to seal seams in the aluminum. Keep it up!

gbranham

08-04-2024, 04:45 PM

I'm enjoying reading through your build. Some great work done and I'm definitely stealing the 3M strip caulk idea to seal seams in the aluminum. Keep it up!

For sure! I bought a 15 foot roll of butyl 'rope tape' on Amazon for $12. It's been awesome for filling in seams, especially in the upper trunk side wall area.

mrglaeser

08-16-2024, 05:36 PM

For sure! I bought a 15 foot roll of butyl 'rope tape' on Amazon for $12. It's been awesome for filling in seams, especially in the upper trunk side wall area.

I actually had not thought about that area yet. I'll keep that in mind. Good hint.

mrglaeser

08-16-2024, 06:01 PM

Ok still moving slow. Found the right bolts for the transmission mount. I find it strange these aren't in the instructions that come from 1/2 - 13 x 1.25 of 1.5

I finished the spacers for the transmission mount to transmission support. I created 6 1/8 inch spacers so I can stack them for whatever I need. I probably spent as much on drill bits as It would have cost to just order Forte's parts.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kHKgnmQ/0/KL23Rn2wTMTVjKDwMhcqzdzXmw3ggKRWZfgwnjzfF/X2/20240814_192711-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kHKgnmQ/A)

After some powder coating in the sandwich oven
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-JXLFtgM/0/MqL5CVj7P8Xh2t6p8pk7qmR8FZP39CrfCRxL6t44H/X2/20240814_205919-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-JXLFtgM/A)

Next I've always liked the look of wrapped headers. So I bought some stainless steal Fox Body headers and gave it a go. I think they came out pretty good. I'll do the J-pipes too soon.

Anyone else prep parts at the breakfast table?
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-dr2wWbL/0/NRt2CWPgvFWPhM3ttNT4Vzfx3qGR4Fk2fCVjVb8Lg/X2/20240815_212501-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-dr2wWbL/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fR995gL/0/LFZJpw6jbT72VF3sGpLBFVFBdZmRdWHH52XWwnsS9/X2/20240815_223035-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fR995gL/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZWKL6VH/2/M7Gw9cjNS7PWPP5xRQXqFNNNc83dRLDd7t24w9wvX/X2/20240815_234909-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZWKL6VH/A)

I also greased the Zirk fittings on the front end, adjusted a power cable that was getting in the way in the transmission tunnel, and took the car off the dolly and on to jack stands. I just need to test fit the trans support, do a couple things on the brakes, put the wheels on and drop the car onto wheel dollies and I'll be ready to drop the engine in.

Also last weekend we had an open house at the Garage Condo Complex. Here was my version of a factory five 'in progress' display.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-d3VwZM3/0/LjQcwB23x7FWVwTXGZ9zpNnr2CTcgxfWVj6j3jkHq/X2/20240810_082328-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-d3VwZM3/A)

Got a lot of attention even though there were a lot of exotic cars to look at. Ferraris, Lambos, Lotuses, a Gullwing Mecedes, one family owns a whole building that has something like 100 Corvettes.

mrglaeser

08-16-2024, 06:07 PM

202814202815

Here a couple shoots of the garage i talked about in the prevous post. Sad thing is none of it ever gets driven.

mrglaeser

08-18-2024, 10:45 AM

I got a little more shop time this weekend. I test fit the Transmission support under the chassis. It will take a little work to get on of the front bolts in but should be doable without modification.

What was a lot of fun and satisfying was putting the Lemans cap back together. Started with a lot of freshly powder coated parts.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wXGN9L3/0/MVpDVkxdzDk9PMvxchRWGZkfnxt8rrMvPGDDLjssF/X2/20240817_120411-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-wXGN9L3/A)

Top Done
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-TBQg7dg/0/M7Mkkcgtrx95jxxJ7f2d2r57ddRVR3dkMzDwsRVXM/X2/20240817_122102-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-TBQg7dg/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-B3dZxbj/0/MSJtnBRLcCg59TWfcHSp8PWgSTXq8cktTFsJvMHft/X2/20240817_122114-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-B3dZxbj/A)

Add the bottom

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-xxcPpNF/0/K9QKTLMBktvQGrmHSKrTLrbxG99hxd9HWMg8VXLSG/X2/20240817_123511-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-xxcPpNF/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-6tVKdM5/0/Kqc8JSvBQ2DpdT7kvWXLppJH28ThkPD9mpsb7SgGg/X2/20240817_123601-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-6tVKdM5/A)

Next put the trunk and hood handles back together

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-5GxR2hc/0/M24wH8qBK4BVNmFFsRvfXBWTkjhWQCVqBgWsNB5ZB/X2/20240817_125449-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-5GxR2hc/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wcMRPVQ/0/LWFNgQ8LwmdSbw8Gbp7TxpshVX8D2JhzXPCvX9q8N/X2/20240817_130130-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-wcMRPVQ/A)

mrglaeser

08-18-2024, 10:49 AM

I was going to put the indicators together. They are pressure fit ordinally and don't seem to hold at the moment. I might try bend the metal out slightly or I might just use super glue. Also notice the powder didn't stick on one of the bezels so it needs to be stripped and redone.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-CdQ572T/0/Lbwjgs5vgvgwHTWfQRvZpHtsfmvcb94g5kxwSSxzM/X2/20240817_130416-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-CdQ572T/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-qBVzSDp/0/NJ4DG6GbQ7JvVzkNVth59kKt86JbX5tTTcL3Q2rtD/X2/20240817_130422-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-qBVzSDp/A)

Another evening meal of exhaust wrapping.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-xScrfT4/0/MCfPJCGZkwM6ZvT7ZG88M78hKvM86KR3wfb5wVvh2/X2/20240817_205923-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-xScrfT4/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-GXN6Xp4/0/LFrgJ9DGw7XtgQ6xxqcDWbwPStJctvNwVZMjkS3FM/X2/IMG_20240817_235152-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-GXN6Xp4/A)

mrglaeser

09-09-2024, 02:53 PM

Well I was hoping to get the engine for the last month but life keeps me from it for now maybe this weekend fingers crossed. So I have progressed on a few things.

I put in the support/fix from FF for the power steering rack.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-XFvmnPq/0/KZVjn4SxGmr7VchF8rqPdzc4JdnCnhbLhzhVb6fJj/X2/20240825_165624-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-XFvmnPq/A)

Finally figured out the correct bolt size for the transmission mount (1/2 inch). They are a little long but since I'm using a GPS Speedo should be fine.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-X7HpB57/0/LCLtTBW2GXpdjdh4LzWht42bmRLrgQzwDK4xH8xZR/X2/20240825_170357-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-X7HpB57/A)

Used some DEI Sealer on the wrapped J-pipes and Headers and cured them in the toaster oven.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7CwRRnP/0/NcBQs9fCrN877Nxq8rf56m2gHfm2vj3xpWgvSj3L6/X2/20240830_135539-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7CwRRnP/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-PNkmr3X/0/McZtBqdkccvL3vpgxZ2BBMR7JDxvZ84SVjHJwrCX5/X2/20240830_135514-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-PNkmr3X/A)

Re-powder coated the front indicator bezels and put them together with the lenses. I'm not super happy with the Silone I'm going to try using a clay modeling knife to clean that up, but otherwise ok.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-HVxBrDk/0/KMWjb3r5cGvhR9CxMzp8pjjjc3sqCWwwQchcdtvVP/X2/20240830_140804-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-HVxBrDk/A)

Assembled the Shifter after powder and the tail lights
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-sP9Wbj9/0/LCFHnRpmcDkKcF6bnFqvF6KmhpMk6mmwpf2LMhKRL/X2/20240830_141622-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-sP9Wbj9/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-8r8v6SQ/0/Kkq8bPSPRJ4mxDMgvPJqm6VmDwpVx9BztmTQnRvwc/X2/20240831_103110-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-8r8v6SQ/A)

mrglaeser

09-09-2024, 03:01 PM

Got the car on its wheel and onto wheel dollies for engine/tran install.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-tXsxGhp/0/Nb9PZ5WZXvMbR786gV9cDHGnsC7wTdJvW64w8SkMN/X2/20240901_121150-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-tXsxGhp/A)

Mocked up the radiator and shroud
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4s6TH9p/0/KRDhSwggsmvDb7vB8SFnnVTsp2ST4T3zVNzMgBh2b/X2/20240908_142650-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4s6TH9p/A)

Had to trim the bottom of the shroud
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-dTCwt29/1/MftJk94m3f2XrDfhdcnnTWrWsjZQG2cTKdCLF2h7L/X2/20240908_153414-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-dTCwt29/A)

I also trimmed off the extra square tube ground it down and primed the grind in prep for using the breeze upper kit.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Rcz3NKn/0/MgHXv2fRbHq5vVkXbjJc3R6WxPxQ2jKLJcjzBMX6q/X2/20240908_151258-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Rcz3NKn/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-JdCNdz4/0/MpCtCpJXS2QN5hN5bmqXhNK7s5mjMbrWLc76D3VRG/X2/20240914_112020-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-JdCNdz4/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-jNTRTDx/0/M927fB5JBt9tD5HG5MVNBjGkt6g7GpGRj9SbfwnmN/X2/20240914_112018-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-jNTRTDx/A)

mrglaeser

09-15-2024, 09:32 PM

Got a little help from the girls today. First while waiting for my friend to come by so we could drop the motor in we put some rivnuts in the Breeze fan shroud.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4hDXqZN/0/KMv7LmWd7zdXHdHRFXjTh44sSh69GBd79S3MNjtZt/X2/20240915_102030-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4hDXqZN/A)

They took turns

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-w8RqtWL/0/LZwxsKhZRCr8LMZw8s2JV7Mj5mxM3SxnHzV3ZTQJG/X2/20240915_102856-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-w8RqtWL/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pW6qNzQ/0/LCjN4ftJSR949tbSMVhWdd226dgc4vvtF3PkwqC6g/X2/20240915_103204-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pW6qNzQ/A)

Then we hoisted the engine up and took the feet off I had put on it for the time being.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gvZWdJ6/0/Ms5HTsk2wddz8B6kkT6x6LTM78VdPp3W6XKRdd7qD/X2/20240915_112301-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gvZWdJ6/A)

power tools make everyone smile

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nCJ9sSP/0/NXDCDm6vrgcQnP54N66px4NrL2ph2RMCCSvrjxTrB/X2/20240915_113041-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nCJ9sSP/A)

Once my friend 'little' Jon (he's 6' 8" and probably won't be comfortable in the Roadster) showed up we got to work putting the engine in. It wore my youngest out pretty quick.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-WFJwJBH/0/LDSR4NGdmDffBt5JSGDTRLCXzgsJpCHWhfGRBt7rs/X2/20240915_115844-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-WFJwJBH/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-PvSvnT9/0/NCmXqhTgZHq8BrBL3NgrQLNDkp3x4c73nSW7Mcmrj/X2/20240915_115854-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-PvSvnT9/A)

mrglaeser

09-15-2024, 09:41 PM

At the end of the day the motor was in. Probably around an hour and a half of efforts. Having done one I could do the next in 1/2 the tie I think. We were being cautious and debating each move. Pretty much un-eventful to be honest. I'm having a bit of trouble with on bolt on the transmission mount so I'll get my tap out and see if I can clean it up tomorrow. It also took us a while to figure out a way to pull the passenger side of the motor up in order to locate the tab/stub of the engine mount on the drivers side. The answer a ratchet strap.

Two notes:
1.) I would recommend buy a good engine balancer/leveler not the harbor freight one. It is a one time use tool. The plastic handle was worthless, and the metal part of the handle was bent by the time we were done. I oiled the thread pretty good so there wasn't much resistance. It's just so cheaply made.
1.1) I have the extended firewall. I think I would have the crank for the balancer/leveler on toward the front of the engine next time. It got really close to the fire wall.
2.) Also I would suggest if you are buying or renting a hoist get one that's legs are 42" or less out side to out side on the legs. I wanted to leave the car on wheel dollies so we could move it around. But the legs stuck out to far and I had to put the car back on jack stands to be able to get the legs under the car.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-T5jjTWm/0/LMckhWGQZrtTtBLBX2DnDWKPkPJC5pJxzjgr9xDqw/X2/20240915_141747-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-T5jjTWm/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3MMkrB9/0/L8rJ4pcrMJNB776S3X9tRxFQzcmVGktKktVNw6ZSL/X2/20240915_141752-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3MMkrB9/A)

mrglaeser

09-21-2024, 10:41 PM

Now that the engine is in there are a ton of smaller jobs to complete. So over the week I could sneak away to the shop for an hour here and there.

First I installed the transmission support and mount.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-sdJbrsF/0/MXrHRfN9B2hKPcFmQ75LPrPNjz5wP3b7FLvMDjnG5/X2/20240917_184940-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-sdJbrsF/A)

Next I installed the clutch cable - it took a little trial and error to get the tension right.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-dDqVCNh/0/NTwxwbHK9r6jKspNXPxX4Ppfd5NQ9HxC5jW9hwt6d/X2/20240917_184947-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-dDqVCNh/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fFv8BTH/0/NMn7N8qknX9ZwSWSG6z6XChTr6WBb2Mzc22wwwbR3/X2/20240918_204322b-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fFv8BTH/A)

Another evening I installed the Starter. Unfortunately a washer next to the starter bolt hole interfered with the starter. So I took it off and ground it out a little and everything went together easy.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-WncsLj8/0/LmZMWFPSQg8bN6FhDnM4Lz3Vqk6KPM2gTvvffqjjt/X2/20240918_190419-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-WncsLj8/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Wr7KFCZ/0/NC9qSwCxR8692JXMmj838rRT7WXBkZGL98NbB8MrD/X2/20240918_191820-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Wr7KFCZ/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Mc9bbFG/0/KkgS45ghXQFHf7S4ZsrMj5fpfdCJ6PDKXBL2f9kwG/X2/20240918_200215-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Mc9bbFG/A)

mrglaeser

09-21-2024, 10:51 PM

More small jobs completed

The Alternator is wired up. I wish I had looked at this closer before installing the alternator. I probably would have re-clocked it to put the wiring out from under the brackets. But it worked out ok.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nfsZCLR/0/LbLfLf92dv5vX38szLTsCPbHSMmvv3pjgrs8hGfCc/X2/20240918_200153-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nfsZCLR/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-J9BjBJc/0/M3SVj3vZhJfmbCQFmJgP7kHRJBfGCwvbnRSJNPk7K/X2/20240918_200200-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-J9BjBJc/A)

Attached the Holley Sniper Throttle Body.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-x8769Vc/0/NLrxCgkQkmp3nvMZFr55df92J6JFWct2T7pTxFfJX/X2/20240918_200456-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-x8769Vc/A)

Adjusted the wiring and connected the Water Temp, Oil Pressure, and Oil Temp sensors
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mqc6GTR/0/NbhVd3k2xjHBfgdzsGgM3WB9jZm3pPqDpcCSrQMpD/X2/20240918_204322-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mqc6GTR/A)

Finally job completed for the week was installing the headers.
Sprayed the gaskets with copper sealer
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gwBmgz3/0/LLZQ4TNTm83F3m9JrsbSBNxjhRv76nV78wFRKZ9j3/X2/20240921_143058-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gwBmgz3/A)

it wasn't fun installing the headers. There is almost no room to get a wrench on the bolts, I couldn't get a socket on there. if it comes off again maybe I'll try studs instead. I figured this job would take 20 min and I wrestled with it for an hour and half or more. But that is a common occurrence on this project.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZMtSgXJ/0/KwDQm8XMPj5qSBWCLvqgprcsGpdGm5k8SfXLgB2q5/X2/20240921_155920-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZMtSgXJ/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-cVhQ3qS/0/KsgnbHRmLqBpQVCDmGWs9pSKNm9FK6fKsL38MRSsK/X2/20240921_155930-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-cVhQ3qS/A)

Pretty solid week getting things going. I also started on the cooling system and should get it at least fitted this week. Once that is done I'll move on to the mechanical throttle cable.

Mike.Bray

09-23-2024, 08:01 AM

I used studs with 12 point nuts on my headers and they worked great. I don't think I would even attempt using bolts.

mrglaeser

09-23-2024, 08:21 AM

I used studs with 12 point nuts on my headers and they worked great. I don't think I would even attempt using bolts.

Yeah it was a one-time show. It won't happen again. But they are on now. And yes 12 point would be amazing. That would have saved so much cussing, sweating, and crying.

mrglaeser

10-02-2024, 10:51 PM

Now that the engine is in there are so many things I can do. I've been sneaking out to the shop over lunch, while the kids are in hockey tryouts, for an hour in the evenings, etc. So I feel like I'm making a lot more progress than I have in a while. Along with some of the other small jobs I posted about earlier I've also been plugging away at installing the Radiator.

Previously I posted about fitting the shroud and cutting off the quarter steel. I did get all the Breeze goodies shroud, upper hinge, lower cooling hose kit, lower cooling hose bracket, and lower support kits. I didn't do things in the exact order in the instructions but I think things came out pretty good.

After cleaning up the cross bar (forgot to get a pick of it all repainted) I fit the hinge and drilled the 4 bolt holes.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-bmZSnCF/0/LzDLbm2rZHKW6wR5vW2Gcb7Rxx9WgV9ZLVGgQ2HBC/X2/20240921_135358-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-bmZSnCF/A)

My oldest tapped the bolt holes and cut out the card board and covered the radiator fins. I then drilled the holes in the upper and lower radiator support.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Lfc9t6P/0/NBx7XwTbrzsgNBsb6KhrqpPhSPthJXbWdqqQ57cxN/X2/20240921_141126-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Lfc9t6P/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-5zxsxXT/0/MxFWkXPcwSwmP8cFw7G3mVkcTSPXFmpRTqbPcMd7W/X2/20240922_160610-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-5zxsxXT/A)

Then I fit the shroud and hinge, drilled them out, and bolted it all together.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DGzd5RG/0/NDf8JLJnx76KPqMNTJVQr7KpWXFgWrPpPzZQgjv43/X2/20240923_193534-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DGzd5RG/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2bjJtPW/0/Kp3FQ7JGfFJBFh5QZGDfGKrzj8fkrHdBcXBcWgtqc/X2/20240923_193558-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2bjJtPW/A)

Next I bolted the radiator temporarily to the cross bar using a floor jack to support the bottom.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fNqjBk6/0/K5jH8nc7MLpRSDB4Pm8xXQZzvcd4Cfsh5mSKf3rNB/X2/20240924_181639-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fNqjBk6/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-TprCsxV/0/KWJsnj5ChnzS4QXRfxqQGjV49Gsp8b2Qkn6pf4jNm/X2/20240924_181645-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-TprCsxV/A)

mrglaeser

10-02-2024, 10:51 PM

I then adjusted the angle as close to 51 degrees as I could and used zip ties to hold the radiator in place. After that I started to fit the lower support. Sliding the hose over the bar, marking the seems for the tank on both sides, and cutting the hose to accommodate the welds.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Gg5gghg/0/KXrjRRTffH6LPqCGt2hZvTdbJgCZsGkc46vPk5TWh/X2/20240924_190359-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Gg5gghg/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-MgPR7kD/1/LqDp2DL7zTC52qnXVnxZTKxGKPGLscV2GMPRTt55v/X2/20240924_190407-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-MgPR7kD/A)

After that I remeasured the angle of the radiator and fit the lower support bar in place. The results look pretty good.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-LQnfFjd/0/NgC9z2N5Pg2VjSW4dk53QMfd6sqFcSTwx8dt9F2Fw/X2/20240925_114808-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-LQnfFjd/A)

Then everything got a good coat of paint.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Z47xfLX/0/LSz572WxRqwbbQ7fXRbQnNdgqHWHGcW42VJ2tzhfB/X2/20241001_115617-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Z47xfLX/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-sGZgCtP/0/LhNGm9qdfMJPrWkXBSK5hX5JhfLh5mT6X5KZCdwGZ/X2/20241001_115657-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-sGZgCtP/A)

mrglaeser

10-02-2024, 11:01 PM

Then I carefully put everything back togehter and mounted the radiator
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-N2dmMSk/1/MWJCxqvcrDx3KsfKN8w9zSq7BpgWgDmfgbtWjjfPm/X2/20241002_183832-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-N2dmMSk/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7nqZkz5/0/LVgkq3spmZdCf5rHJxCGQTgs7LX9n38QCGCCgBNZT/X2/20241002_195510-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7nqZkz5/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-66tSgZj/0/KxbBhQGvtsCF4dRLJdFFCjQQcng5CF7492NLLSHLP/X2/20241002_195518-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-66tSgZj/A)

I also made a rock guard with some aluminum flat stock and stainless steal mesh. Fist I measured everything. Then cutout the frame and laid it out.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pQkkpWp/1/KbCn8JzPhD38Gv5nRPbLgvSLNMwfrqqdnKX528Jrv/X2/20240926_132236-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pQkkpWp/A)

I tried using a lot of painters tape to keep everything in place as I drilled through the upper and lower frame. It worked pretty well on 3 sides. On the forth there was some slippage and a few holes got a bit wonky. No well will probably ever notice but I'm sure it will drive me just a little crazy. Not enough to buy more metal and do it again.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-JhXqFwk/1/MfFpmM3cnHfxkTXqVgwkLW2Qx9PwHNxnr8dD5B3TQ/X2/20240926_185212-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-JhXqFwk/A)

Laid out the frame and cut the mesh. It was completely square so I ended up trimming, and trimming, and trimming again to get it right.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mGHMz7V/0/MDq34BbWrK2gDtMFXQdz78vGTcxWvQ2xCfmZpX5mk/X2/20240926_125014-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mGHMz7V/A)

mrglaeser

10-02-2024, 11:08 PM

Popped the mesh between the top and bottom frame, rivetted everything up and boom it's ready to go. I will note a couple things. I had to use longer rivets to fit through everything, but they were to long so I took the rotary tool and cut them down. Also I over lapped the corners so on the top frame the longer aluminum pieces were the vertical pieces while the bottom from they were the horizontal. I think this gave it a pinch more structure. All in all it's a pretty solid piece.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4hPfjTD/0/Kq256f5kwwxXpRQFFZgWp7VQNMXMTN435bfX2RrM7/X2/20240926_194511-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4hPfjTD/A)

I still have to paint it and do final install, but here is the test fit
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-xBRvSJ8/0/MpNp72fWvSXBZZwbLdksDvrS4Xqc6GBwhnfsVNMXp/X2/20240928_085932-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-xBRvSJ8/A)

A few other bits I got done this week.
Received and installed the power steering fitting from Breeze. I really don't like the length of the hose that came with the kit. I might have to see about getting some a little shorter.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-zkMcVsp/0/L9jSQcW8hKB277WDFgftBDPqw84JvRR5D6Mpxmrp9/X2/20240928_101911-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-zkMcVsp/A)

Installed the dip stick.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-spDdfjN/0/L4sxcNVL4MkNdT6zvZdmvttdtr67s3ZCR6zKkM9QQ/X2/20241002_201254-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-spDdfjN/A)

And also got the Drive shaft installed.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZS6W5GF/0/KjSjPRkB9Qtf7qM6DQnXx7cgDn973CGzxtg53KMf3/X2/20241002_204717-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZS6W5GF/A)

Next up will be doing the cooling hoses, heater hoses, drive shaft safety loop, and the bigger project will be setting up the mechanical throttle linkage.

mrglaeser

10-14-2024, 01:48 PM

A little more work went into getting all the cooling and heating hoses figured out.

The lower hose is the kit from Breeze and went in pretty simply. I do need to drill and tap a couple holes for the bracket on the x member but it looks really nice.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fd7gJtd/0/M77Ws72hwxSRrmhjJVn3fRRJWJpXwR8Rt6Fvz9Lfn/X2/20241004_143025-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fd7gJtd/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-D6djtRN/0/NNMFRLbFXnWhvhjVwdN4PgLVZfBhWd9Vj2hskn6kC/X2/20241004_143045-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-D6djtRN/A)

Then I tried using the hose from IE 427s video but it didn't work out as well for me. I think he was using a generic radiator so that could have been the difference. I ended up using a NAPA 9543. Worked perfectly. Two Cuts and it slips on the kit T filler (once I removed the hoses already on there)

https://www.youtube.com/watch?v=1CVTZ9tXNSw

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-FfjR2CJ/0/MRNp9Cj6Cbc7LRWxzQpDqDMS4KVB77ZqxwXNSRfdK/X2/20241013_121640-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-FfjR2CJ/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gzk542c/0/Kc8X5XVPT3btMrzwZZS2cb4TNZdjSGgHfBMnxCpHf/X2/20241013_121648-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gzk542c/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-JmTPZ3s/0/MM98dJ2fZ4mQGQctvcWRCs9zk95nC4L9SFZTKGzpR/X2/20241013_121656-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-JmTPZ3s/A)

Next I used Breeze fittings and Fragola premade lines and ran the power steering. I just need to finish with a little rubber hose section on the return.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-sS2W3Xb/0/MH8ZVhGxvs6Mv2TzK6ddXjQkDXZxbMdFFfvJws7CV/X2/20241013_122145-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-sS2W3Xb/A)

mrglaeser

10-14-2024, 01:52 PM

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Jx2BFJ3/0/LfSn3sZVjsxDLKxDXcMq8D5k4GKWjhwMGqqgfHTTb/X2/20241013_122157-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Jx2BFJ3/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-FBh5gwF/0/KQHv7wSmnDbXmzs294nCX93KCmp6MztWZ9HRjFGqV/X2/20241013_122149-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-FBh5gwF/A)

I put in the heater hoses including the shut-off valve.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-dmf9tLP/0/KrtxXmK8bRHR3rVCDcHNVG4jGpcvbZnvmd3LzQTf2/X2/20241013_124505-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-dmf9tLP/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Mp8tQ7p/0/MjZzJwtDNmcg3qr2rf5MvSB8jGxT3P7HjfqVrDrm8/X2/20241013_124501-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Mp8tQ7p/A)

I also finished the wiring for the fan and installed the overflow tank.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-skdTTjP/0/Lp3m34X73gtV9TZTMqKbfGwmPqV8J8xMwbk7RHVvc/X2/20241013_133816-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-skdTTjP/A)

Lots of trial and error + I bought an extra hose to cut up, but overall a nice couple hours of work.

John Ibele

10-15-2024, 09:28 AM

Good progress, Matt! You've got a nice clean engine bay taking shape. Your radiator screen turned out great; looks even better when PC'd black (too big for my toaster oven, so that was part of my last load to my powder coater before he closed up shop).

Good luck with the throttle linkage.

mrglaeser

10-20-2024, 09:05 PM

My Fuel Log came today from summit. I'm going to run a Sniper Stealth 4150. If differs from the original sniper in that it does not have built in pressure regulator and the computer is on the pass side rather than front (both changes I hear the new Sniper 2 has). Also it looks more like a 4150 carb. Anyway a 4150 fuel system is 3/8 or so inches to short. But a Holley Ultra/XP kit fits perfectly. Kind of a pain trial and erroring a few kits till I found one that fits.

Additionally I found some nice aluminum spacers to control the heater hoses.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-drPbsrV/0/L6kdx2hpPG8TKrwJfDQk26jcTrrkSzKdk8FDQMBCP/XL/20241019_203356-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-drPbsrV/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-XvPd4Xq/0/MtfdmBQzmBTNtQztxGBv2s8p8MBM8hmf4khqZG3mK/XL/20241019_203406-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-XvPd4Xq/A)

mrglaeser

10-20-2024, 09:21 PM

This has been a project I've been looking forward to for a long time. I don't know why this one intrigued me so much. After seeing John Ibele's car a couple years ago I was fascinated by the mechanical linkage. So finally having my engine in I could tackle.

The first thing I noticed is the instructions and most of the forum posts I found online had installed it with the Wilwood Pedal box. I'm using an 87-93 Fox body foot box I bought from a drag racer and restored. So when I was first mocking it all up I noticed I could not have the lever arms work above the rotating bar. The clutch quadrant gets in the way.

Not the best pic but you can see the rod getting jammed on the quadrant.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-tKdNGc6/0/MVJBWQK5MbBgG5RRxpLPJDM5G2bRGnLQ79vbNqXhc/XL/20241014_191912-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-tKdNGc6/A)

Additionally there is some pressed/formed steal in the pedal box that gets in the way.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-BDf49Bp/0/LcQWLJVq8GLbCm5CsGbqfb54mJZMmNQNmjcLW9D22/XL/20241014_191924-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-BDf49Bp/A)

But I did find this post where someone had created a mechanical throttle linkage and they were using a 98 foot box (not sure what other years this covers).https://www.ffcars.com/threads/mechanical-throttle-linkage-mock-up-on-small-block.289014/
In this post they had the arms hanging down under the rotating bar. I played with this a little and it seemed to work except for that bit of the steel in the way I mentioned before. So I got the harbor freight version of a Dremel out and went to town. After which I spent and hour with a file as there was one angle I couldn't get.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4qbVDJ5/0/Mx5pHNMPgqXTbxR3bzHWnpbjq8nwgRqHDmxpDghnf/XL/20241014_204352-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4qbVDJ5/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mH6PbM5/0/Kt47SP5gGGxqpxFBFNDhrFLwgg4rb25TPQcM8dCSw/XL/20241014_191955-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mH6PbM5/A)

After that it was pretty much the same job as everyone else. Cut some holes, play with the angles until you can get full movement without interference, tap the rods that connect the pedal and throttle to the linkage, and assemble. I did have some aluminum tubes with a larger ID I could slip on and off the connections to get the sizing right buy cutting them progressively shorter.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-59B4T33/0/MBZQsTgx5R7fQCKBn2mBGRFzVDjkg7qq2nvW5j5Qd/XL/20241017_203539-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-59B4T33/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rNFFBF2/0/L9rTX3vkJX2FGpTBMGwW5SVqmvhMS5tLMhkBMwzkz/XL/20241017_204249-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rNFFBF2/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-cdh89gM/0/LsXMj5XqX8zkFhMwFmRHKVc8MJggtN9mMFjGPvzQF/XL/20241017_210804-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-cdh89gM/A)

mrglaeser

10-20-2024, 09:38 PM

The tapping took forever. First I did it as a test with the cutoff pieces to verify the tap size 1/4 - 28. So I tapped 3 holes instead of 2 and I went in as far as the tap would go. It was challenging because if I didn't back out often enough the tap would get jammed by debris and spin in the vice. I was really worried about squishing the tubes and didn't want to crank the vice down too much.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-XqZ7bF6/0/Ngn7g56jBR5R7QZvXKB4ktBZcR5MrsZvJMPRrPr62/XL/20241020_093633-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-XqZ7bF6/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gPW5PQM/0/KntvXHN5KWxgBLgCfwpZg3pTvmBLp8HQ5nfWGVz2C/XL/20241020_094000-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gPW5PQM/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-6gVgTDR/0/M7krjJnBNgmxVBQkgggC2PV46cb4qcFSVzxMRMRr3/XL/20241020_110004-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-6gVgTDR/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7fQpF8c/0/MfqBHxV8DJZMQ7mSxxtFSmgHmHcRGknspVtdBxDpG/X2/20241020_110008-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7fQpF8c/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kjZfFWj/0/LD2kr9kLkJgq5d4SK7nGCV9QdcDGW6cJ5v5NZrRWr/X2/20241020_125616-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kjZfFWj/A)

I didn't get a photo but I also had to drill out and insert spring pins into the arms. Forte had pilot holes so this process was pretty straight forward. I took the rotating rod out of the car and did the end inside the footbox. Then I put the rod back in set everything else up and did the spring rod in the engine bay. Hopefully this assembly doesn't need to come out because it will be a PIA. For anyone else trying to figure it out I used a 1/8" drill bit and the used the spring rods supplied with the kit.

I also wire brushed the the push rod/tubes to give them a fun finish. I'll coat them in Everbrite next time I'm working on the car. Anyway I'm super happy with how it all came out. It was a fun 'Detour' of a project and it took me about 7+ hours to get the way I wanted (not including google time). The funny thing is most of it will be hidden as I'm going to mount the brake reservoir to the fire wall. The bracket will be like 5.5 inches I think. But that is a couple weeks away next I'm going to fit the top and outside of the foot box so I can paint and take down my paint booth for the winter (need the room for storage).

mrglaeser

10-29-2024, 01:57 PM

Nothing too exciting this weekend. I fit the drivers footbox aluminum so I can get the painted and take down my paint booth and store our other car for the winter. I wish I had fit these before putting the firewall in. I have the FFMETALS extended firewall it was a pain to keep working the panel in and out from under the firewall. Small lesson learned.

First I did the outer wall with the weird little extension pieces.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2dRHxg4/0/M6xm6ZFCNWTGjfcdDM9vrhrbqnCV3LZCrwWp7fnZ9/X2/20241027_120349-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2dRHxg4/A)

I might have gone a little rivet happy...
Next I fit the top panel with the access to the footbox

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-6dvFNrt/0/LGrVvfFJ4sM6B9F6wkBmG4rgZBHtpRsHGbNkgsp74/X2/20241027_113317-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-6dvFNrt/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-VQKzqnp/0/LqkkjncM7Cjzx86FH69VDwgvGKBxXrBszjBrjgkqh/X2/20241027_123733-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-VQKzqnp/A)

Onto the gap for the 3/4 steal.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-KG3mh28/0/KmwnhTfV99R4ntLNsHgVnkmx79qLHtNCRb9D9B3MN/X2/20241027_130217-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-KG3mh28/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZQq2Rv2/0/LcqP2nqj6pNXDFshkpwPxzSw7Kfv3jJnhSrFBsnb3/X2/20241027_132404-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZQq2Rv2/A)

And here is a everything fitted and cleco'd

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-m3pLRWj/0/MsH3FS2B8m55bjj9BJSZcxmBx34293v5XLjrCXtJw/X2/20241027_134009-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-m3pLRWj/A)

mrglaeser

10-29-2024, 02:05 PM

I did mess up a little with the panel with foot box access. After I fit everything I was going to add rivetnuts so I could pull the access on and off as needed. But I measured wrong and chews some holes in the main panel. I was kind of pissed at myself and initially figured I was out some money to order new panels. However over night I thought about it and figured I could make a new cover that is longer, cut out the bad metal, and put the rivetnuts further back. I didn't take a photo of the screw up as I mad that I screwed up just by being impatient.

here is the panel cleaned up you can see in on corner it's now rounded that is where one of the rivetnuts was originally.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-bmsBkDX/0/LNsxsH36wknGSMhPLw6sWvCmT9FGbxpK9pjhwgppK/X2/20241028_195438-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-bmsBkDX/A)

I flattened the old cover and traced it on a piece of scrap aluminum I had.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-cz7FLQZ/0/LDtRrzjcTPh4tZjDKJ9fpbZsTvb78zL5bg9z52WM3/X2/20241028_195807-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-cz7FLQZ/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pQ7q7W4/0/L7r35Fx4QmH59C86Fs3svDf7Vs3BDqHdJjGmH859n/X2/20241028_201205-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pQ7q7W4/A)

I used some 2x4s as a make sift metal brake.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2rnxfnq/0/K4dckqK6hR4FZ5dX33M3Ww8pgNmMTcS9ztvLfQ7gH/X2/20241028_202702-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2rnxfnq/A)

In the end it came out perfectly keeping me on schedule and well I kinda of stopped trying to keep to a budget.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2rnxfnq/0/K4dckqK6hR4FZ5dX33M3Ww8pgNmMTcS9ztvLfQ7gH/X2/20241028_202702-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2rnxfnq/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-hwPfBS9/0/NMzwfnGtMfrsHqXVx3Sr752Kz9SV4FRxbr94rZxDb/X2/20241028_205455-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-hwPfBS9/A)

I did a little more trimming after this last photo just to line up the back of the cover with the panel but I'm happy with the fix.

egchewy79

10-29-2024, 02:26 PM

mrglaeser

10-29-2024, 02:56 PM

Keep in mind that you might not be able to reach all those rivnuts once the body is on. Try to take a look at some of the pics of cobras w/ the hoods up to see just how many you might be able to access. I only used 3-4 rivnuts to hold that panel on, and made a "gasket" with some sound deadening material I had left over.

That is great advice. I did make an assumption there. I guess I can adjust when I do body fitting (hopefully in late winter/early spring)

AndrewIdaho

10-29-2024, 03:07 PM

mrglaeser

12-01-2024, 12:20 PM

Hi Matt,

I am enjoying following your thread. I received my MK4 in late July and I am slowly progressing (panel fitting in prep for powder coating). When I first got my kit I took some body on pictures to help remind me where interference may occur. Attached is my picture of the DS foot box that might help with your access panel question.
205886

Best Regards, Andrew

Thanks Andrew! I think this confirms all but one of the screws will be accessible so that is good. For looks maybe I'll cut the head off a screw and JB weld it to the panel.

mrglaeser

12-01-2024, 12:32 PM

It's been a while since the last update. I spent two weekends at the shop doing fall to winter prep and not a lot on the Roadster. A lot of the work I'm doing is minor clean up things.
-Wired the Hi/Low head light switch
-Painted the panels fitted in the previous posts
-Filled fluids
-Put on the radiator rock gaurd
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-6HD34sT/0/MgRPxm4NRBvS5qD9bJtGhgkDhCgZhnbvXCBVGmMjd/X2/20241130_111909-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-6HD34sT/A)

-Finished installing and wiring the horns
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-krVPKVK/0/KbHMS5xDNwsnVVfvwJSTpnPdKwGT46VrwPJkhL342/X2/20241130_111904-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-krVPKVK/A)

-Powder coated and painted my mirror
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pLNbLKW/0/LBzLP89Bz4wNjXp37S24PKQs2hGVZvCQNSZdcX3hb/X2/20241107_161646-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pLNbLKW/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rQMZVvH/0/NLCthBBhkmbLw8SNXs6f6VHSdpVtfKbWF4L3vfP8f/X2/20241107_161652-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rQMZVvH/A)

-Started working on footbox vents
I got these 3 inch Marine Butterfly Damper http://www.go2marine.com/
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7VkzPF5/0/NTW3LpPDhFSKwVDRSJmjQWcV5SfBBZ4BqqTDrPgZJ/X2/20241103_113022-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7VkzPF5/A)

I then copied John Ibele's idea on how to activate the Damper cutting out these weird shaped plates
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2HBTcBk/0/KpVt46RjbBHQxztHmzQmWhwbRMGrvnM2rnKDShZPL/X2/20241103_183017-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2HBTcBk/A)

i then took the ends off some cheap amazon throttle cables, got a few aluminum tubes and here we go. I think they turned out pretty good.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-TJs8zCP/0/KSJwtgsRFV3vgcVNjqztczb3ZHncHsk3NNJpJXt4x/X2/20241103_183731-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-TJs8zCP/A)

I'll post them again once I powder coat everything.

mrglaeser

12-01-2024, 12:45 PM

This weekend I made lot of progress on getting the Holley Sniper and HyperSpark ignition set up.

First I put in some riv-nuts and mounted the control box on the PS foot box.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Wvnc4b8/0/NBSMrd48j7RzHkx4PFhC8bt8xTnfP9wFTPndwrgBb/X2/20241124_155328-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Wvnc4b8/A)

Next I removed the Fuel pump relay from the sniper power harness. I plan to use the smaller blue signal wire to activate the RF harness relay as I had already wired that to the fuel pump last summer.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-tVvXmdK/0/LLC5978mBtSmhqGzqKrfrNCxrq2RRj872h7zBxFjz/X2/20241130_111839-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-tVvXmdK/A)

Then I de-pinned most of the outputs on the alternate output harness
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DPG6hHT/0/KgmtbQvWmqFmZrv8GNHZNZWL55jsvZDcRKJmhDFqQ/X2/20241130_112150-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DPG6hHT/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-WDZ2ghW/0/MzhW9bnmKc7NCmhHPXbkQBrn5FTn9m2bm6CnfsCrd/X2/20241130_112701-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-WDZ2ghW/A)

however I did have to come back and add the brown lead for the tach output... ooops. no biggie it snapped right back in. I have weather tech plugs on order to seal the connector up.

Unfortunately that is all the phots I have as I didn't feel the engine compartment is ready for it's close up but should be next time I get out there to wrap up this part of the wiring. But I did most of the wiring between the components. Control box to Sniper, Sniper to Distributor, Ignition power, Water Temp, Ignition signal to gauge, and control box to coil. All I have left to do is fish the control wiring through the dash from the cab, cut the fuel pump signal into the inertia switch ground, and wire the positive and negative powers to the 8 gauge cables I ran from the battery last summer.

Once that is done I'll put the battery in and do some initial tests and setup. Then I just need my exhaust from Gas'N (ordered in August so hopefully here by xmas) and I can attempt a first start!

On a side note I also switched out the flashers for the LED flashers. Not a big job but one that was on the board for nearly a year so time to wrap those up.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Xf8QS7Z/0/M3wjfHzSVPJWCGgRZMZJtgRc5cCz3kdjRPbX62ZxS/X2/20241130_111930-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Xf8QS7Z/A)

mrglaeser

01-07-2025, 12:08 AM

Last post was a little over a month ago. I have been steadily chipping away at various items. Just no big sub-quests or projects to speak of. I was hoping to do a first start over a holiday break but I'm waiting on some parts that will come the end of January. Maybe I can still get it in by Presidents day so 2 years from delivery.

So First off I powder coated the dampers for my foot box vent. I also found some nice vent cover/louvers for them (I'll get a pick once installed). I haven't installed them yet as I was focused on doing the Sniper/Hyper Spark/Under hood wiring.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-35L6vWJ/0/KPRrWwhVsRLbsBb56KZ7VdQ9jFhgWHJS5cmjzpXqZ/X2/20241207_105905-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-35L6vWJ/A)

Next I found this hose on Amazon with a lot of different formed bends in it to connect the return hose for the power steering.
https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-NQbxjKG/A

Not sure what happen to the photo of the cut piece installed.

I did finish the wiring for the above mentioned Sniper/Hyper Spark/Under hood setup. One particular PIA was hiding all the extra wire in the Sniper harness and putting in a distribution block for both Positive and Negative direct connections to the battery. i just need to run the handheld controller into the cab and it's done.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fhcrVdZ/0/KsTCzvtbLhfWDGwJ9PjPWp9DWZGLhxcg9wt3kzg8F/X2/20241217_202715-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fhcrVdZ/A)

I installed weather pack connectors on the front indicators, headlights, tail lights, and all harness endpoints. I know this was recent hot topic on the forum but I expect to drive in gel coat a while and possibly take the body off a few times prior to paint. I've had great luck with them in the past so I went a head and installed them. There may end up being a little extra wiring but I'll just zip tie it together to shorten it.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZQzNQ7m/0/KbspZZQHsqVkxgHm5jcLDfntFmwLJxfs7Xv4mgP8z/X2/20241228_164647-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZQzNQ7m/A)

After that I riveted in a few smaller aluminum items. The little cutout on the trans tunnel and the brackets for the cables that will operate the footbox vents.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-M9XL7xq/0/KmtSwcKC2QCp49xjZV6q29VWQppdKhhNTjWcMJrV5/X2/20241224_144443-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-M9XL7xq/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-v2gpKR4/0/Ktd37gT39trWMW9pq5mDxfQm27XhZxkxGkcft7rrF/X2/20241224_144448-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-v2gpKR4/A)

Finally for this post I used some left over sound deadening/heat shield on the outer DS footbox in preparation for carpet. I have the breeze kit but didn't like how that piece fit so used up the rest of the other stuff.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7F3zrs9/0/NbVxjVkCzSJ6kd6rk3dT4Wd4FtTPmkzrt2dWXkNKQ/X2/20250103_160308-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7F3zrs9/A)

mrglaeser

01-07-2025, 12:16 AM

The on area I have been able to spend a little time on while jumping from other minor tasks was the trans tunnel and cover.

I installed the gear shifter so I could sit in the car and make Vroooommm Vrooooom noises and POWER shift.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pC3CgHQ/0/M9sSFXmXJMtmbK6nzBsmM7bsc5zLLscF7MnJmh7wT/X2/20241227_170231-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pC3CgHQ/A)

After a good time winning some races in my head I mocked up where the shifter aluminum and bezel should go. Painted, riveted, and Rivet Nutted everything together.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-JXhJ9Ww/0/MhpmZVqj6CMcmWhKcznJgCxhdRXWWCqzDqq7DSPF2/X2/20241227_191006-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-JXhJ9Ww/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-xrSmtLR/0/MdRM9Wwxsh7PfDhN4W9xxTm2WqkK5GmHHL4PGphVq/X2/20250101_140728-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-xrSmtLR/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DbLWFKT/0/LNvQRSngmnM5pJfvQCH6spCJzQCQLR3zKv4RH2jHP/X2/20250101_140705-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DbLWFKT/A)

I cut some 3/16 x 4 inch rolled rubber to attach to the panel immediately in front of the tunnel cover and to the end of the tunnel cover to keep rocks and gunk from coming through small seems left when I trimmed the cover to make it removable.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-zbFVbTK/0/KtsHzrNQpxMjWd2kv9NvSVPffxhhj7VD37kpRbLkV/X2/20250101_143637-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-zbFVbTK/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-PWVpSJM/0/Kjb8qZK9GGfrLtFhW9xDvFgd22f5S8mX9jDpJgtVq/X2/20250101_144933-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-PWVpSJM/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-jnbpH7C/0/LgBk3qPff9ZpJ3sT34CGCWWztcc9LLq743VfBdF3m/X2/20250101_140702-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-jnbpH7C/A)

mrglaeser

01-07-2025, 12:29 AM

I then installed the Breeze Kool Mat pieces on the tunnel and cover. I also put an additional layer of sound deadening material on the under side of the cover. Again just in case things kit up in there it should muffle the sound (I didn't get a pick of that bit).

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-f9XKtLS/0/MbrkGHSrrGpN9bXxSzTzP5nWxvsvJ2RCGHk9RZBTK/X2/20250101_153101-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-f9XKtLS/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-qpmnxWG/0/LkXN2k9bFVRSH94pfKbGXGrK9B73kwRcZWbzfdNCV/X2/20250101_153040-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-qpmnxWG/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-X85KxcZ/0/LFBspGRjjRGGtn2LhtgLdSfnnWP8RwRcxnTKL8tXC/X2/20250101_160947-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-X85KxcZ/A)

I drilled and tapped holes to keep the cover in place once covered and carpet is installed. Another note for the next photo - I also installed the parking brake handle, ran the cables, and connected them to the handle. I still need to take the wheels off and connect them to the rear brakes.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ndFNcqm/0/KG79mQW2fR2ww25ppnSQzLCbLdzR5GxvcfQqnRCwc/X2/20250101_173631-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ndFNcqm/A)

I'm debating on if I'll have the tunnel cover - covered by the interior shop that did my dash and seats or if I'll attempt to cut some foam for a pad and do it myself.

The final bit of - just keep moving on what you can - tasks I started to put in the carpet. Just 3 pieces so far but they seemed to go pretty well.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-xcQdbCV/0/Mrd9cT4kWxM2V3ghpqsPjkg5DG3QGGxC2kFd7x35d/X2/20250103_160249-1736227360377-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-xcQdbCV/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-8PZRdfj/0/NdT8ZMtBjP9hbScnKgXb373PJ39C64mmzQgLj9Zb3/X2/20250103_164332-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-8PZRdfj/A)

mrglaeser

01-07-2025, 12:31 AM

Found a pick of the return line hose installed.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-NQbxjKG/0/NRz354ndF3kDqWntTwQ7Bd9ZPMVSbChPMj4Hk5C2S/X2/20241207_105913-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-NQbxjKG/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-dTvLKhS/0/Lnm7mKGDXSmVh93jQ7ddHMJg4HTph2jnbZFvm6ZvF/X2/20241207_105943-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-dTvLKhS/A)

gbranham

01-07-2025, 05:00 PM

Looking good, Matt! I thought about drilling and tapping the side of the trans tunnel cover, as well, but realized I wouldn't be able to get to the rearward couple of bolts with the seats in, so I think I'm going to cover the horizontal surfaces of the trans tunnel with industrial velcro (down each side front to back, and the 3 diagonal 3/4" square tubes), with the corresponding velcro bits on the underside of the cover. That's after putting Thermo-Tec mat on the underside and padding then carpet/vinyl/suede/leather on the top of the tunnel cover. I think it'll hold. Time will tell, I guess. If it doesn't I can always go back and use screws/bolts, I suppose.

Greg

gbranham

01-07-2025, 05:04 PM

mrglaeser

01-08-2025, 02:11 AM

mrglaeser

01-08-2025, 02:13 AM

Oh, and on a side note, did the two TKX shifter bolts fit the holes in your shifter? My TKX bolts were too big, and I wasn't about to drill out that stainless shifter. My kit also came with a short shifter (dunno why...I didn't order it as an option, but maybe it comes with all complete kits), and it fit. I really like it.

208692

Yes the bolts were too big for the shift handle. I did have to drill them larger. It took some time to do but I think there is enough metal there that it isn't a big deal in the long run.

Highplainsdakota

01-09-2025, 07:42 PM

mrglaeser

02-02-2025, 08:20 PM

Also look what the kids got me for Christmas!

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-WNj8L8r/0/8181b68a/X2/20221231_120325-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-WNj8L8r/A)

Matt, Your roadster is looking great! I'm over here in Bismarck, ND and just took delivery of my MK4 in December. I love your steering wheel in the above pic. Can you give me details on where they found it? I'm doing the quick detach steering wheel hub and it takes a different bolt pattern than the FFR wheel. Since I have power steering I don't need to have as large of diameter, but I want a wood wheel. It really is the connection with the road so I don't want to skimp here. Thanks!

Hi Highplainsdakota sorry I didn't see this sooner. I can't find my original links but I'm pretty sure this is the same wheel:
https://vswsteeringwheels.com/products/st3027

Also I can't find the same center anymore, but if I had seen these I would have ordered it instead.
https://vswsteeringwheels.com/products/ste1048blk?_pos=5&_sid=172e83f56&_ss=r

I also was hoping having a smaller wheel with the power steering would improve the feel but keep it easy for my wife to drive. Time will tell.

Congrats on getting your kit. It's an exciting time. I've only driven through Bismarck on my home from Montana, but looking at google maps it looks like there could be some good mountain roads to go cruising in.

mrglaeser

02-02-2025, 08:35 PM

It's a while since I posted. Not a whole to get into. Mostly just carpet. There was also some rework I might get into later but that slowed me down in January. So the only forward progress is some carpet.

First the tunnel. I'm make a removable cover so I had to cut out a lot of the carpet in the middle.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DWwHTKP/0/LB7Zxdx2LLPk9zvPdnJ8vNTnf7xrXMtwc8STGKmcv/X2/20250126_151024-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DWwHTKP/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3r3Q9Md/0/KpVpJRkXbS8t7xr8MZZWHKxHb3bJtkvS5C6LTPHXs/X2/20250126_151037-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3r3Q9Md/A)

Here's the transition between the tunnel and back of the cockpit
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-WdwHGrj/0/K5Cs8T8m4PvqXh7fsRjmTKmvLd9XT5LcfJb8H8BDQ/X2/20250126_151026-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-WdwHGrj/A)

Then I did the inner footwell walls. Kind of a disaster. The PS fit perfect, the front above the tunnel fit great. But try as I might (installing and removing the piece 3 times) I could not get the DS right. It always has a huge gap at the bottom. The piece must have been cut weird.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-5wxRLHK/0/Kgm6XF9zJWszZZjNkXqwk9Fh4dbXs3qKBxK4z64NV/X2/20250126_162003-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-5wxRLHK/A)

I even though oh maybe once the floor is in it will work. So here that mocked up:
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-BhsTn2V/0/Md4NbzpmwPNq4BmFXsqGKBwT6FnQ7c4v3VDVHHFLP/X2/20250126_162130-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-BhsTn2V/A)

I thought about cutting a strip to fill the gap. But figured that would look aweful. So since I had used vinyl in the trunk I used the trunk piece and cut a new inner footbox piece:

mrglaeser

02-02-2025, 08:40 PM

The Trunk Carpet is actually just a little bit small. So the corners in the PS got trimmed a little. But you would have to stick your head in there with a flashlight to tell. If someone is doing that I'm not sure I want to be their friend.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-G6q56NL/0/LxJJ9F2RKtDgntGgMXvBmvFNBdNRjZC872ZdCXrCL/X2/20250202_093340-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-G6q56NL/A)

First I cut the top to match:
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-hc6VLC5/0/K8vqZ34FLGNMFBcRJPRP2zvVdJJngv8GKD8rQsxvj/X2/20250202_094246-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-hc6VLC5/A)

Then I left all the extra fabric on the DS but cut PS mostly the same.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-WSns8NZ/0/NRG5NrRXDTjhK7X38xCSwgCxCDRkZFV6pFMVZNdhm/X2/20250202_094834-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-WSns8NZ/A)

Here is the front and PS. The photo looks dirtier then it is. I'll have to clean everything really well once all the carpet is in.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZFGQcwT/0/L24jBX2LTpG5ms9L9Q3CQwtfKvQ79dg7sKDtDw42J/X2/20250202_113030-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZFGQcwT/A)

Here is the much improved DS. Though there is a spot in the middle that isn't sticking so I'll have to peal it back and re-glue it for the fifth time. I think I might take the throttle pedal out next time it makes it hard to get in there with wet glue.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-s4LMXM8/0/LqKmvncqt229fKCQVqPzvpkFcCNBmsRMMHgZ2TSnb/X2/20250202_115458-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-s4LMXM8/A)

mrglaeser

02-02-2025, 08:43 PM

Also prior to installing the latest pieces of carpet I cut the wholes for the fresh air vents. I figure the metal shaving would never come out if I waited until all of that was done.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-tfP7zr9/0/McTjMRh3c3Bb652KsdrCXpnZCMZj4bMZw4wTjMmfx/X2/20250202_102223-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-tfP7zr9/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-dGcS4X5/0/LkwT7ddjPMz8tmvz83dFXzqPsg3DjXGrpHrmgpBfd/X2/20250202_103216-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-dGcS4X5/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-d6LsF3g/0/MW6QDPg9TbxzwFrcx9CMm2XC8Q6L9RdWvcJxqmBVx/X2/20250202_102038-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-d6LsF3g/A)

Not the most exciting update. I think next weekend I'll finish the carpet easily. Then I'm going to test all of the electrics. After that probably first start.

gbranham

02-02-2025, 10:16 PM

That's a whole lotta hole. Nice job.

mrglaeser

02-09-2025, 11:43 PM

Another little update. More carpeting

Front of DS Footbox
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-vZDLTCv/0/KRchThJVDRmvpzQ2Fz9JWgmj2QQMnFCwM9hHkTgGW/X2/20250208_164431-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-vZDLTCv/A)

Outside DS Wall
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-34jGfF5/0/KcwD6C8hkmMFJfk3LcfrPbdcDk2LD26bv7rHQd4jx/X2/20250208_164446-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-34jGfF5/A)

Outside PS Wall. Took a lot of clamps, bars, and other bits to get things in nice and tight.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-5JPGck6/0/KmWCK6xkHtqJM5gKBhSVGJpwkGRbZVknqmsbcwT5H/X2/20250208_164435-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-5JPGck6/A)

Front and outside PS Footbox
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4bmVRNB/0/LMkxbJdx95Q5qPVBZnTW6882R6K4s56w9vcnzpQWQ/X2/20250208_164452-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4bmVRNB/A)

PS upper floor.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kjjbB32/0/Kn2R9V67tscznWnQ9hmSzwk9njqrk9MPF2VxSjSHp/X2/20250209_113123-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kjjbB32/A)

PS all done.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-VGqW2ng/0/Mx2R28qMqHJ9z6DJWzD7vMgh4gndKJHkBHpB3CHRm/X2/20250209_113129-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-VGqW2ng/A)

DS all Done.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-BzWJGTf/0/KMqhSjkQ95TP8LVLjxDvCMFnWdMfcWG74VhHFdLv2/X2/20250209_114539-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-BzWJGTf/A)

Good news is I finally got my Gas-N side pipes (ordered in August) this week. Bad news it was two drivers side. So got a return label and sent them back. Bummer. It happens. I would suggest though anyone who wants Black Ceramic Coated pipes order well ahead. There is a shortage of stainless that puts all pipes out 10 weeks. Then there is another 2-4 weeks for coating, BUT....... now there is also a shortage of coating medium so there could be an additional delay.

Still hoping for a first start this month we'll see (was also hoping for December, then January, but it's a project with no deadline). This week I'm going to try bleeding the brakes, program the sniper, and test all the electrical components. Maybe I'll do the roll bars or possibly some under coating. Figure keep moving with whatever I can.

mrglaeser

02-15-2025, 10:50 PM

Still waiting as expected on my side pipes from Gas-N. They received the return on Thursday but haven't seen a new shipping notification so still waiting on the.

So in the mean time I went back to working on the foot vents. There are gap between the sides of the pipe and the flap that would let a lot of air through when closed. I've seen people use foam to close this. I thought I might as well but I wanted to test it and at 250 in the toaster oven all the foams shrank to 40% their original size. i didn't think this would work. So I ordered some stove rope which is good to something like 1500 degrees. But I couldn't figure out an easy way to install it and keep it from unraveling.

Next I looked into silicon and found this 1/2 inch round 10ft for something like $8. Figured I could order it and play with it. I tested in the oven. No shrinkage and no melting. But the shape was a pain. So I cut 2 straight edges. It took several tries to get close to consistent cuts.

Here it is whole:
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-V2VH682/1/M5ZdNTKWs5TsxmPBCL6XMVB8bp63VWvRvf3wLR9Mj/X2/20250215_103715-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-V2VH682/A)

Here it is after the first cut:
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-XKzJktt/1/LKMW4WqMcfnQB6ggzmFn7J6nt4n7hdsG3S2GTrXFg/X2/20250215_104111-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-XKzJktt/A)

and here is a profile after both cuts.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4dXhZPg/0/KXCH43g5hqfdNKH4TNRGRzD9JzCc3VMFgQK8Bcz9G/X2/20250215_104337-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4dXhZPg/A)

I drilled a few holes and rivetted the gasket in to the flu.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-btCwGJc/0/K6G4Lgf3WhgmwQ84wgSjnH8Nvnhxqw4H4smkcnn2D/X2/20250215_151142-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-btCwGJc/A)

I think it will work well.

After that a friend came over and we started testing out the electrical system.

So Far No white smoke has been released.
-The power cutoff switch works
-The ignition switch works for On and Accessory. I did not test the starter
-The Holley Sniper system came online as expected
-After programming the basics the fuel pump turned on and showed me a couple leaks
-The Headlights hi, low, and hi indicator worked perfectly even with the Mustang switch
-The parking and tail lights worked perfectly
-The Blige Fans both worked but were making a huge racket so we cutout and thicker isolators and the problem was solved
-The Heater fan worked for all three speeds but also made a lot of noise. A little adjustment on the bracket that holds the motor and problem solved
-We could hear the electronic cutoff valve in the heater hose moving when we adjusted the temp knob
-The cubie light works the trunk light doesn't will need to check the solder points. I forgot to test the footbox lights
-The 2 power accessory ports worked
-1 of 2 usb ports worked. The other had the power and ground reversed. A quick change and both work
-The horn didn't work until we redid the relay wiring, blowing a fuse in the process
-The brake lights don't work. I suspect it is the used switch I threw in there
-The Hazards work and the turn signals work like Hazards. After a little research I think this is due to the switch I used for the hazard. I replace it and try again. I also found 1 lose connection keeping the Driver Rear turn/hazard from working - fixed it.
-The Fan override didn't seem to work. I'll test it next time. As I didn't run the engine I wasn't able to test that the fan works.

Over all not bad so far. I get those items above sorted then once I get the side pipes I should be in good shape for first start. After that Brakes and maybe go-karting

mrglaeser

03-09-2025, 08:58 PM

Things feel like they have been moving slow lately. But still trying to get whatever I can done in the little free time I've had lately.

A couple non-photo related items.

-I found a Duel Post, Single Throw switch for the hazard lights and that fixed it so my turn signal lights work correctly. Though now that I've done that I found I could have just a couple diodes.
-I fixed all the fuel leaks at the pressure regulator and it seems to be holding the pressure at 60
-I tested the connections and the brake lights work so it must be a bad switch. I have a replacement and will see if I can get it replaced this week.
-I did the setup procedure on the Fuel Gauge and now it works.
-I fixed the wiring for the trunk light

Here's my daughter putting in a weather pack for the new hazard switch.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-JsgMQ53/0/M8PhCpDWGFScpGzTp6gkkXTL5fZDxtqmVvvXXck9c/X2/20250301_160839-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-JsgMQ53/A)

I also finally received my Gas-N side pipes. Here are some un-boxing photos
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-9xZ43xX/0/LwF26V2VDvdNxnx8zPZdXccp5J8T32QWNc4r5ZWDp/X2/20250301_151927-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-9xZ43xX/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-t8LxP6m/0/NTxGP8btV9wZ2vDtJVxxzZNb7ZgLNxgjHrwXbvFJj/X2/20250301_153012-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-t8LxP6m/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-zsTm3JL/0/LxD55FqZrqd3HhMBk9kb2rQhSbLv4gdWgnKrQNFNn/X2/20250301_153322-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-zsTm3JL/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-LRwSKCK/0/NR4j7vHJfzSbL4TXJ9PFZrgKNDJw6WhgQ3mc7pXpd/X2/20250301_153514-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-LRwSKCK/A)

So maybe next week I can get them temporarily installed and then it's time maybe for first start!

mrglaeser

03-09-2025, 09:03 PM

I also went ahead and drilled all the holes for the role bars. That was less than fun. But glad to get them done and the go-kart looks more fun with role bars. The trick I found working with them was to use a wire wheel on a Rotary tool and clean clean clean clean the inside of the rear sections.

I have some black stainless button heads on order to replace the bright ones.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-TLf4ZKr/0/LQXgv2VSjCRStdQKh92HHb2VpknbzMJQjMrhCtcrp/XL/20250308_172947-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-TLf4ZKr/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-V5wXRWR/0/KKZhKrZ4Qb5n6VS3scJrgXnCkjw9rqrBfsKv6Wn6X/XL/20250308_172951-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-V5wXRWR/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Zw3wmNt/0/NMvTFXKc3JpvJMqR2xZW7nR9kb6QQhcb35w58sWrt/XL/20250309_114819-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Zw3wmNt/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Q88bvwL/0/LpCdr85z83VwS32f6Wx6pT9nxrHMh4BbwrbxWTjM6/XL/20250309_114832-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Q88bvwL/A)

mrglaeser

03-09-2025, 09:07 PM

Finally I messed around with the J-pipes and some support hangers. The drivers side seems short so I'm a little worried there. We'll see when we go to hang the pipes to see what happens. I used some Fiat exhaust hangers, generic rubber isolators, some stainless z brackets, and hardware store turn buckles. I think the supports came out nice.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-cbw9FpG/0/MSg3gxk4GrHVHLt6h37j7ZScSpwrqj2pGXRD3sQqX/XL/20250308_161412-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-cbw9FpG/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-HbRCQm2/0/LTWJpQTRccBZcWPMsWjGgNMdDsg9dpBMfXtpWwKHT/XL/20250308_161418-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-HbRCQm2/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fBdVHZj/0/KnptwgZCm3vTQpgHchwMnS4Kjc2kznLc4h5hKppsM/XL/20250308_161427-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fBdVHZj/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-BpqBsbN/0/M8zTbtrtr5scn6XbZTSrpQ6Q4xFqJjdq3rnJvKps8/XL/20250309_124442-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-BpqBsbN/A)

mrglaeser

04-06-2025, 12:43 PM

I had a lot of work travel in March so I didn't get a lot of shot time unfortunately. But I did make some progress. First I had test fit the side pipes to the J-pipes and it was not looking good. The passenger side seemed to stick out and the drivers side looked like it had a 3/4 inch or more gap. Eeek. I thought about ordering a stack of spacers from Breeze, but decided to swap the J-pipes side to side. I couldn't find any place that told me which side each J-pipe should be used on. I had put the longer one on the PS side and the shorter one on the DS. That was backwards. Once I swapped them the side pipes lined up pretty well. So now I know longer one goes on the DS and shorter on the PS.

Next the parking break.. oh the parking brake. I saw a ton of forum posts about the parking break. I just thought come on how hard can it be it's just a couple cables. What a PIA I spend 15x the amount of time I think is reasonable messing around with the parking break.

I am using the Summit Wilwood kit for Factory Five Mark IV rear calipers. They integrate the parking brake with a single floating caliper, no second caliper I see on a lot of builds so I suspect it is a different kit than FFR provides (it was 30% less money). I'm also using a later Foxbody Mustang brake handle and have a solid Axel. So I ordered standard Mustang parking cables.

The first challenge is the cable ends at the calipers were to big for the bracket on the Wilwood Calipers. So I tried ordering the disc brake cables for a Mustang and same issues. So I had to clearance the bracket. Not much but just enough. The cables slide in with no slop.

The next challenge was the cables were way too long on the unsheathed end. I ordered some cable stops off amazon and some automotive sources but none fit the thick Mustang cables. I finally found these https://www.littleshopmfg.com/parking-brake-cable-stops-for-dbc-kits/ . Though when I got them they were quite large. So I took my dremel out to clearance the bracket for them to fit. Hears a photo that shows the cutout I made to retain the stops.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-FZxH5zM/0/NBJZGXS35gkV6DWj3CC2nxrxJhv3KmCnXhXxhct86/XL/20250322_140133-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-FZxH5zM/A)

Next up I found it hard to get the right length to the cable and then pull the cable attached to the handle to attach the shortened cables. I read online about preloading the spring and holding it with a retaining pin. So pulled the handle out and using my vice and some leverage got the pin in. Reinstalled the handle. Adjust the cable lengths and got everything assembled.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-jmWFkpX/0/MxJ2sdT34NPvQdGrxq8kCF6pW6c6pQ5p5wC5H6wDp/XL/20250322_133223-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-jmWFkpX/A)

HA! What I didn't realize is that heavy spring in the handle is only needed for drum brakes. DOH! Now I could get the parking break to engage but not disengage the handle spring completely over powered the

Now at this point I should have just swapped out the handle and done the over the 4inch tube mod I've seen so many others do. But I'm stubborn. So I kept researching. Apparently on Foxbodys if you add rear discs you have to modify the handle.

First cut out the spring. Ok Done.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-zj4TX8P/0/KcJFzNHjxqfgLdCfhS3mqp6LLMDdK2FwhQLHrz3jC/XL/20250405_104044-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-zj4TX8P/A)

Next lock the handle in place with a weld or this fancy little Ford Racing part. Done
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wWzvcxF/0/LcMKCkQs5K6PtdJkZ8DMqmQmLPnTQgvLVV4xFp9k7/XL/20250405_104053-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-wWzvcxF/A)

Finally drill out the bracket that you attach the two cables to and install an adjustable cable that goes to the handle.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-694j2mC/0/LgGbFVdDBvpQjqw85T2jsHK9xH3qpfNrL8m8SVHD3/XL/20250405_104758-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-694j2mC/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-bKkNZp8/0/MCzZS6BTgn5MdxXfSfNJGnRMfzx3qK9MwRJsTtJbV/XL/20250405_120155-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-bKkNZp8/A)

Finally install. After 30 min of adjustments and relengthening the cables, plus some clean up I have a working parking brake. W00T. So I put the cover on for a finishing touch.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-RfsJdr9/0/LWKGMhhZ7FGW2sdrq8CvG8pWdccCNWPr2sHtg2Kzz/XL/20250405_130315-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-RfsJdr9/A)

mrglaeser

04-06-2025, 12:45 PM

Finally I know a lot of folks find the cables bind and use a pulley system to reroute. My Ford cables came with the these springs I positioned on the 4 inch round tube and the brakes feel like any production car I've ever driven. So I think all is good. I do worry about some wear points though. So if that is a problem I have a plan to build a bracket with a pulley and use a longer front adjustable cable. But for now I'm happy if things last and work I won't mess with it again. But seriously that was more work than it should have been.

Also here is a pick of the bracket with both adjustable cable stops showing before I installed the adjustable front cable. You can see the springs just barely.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-8HSXtnw/0/KLQvx2zgdMhS78qD8kxJfsvRtxPWwZnkFX52P6538/XL/20250322_140200-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-8HSXtnw/A)

Highplainsdakota

04-06-2025, 05:56 PM

It’s really interesting when you get to the next part of a build and things may just fit right in place, or you spend 2 weeks, 100’s of dollars in random other parts and fabrications to get something simple to work. All part of the journey I guess. Nice to see another section one together and be able to move on though!

mrglaeser

04-07-2025, 10:41 AM

That's 1/2 the fun I suppose the problem solving.

mrglaeser

07-16-2025, 05:37 PM

Oooof 3.5 months between posts. Not a lot of forward movement. Have some first start things to sort out which hopefully happens soon. But a few things have moved forwards.

Did a little more work on the foot box vents. I found these 3 inch grill vents for jet skis. I pointed them so the air should flow down coming out.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-vZXSsmg/1/LwHzDKqPqBRtzfbghp5Xh39WNcHTj3CsHcKNwttW5/X2/20250626_195215-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-vZXSsmg/A)

I bolted in a flange and pressed in the grills
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-9CTVWfF/0/MhBgk7vNTtp7K489VMSVqnq3BwnBV6sTQzgrhLR4N/X2/20250626_195131-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-9CTVWfF/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-c8fn955/0/NLjLWH6JG6vmL93zkcbx6vVcmX7mtccz6C6qc2mt6/X2/20250626_195258-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-c8fn955/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4nsQzb3/0/Ln3zJBSqJ6HfLD2K27HV9DjTrsTmdF2xfFR9ZcfnM/X2/20250706_094819-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4nsQzb3/A)

Then I used a silicone union to attach the marine flues I prepared earlier
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Sqgsjxf/0/Lx53zg4MKtctfNw4TKhTBhZrcmkwX4CfgVdfwwCQW/X2/20250626_195451-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Sqgsjxf/A)

Add Napa pulls and now have a working cutoff.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-FGbSZzS/0/MKDNzF9WJ4K2JcGCbmPMx7DCqzLbZxBNhnR5XV4w8/X2/20250706_104459-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-FGbSZzS/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-TgRPV2c/0/MSLdwPhkP4kkP8pPdG3Fvkpd7CBFvZmNbz53xgWDh/X2/20250706_104518-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-TgRPV2c/A)

mrglaeser

07-16-2025, 05:39 PM

Here are a few more flue install
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-NvVfZN8/0/MjQL3JvJsgdb2cH6V4xXFsP65cBjpZmR42bsQc8Kd/X2/20250706_104510-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-NvVfZN8/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-V4XR9ms/0/LqwCSrqW9NVw6JRFjpnvpjThn4FLN6cDmQLtFNPz5/X2/20250711_162853-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-V4XR9ms/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Sr5Psn5/0/MjsPzZxX4C7rSbxD5xqSFHD8h5DdNPh7wmXTxcWBf/X2/20250711_162858-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Sr5Psn5/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Qh7fWbM/0/MbTQQj69RTT3SSftjGc3tmqSFvgrzNQQ89WxNDfxV/X2/20250706_104504-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Qh7fWbM/A)

I will add the hoses later. I wand to use rivnuts to hold the panel that goes behind the front wheels on and will need to cut a hole for the hose and an indent or use a dog bowl for the master cyclinder.

I also re-assembled the license plate holder/light after powder coating it last year.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4NFvdpp/0/M2wrL29r7cMw62LzrjshL8Sm6CqzwtWfzVL6G9nPT/X2/20250810_174524-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4NFvdpp/A)

mrglaeser

08-17-2025, 09:27 PM

https://youtu.be/yOFGhnr4rto

For some the 3rd time is the charm. For me it was more like 6. But that's ok this is a journey. Mistakes were made. I'm new to this and decided to do as much myself as possible that included assembling most of the engine, install of the clutch, installation of the TKX, and rebuilding the rear-end. There were bound to be challenges. I was hoping to start the engine last fall actually so now I'm only about 9 months late.

Mistake #1 - I used the wrong head gaskets. With a Boss Block there are larger head gaskets. If you use standard gaskets the larger water jackets are slightly exposed and when you go to fill the cooling system coolant leaks from between the head and block. I found that out last winter. Then had to take the top end of the engine completely apart to change them out. I wrapped this up in Feburary (needing to of course wait for parts and due to the fact I only have so much free time to work on the car).

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-6XBRLF6/0/KVsLFHVph7d8x9hJ5FCgb8L9r7NR8F8c8CNwHMtbx/X2/20241230_175644-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-6XBRLF6/A)

when I first assembled the engine I was focused on the gaskets being lined up and oriented correctly I honest should have but didn't notice the gaps (See above). Below are the nice larger gaskets. Now I did just install the gaskets that were sent to me with the top end kit. The company that put the combination together knew what block I was using - but I should have noticed.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-QDTmSNp/1/MhpzWJGS4FPbFZ39c8TmXGH7GZx9fm5ZB3ggJdtkv/X2/20250104_160026-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-QDTmSNp/A)

I ended up working a lot and taking a lot of time to install, wire, and plumb the Sniper/Hyperspark setup. So the first test fire was in May - it did not go so well:

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ShhZG23/0/NQFbCPccQwN2Tcw4wJZ2BJhcd4JdDWGTcK25FTkRs/1280/Roadster%20First%20Start%201%20Poof-1280.mp4

Mistake #2 - I installed an in-sufficient ground. The ground cable "nope'd" right out of there and melted. Then the electricity did was it does and found a new ground as it flowed through the Sniper casing, arched from the throttle bracket to the mechanical throttle linkage. That little puff of smoke was a bit of the Sniper casing melting, the throttle return spring deforming, and the plastic bushing for the throttle return spring melting. I thought I could replace the spring but Holley doesn't sell it. I figured this out after disassembling the throttle on the sniper. I did send it in to Holley, they put it back together and tested it, but did not replace the spring.... But they also didn't charge me. So I bought and external spring assemble and re-installed everything. By this time it was the end of June. I had 2 work trips and 2 weeks in Europe with the family so no work got done in July.

Mistake #3 - I caught this one before there were repercussions. I wired the sparkplugs in reverse order. I did it clock-wise and it should have been counter clock wise. Not failed start here but I did do it wrong initially.

So today I tried starting the engine again. Here is the first attempt:

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wM6v2ds/0/LkTGrzTMv3jB6ZMrBhfWQ3H2HQGRnJ5nVCQnJhnJC/1280/Roadster%20First%20Start%202%20Splash-1280.mp4

Mistake #4 - When I installed the Hyperspark distributor I was on the exhaust not the compression stroke. Honestly it took me a little while figure this one out. But we pulled the distributer and valve covers. Figured it out and reinstalled the distributor.

Finally we tried again (click image to play video) -

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-QtwT6VS/0/K5kFCC7BS4BRBMnQZ5t9pRBjKWrJ3Pg6nPjZ6rRqg/1280/RoadsterFirst%20Start%203%20Wohoo-1280.mp4

I had wanted to get up to temperature to verify the gauges and cooling fan. But the Clutch cable started touching the headers and got a little melty (the casing anyway) so we stopped. Additionally the header wrap seemed to be burning something off. Not sure why. I did use some header wrap sealer but didn't expect it to do that. So we took this as a win. Later this week I'll deal with the clutch cable, check with the manufacture of the header wrap spray, and we'll bleed the brakes. Next time we'll start it outside and not fill the shop with such fun toxic smells. But in all honestly the car started right up once we figured out the distributor and it sounded great. No weird noises. I'm taking that as a long awaited win. Go Kart - here we come.

I wasn't sure if I should post all of this, but I figured there are folks on here with different levels of experience. Many with more, some with less than me. I figured why hide the mistakes and re-tries all us newbs are all trying to figure it out.

gbranham

08-17-2025, 10:29 PM

mrglaeser

08-18-2025, 07:14 AM

Your idle sounds like your timing is way off, just like mine did on my first start. As a consequence of mine being retarded and not advanced, my headers glowed bright orange at idle. Might explain why your header wrap is burning.

I don't think the timing is off. Maybe the video sounds different than it did IRL. I was pushing the gas pedal to change the RPM's and listen for unexpected noises. I'm sure the timing wasn't perfect as the engine didn't even get warm enough for self-learning to cut in so the Holley would have been using some default based on the initial inputs I gave it. I used and heat sensing gun and neither the block or exhaust seemed out of line (just under 100 f for the block and just over 200 f for the exhaust). I did a little looking and DEI's site said the exhaust wrap coating will off gas and smoke until it has been heat cycled a few times. Also if I'm being honest I think a fair amount of oil got on the exhaust from when I primed the engine and made sure oil was coming out of the rocker arms. So for now I'm not too worried.

cv2065

08-18-2025, 10:22 AM

I'd probably take that header wrap off until you get it all dialed in so you can see and measure what's going on. I'd also look into some spark plug wire management so they are secured and don't touch anything hot. What's your base timing set at?

mrglaeser

08-18-2025, 10:52 AM

@cv2065 - Wire management is purchased but as I was pulling the valve covers on and off setting things up I didn't install yet. Will be working that this week after figuring out a better routing for the clutch cable. Was really just focused on getting the engine to start before cleaning everything up. The wires aren't touching anything and don't seem to move as long as the chassis is stationary. As for removing the wrap... once it gets hot it's not re-usable (due to the sealer) so if I pull it off I have to re-do it all. However I might see if I can find someone with a full sized oven that would let me heat cycle the headers and J-pipes. They don't fit in my toaster oven and there is no chance my wife will let me do that in the house.

mrglaeser

09-04-2025, 10:22 PM

Just a few updates over the last couple of weeks.

First I got a reverse switch pigtail, ran a power to the back for a backup light and tested that it worked when in reverse. Photo isn't great but here it is anyway.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Cn6BBZX/0/LrHF8L2Lq2jP2c5VNp6nZ9FNHw98v9wczLDW45WKH/X2/20250904_192533-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Cn6BBZX/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-w22smVH/0/Lgz7wT33CgZZxP33pftG9spjR3vbVBFZmBdvtc3ww/X2/20250904_192459-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-w22smVH/A)

Next I don't have any photos of it, but I finally figured out the right way to wire up the courtesy lights to the 65 Mustang Light switch I'm using. So now I can turn the knob left and get lights in the foot boxes. Not a big deal but it was bugging me. The trick is the RF harness is expecting a ground interrupt switch the Ford is opposite and you have to wire the power to one courtesy light post on the switch and the positive leads to the other, then ground the lights to the chassis.

Next after all the worry above for my birds nest of spark plug wires I put in the cable management. I think it turned out pretty good even if 2 wires were a little short to wire exactly like the diagram.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3pRK3rD/0/Kfjbtqcm2NTnQzPDDqZzNwK84FFv8XgJJFJ2msmJB/X2/20250904_191755-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3pRK3rD/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-343tKWN/0/MzjvMH6FVkT8DtLtsHR973gPsw4Nq2stcGB34Pnvb/X2/20250904_191750-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-343tKWN/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-x6wGxnD/0/LdnnChrfNgZkz4Xh52QNmhnkJgwHzz8sWnpKggGHS/X2/20250904_191741-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-x6wGxnD/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-TFTpdqV/0/LHq6FZKSPNGJ5wjc6GgsgHK4ZQTNJjrzCkmpspzrd/X2/20250904_191729-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-TFTpdqV/A)

I also spent some time creating a fitting so I can power bleed my brakes (this weekend's fun probably).

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-sX5MpWg/0/KcGPCD2LjmFpqrRGFXNw5L8b2qm6Cs5ZPwxtpndh3/X2/20250904_191724-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-sX5MpWg/A)

mrglaeser

09-05-2025, 03:16 PM

Another side quest I've had going on and off this year is what to do with the tunnel cover. I thought I would attempt it myself. And I did. Attempt it. The plan is two cupholders, oh-Sh*t handle, and nice little elbow rest in the back using the same vinyl as the dash, seats, and doors. It took me two tries to get the foam cut (marine waterproof foam), then my first attempt at covering it failed because there was line along the foam/metal seam.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DHxXLf2/0/KbKrvDzrvxq3xgmbChQtZ37McWng4h8TPbSbjDDnr/XL/20250608_172206-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DHxXLf2/A)

So I pulled the cover off and added some batting:

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-sLhHJp2/0/MMRBHXPZrMmFcpQxhbvBcdbPxpsBTV2Hjm7nPTkD5/XL/20250608_180627-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-sLhHJp2/A)

But this also left a smaller seem where I had joined two pieces of batting.

I don't have photos but I did re-bat (is that word) and covered it again with a single piece of vinyl. With the larger pad for the elbow I could not get a smooth laydown of a single cut of vinyl. At this point I was as far as I can go without access to a heavy duty sewing machine. So I took it in to be covered. The interior shop was able to use my foam/batting job and did a nice job covering it.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-3xFnbMh/0/L2jkSMFz9SG2gvJScKRQG3QX6pJpTNcKnnb6fFVQW/X2/20250818_132411-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-3xFnbMh/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nWXtc94/0/LVvxX2fscnmjQDKGbhMrxKKDz68m8m4FMmtT2W6Cm/X2/20250818_192930-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nWXtc94/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rnJqc5n/0/LQJs74fD73GJpvxxZ2S7DtWVRzLq3sNXGcqzmZq4C/X2/20250818_193218-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rnJqc5n/A)

Still need to punch some holes and screw it down but I think it looks pretty good.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kKmcsft/0/MVq864kjLKx2K3xLgN4nn8mN42WGtq6mjqR3NjDPN/X2/20250818_193231-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kKmcsft/A)

mrglaeser

09-25-2025, 02:46 PM

Still no major changes on the project, but progress a few items
.
First it took a lot more work then I though but I did get the tunnel cover screwed down. I had to remove some sound/heat map on the bottom of the cover and trim some of the vinyl wrapped around and glued. Plus I trim some carpet and a little sheet metal in the cockpit. I should have waited to drill and tap the holes once the cover was wrapped rather than doing it with bare metal.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Cf5rkSL/0/MX2ZG4NJxkVmCq3gW7grkgxd9xJDK33xhPFjxGF3P/XL/20250920_165954-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Cf5rkSL/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-NhZk3ZK/0/NBVP66K3xkPcwChgrK97RPLNRhgjHGzcJgnDRKd67/XL/20250920_170013-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-NhZk3ZK/A)

Next I spent a full morning and a then some cutting, cleaning, painting, and drilling bracket for the vent louvers and to hold the clutch cable. It never stops to amaze me the number of hours going down a rabbit hole can eat up.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-hzR9qBG/0/LRb7fGQr3Hcbm2PTH7Cpnd5pRR5ZjBKQ7nWN4XZVm/XL/20250914_120721-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-hzR9qBG/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-djM38vK/0/MbdTR3kPTKgqBjfJnDwDJQqfhckXcptgkppCPjkbc/XL/20250914_135210-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-djM38vK/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-LLGzdph/0/LRzhQJCcXWDC6zmXDznC8qQwSjzrwmG4kPJrCK8Bx/XL/20250914_144252-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-LLGzdph/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-55tSxHN/0/K3X4sxKKkGgkB9WVV2KfV2dH8VzMN4BmHqMkMzZ3z/XL/20250914_160527-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-55tSxHN/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-qNgBmCR/0/Kdm5dpNkG36vnsGnWFKRLkH3VSXBKpgT4phbhjdm6/XL/20250914_160535-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-qNgBmCR/A)

mrglaeser

09-25-2025, 03:07 PM

I also installed the brackets to louvers in prep to locate and install studs on the body.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-m8RPbdT/0/LVzBT8Q2BLsZHthnGn8dfgpM2bwFS6KLdRxwV5Q2X/XL/20250920_111910-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-m8RPbdT/A)

I see many folks use 8-32s I used silicone and 6-32 button head and lock nuts.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Smgx5DT/0/K2BJqZFrSm3KFwfdtg4jqS5gZMbz2kphgr4gHXgdM/XL/20250920_122036-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Smgx5DT/A)

Horrible pic but here is the bracket for the clutch cable to keep it from rubbing the engine mount
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-KnthkCs/0/KrpWSZzMz8FbnZsHbLNNhpbb5GLJtK92G3x5R36r2/XL/20250923_185043-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-KnthkCs/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7L4Lnjp/0/LKCHfKmfZDxPdpxMSrmfkfhGSkm2h5DxV8Kxd7Fj4/XL/20250923_185124-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7L4Lnjp/A)

Additionally I tested the cooling fan it works if I bridge power so I've reached out to tech support of my fan controller to hopefully explain how to wire the override switch. The way I have it the override isn't activating the switch.

Finally (no pic) I installed four stainless bolts and couplers in the back so when we fit the body we can use Kleiner's rear quick jack mod. Tip: when creating a a custom drop trunk leave a little room to get at the quick jack mounting holes. I had to get a little creative

This fall I'll be working to trim and fit the body. I will admit I have some nerves about cutting the fiberglass but one of my goals was to do as much of the build myself so I'll have to get over it.

Blitzboy54

09-25-2025, 10:16 PM

Interior is elite.

mrglaeser

10-30-2025, 10:20 PM

Still pretty busy with work and 'Life' so not a lot of progress on the roadster lately. But still haven't stop and get at least a couple hours a week in.

First John Ibele came by and helped me start to get an initial alignment. We got through some of the steps, but only got so far. We set the initial ride height. We couldn't get the upper A-Arms to the right initial measurements. The adjustment sleeve was too long. So I ended up cutting a bit of the sleeves and was able to get the measurements where they should be. We'll come back to it in a couple weeks. That was enough to get most the tow in taken care of and reduce the camber. So now I at least feel comfortable doing some go-karting in the near future.

I also purchased some Schroth ASM II harnesses for the car and installed them. I got the normal ones because I really like the cam lock. I don't think that is a big issue in MN. I thought about changing the brackets out to bolt in as these come with snap in, but it was just as easy and much cheaper to just install eyebolts. Here are some install photos. I'm really happy how it all came out.

First installed some nice powder coated bezels/trim.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Njw7Q52/0/MKN3Sd2v3kCswQCgcGZjjqFFDCq8KfhT2C96WbZtS/X2/20251026_105608-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Njw7Q52/A)

Then the eyebolts
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-VtLBk5x/0/M5vL8S4F4bfXjwvrLjgbTNgJDx3TBcb3P5Qhcm7mc/X2/20251019_104845-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-VtLBk5x/A)

Then I pressed my high schooler into service for the detailed work. We both learned to wrap the brackets. It turned out to be a lot less confusing than I thought it would be.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-KcbfBmJ/0/NfqwjcCgG3CkZKtrJCfsx6MXKCPXgPcNTcfKPv6z6/X2/20251026_113638-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-KcbfBmJ/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-9rSnrNt/0/KTcZfgBMsN2BksKbnLkzd9zC4gF7t8ztc7cWcM7kz/X2/20251026_115108-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-9rSnrNt/A)

Slack rolled up nice and Neat.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-cBKFRLs/0/LgL3fcXBxm2vmzPBZD9WvkwpXM2RdTBB76c9kNFZr/X2/20251026_115116-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-cBKFRLs/A)

The Eyebolts and seat seem to fit fine. I'm going to use adjustable seat tracks and raise the seat an inch or inch and 1/2 anyway. So I don't see an issue with fitment. (fingers crossed)
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ghkf2Cn/0/NJPztWZpHMvSD2sLDRwsgNG7tJB2fwVzhWXndBD24/X2/20251029_130049-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ghkf2Cn/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wvnSJzw/0/M857GQ9j9LwFhtMCtQXFppgGb3tCdfwdcnsvXcmbR/X2/20251030_155038-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-wvnSJzw/A)

mrglaeser

10-30-2025, 10:28 PM

Continued....

She thinks this qualifies her to drive the car....
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7P36hDW/0/LDKz2wwX6m8Qw78HVK2wcJ6vPXTvKd9FNsX7whdrZ/X2/20251026_131059-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7P36hDW/A)

beyond installing the seat I also marked out where I'm going to trim the body for side louvers, open the exhaust cutout, trim the wheel wells, and clean up the trunk. Hopefully I do that all in the next couple of weeks and then the plan is to fit the louvers, under coat the body, and then fit the body to the car.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2L5Q7SW/0/LCgVvVk9sXkGKKvBvbtkm68R4XCfnDzZKKh65TwNR/X2/20251019_132009-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2L5Q7SW/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DnhD6f9/0/KQ7LhPdG4dFbSmGVvV96ZptLjqw38d4KGQbL6ZjT6/X2/20251019_132018-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DnhD6f9/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-KB9d9Jx/0/Kmzh55FZgFcQ8HtBhgCrKVrR3sxmHWFDHMh3cpM56/X2/20251019_132022-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-KB9d9Jx/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-h7r9pVF/0/NNZqGPcXkvxsnf6mkj4Kw4BWzFC6CH3xCpBNSW6WB/X2/20251019_132935-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-h7r9pVF/A)

I also created a harness for the headlights and ran it through the head light bucket. Along with drilling out the locating holes for the buckets - So I guess I've made the first modification to the body. A lot more to go.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-t7VFwGn/0/LCDc9WpfdrwNZFZ8fZr5LJxGzp2786J8LtT68TVh5/XL/20250927_114848-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-t7VFwGn/A)

Finally I got a rubber block off amazon and cut some 5/8" body spacers for the front of the car.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-CcznxSL/0/KcTDNhJPN93qzLBmHx7DcCRPPZX5RXQvR96Nnk9Rj/XL/20251019_104859-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-CcznxSL/A)

mrglaeser

11-10-2025, 11:26 AM

More small progress... which hopefully will add up.

I installed a quick release Fire extinguisher mount. Pretty easy drill and tap two holes for M7 counter sunk bolts. And screw in. Here are some not very exciting photos:

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pqH5mXs/0/K2tjSxrdvCQWt846FdB9ShRbFkdDfH5JcJpHkDQm3/X2/20251107_194547-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pqH5mXs/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-LnMTF5f/0/MKtpjDXPx79nzSvVcwJmMHT6gTSsvDn65XvNBfMCm/X2/20251107_194554-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-LnMTF5f/A)

And I made the first cuts to the body. I'm testing a few techniques with some new tools so I only have worked on areas that will be covered up. So I widened the wiring holes for the tail lights and front indicators so I can fit weather tech connectors threw them, straightened one of the rear roll bar tube holes, and radiused the whole for the gas cap and low body lip by where the gas tank will be. My plan is to work up to more visible areas soon.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-RbSL4Sm/0/NR3HGtMsfXkxmmG3MdnbVtKTzHnDTGV72k2H7sxWw/X2/20251109_140146-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-RbSL4Sm/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-66vwK8G/0/LkFx6htKgQPtpnqxgFCRfQmVnDv8vt3mfmjs2T3Mt/X2/20251109_140151-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-66vwK8G/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rPg9KCp/0/LQtgnvQsXDfFHfdvdFTmg7Q39kw3gkZqVhVdzWZff/X2/20251109_140226-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rPg9KCp/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ThrWcVs/0/Mq34TNcFT2qGh2Jtdmntqn34n8RwZL8hc3LMjLQhR/X2/20251109_141019-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ThrWcVs/A)

mrglaeser

12-02-2025, 08:42 AM

After playing with some smaller cuts I jumped in and did the wheel wells. First I marked of the area to Keep.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZD38WtN/0/L3Ks9nNCSDZZW4VNL6tm36BCWhDLXgs2x9hx7THX6/XL/20251012_151739-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZD38WtN/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Pk7KfXn/0/LKqWqrkNRssT5CZ9jr9CSgj9JMWH5J4X6qLsSV43P/XL/20251012_151819-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Pk7KfXn/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-2L5Q7SW/0/L5nFFX9CL7qcss2HtjswnJfHCw4h8djBt22v7MrrP/XL/20251019_132009-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-2L5Q7SW/A)

Then I used an air saw to cut the extra off and rounded with 80 grit. I ended up with a couple low spots I'll use some filler to build back up when I fill in other gaps. But that will be after a summer in Gelcoat

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gzjs58w/0/LCfjLKPBZdgMxkdt49hN2cN5xfH66SG5CSGLnPgdW/XL/20251115_203411-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gzjs58w/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-xbwsc3z/0/K7GGqJWQjZ4X2r6SbRcT7jspnqF9kkBzVNCPhqwqX/XL/20251115_203417-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-xbwsc3z/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-KSncgSc/0/Kmf6n2xnkCrwSX2SdMXHBzq9KPkdhzcr4m5t49DPK/XL/20251115_203402-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-KSncgSc/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wtVwpSF/0/LTJrhkgNX8CzHvQ4h4z7ddhm6rm2Bgf64tqmJC3Mn/XL/20251115_203358-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-wtVwpSF/A)

I'm probably a little bit slow but this whole process took me 5-6 hours. I can see that the body work is going to take quite a bit of time.

mrglaeser

12-02-2025, 08:52 AM

I don't know if this is something that bothers other folks but the trunk opening was not trimmed evenly at all on my body.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-h7r9pVF/0/NNZqGPcXkvxsnf6mkj4Kw4BWzFC6CH3xCpBNSW6WB/X2/20251019_132935-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-h7r9pVF/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nWxLtDJ/0/NQPcxhV8HQxgjs4Zr2C7pWQ5G27WZgqwj8BSBwkS9/X2/20251019_132940-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nWxLtDJ/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-bcpLLs7/0/Nhr9jdb76v498nvkZDLhHCdL998R48gs8Hm9mXCXv/X2/20251019_132955-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-bcpLLs7/A)

The photos make it look better than I feel it was before I started. But I used an angle grinder and 80 grit to make more even. Then again round the edge by hand. Here is photo after the die grinding. I didn't take one after cleaning the edge.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-cdtKcPJ/0/NdxK9M6HRShnP7NbTJvmGKGFTZ9rz569C26C9knQ6/X2/20251120_125358-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-cdtKcPJ/A)

Another 1 to 2 hours on this activity.

mrglaeser

12-05-2025, 04:16 PM

Probably one of my biggest worries is getting the louver openings cut correctly. I've seen so many different ways of doing on this is site from air saw, to router templates, etc.
I ended up just doing what Kliener says he does with thin cutting blade on a grinder and an 8 grit sanding drum.

Of course I spent way to long cutting out a template. I must have done it 1/2 dozen times until I was happy with the results. These aren't the final ones I used but show my horribly slow multi step process.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DpGSvhQ/0/NQLQBGxF3943tJvQLPNcPV6cgpzGcrt8CF6pgprg3/X2/20250811_175844-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DpGSvhQ/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-czX69Ps/0/K6DJtJDTZ68FBPH9MxhHrv6zJ48kJqhFgjkxXxLTF/X2/20250811_180832-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-czX69Ps/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-PDR6Q8J/1/NGKcpCb3q4Mq9DW3SPd3VWFSVFmqTsQxdDCtGs6v5/X2/20250814_214950-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-PDR6Q8J/A)

I also didn't get photos of the markings on the Car prior to cutting. I wish I had it's interesting how big a difference there is between the upgraded and standard louvers. But the cutting went pretty smoothly and sanding with a drum sander really did the trick in making a nice smooth transition.

Before
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZfdvgVZ/0/K2nxx6xc9VdcL4VmKsRrJPwH2LDCKhTqw37PVTZMb/X2/20251120_121638-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-ZfdvgVZ/A)

After
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-6fmz6tR/0/LnNhcTc783KnGtbDXfgwWKDPcKd4m7f59nTvbgRdr/X2/20251120_125350-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-6fmz6tR/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-xJFN5z5/0/NWstbf7FHQVrHGqCTgRWtNPKNBKnGBXrwV569zp9n/X2/20251120_135335-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-xJFN5z5/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rSPVjqV/0/M2C4t3ZnmZVVJcG4tCzb38fS4VBVBM7PDwNXsZbBH/X2/20251117_141231-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rSPVjqV/A)

Still a bit of clean up to go, but I don't think I completely botched them which was my original concern.

mrglaeser

12-05-2025, 04:24 PM

Additionally when I cut the louver holes I also expanded the exhaust cutouts in the front.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-PgT9m3p/0/Mq64ww8MTTC4Mq6rbH7LTKHtbvZSpzvbfPjzgfMSP/X2/20251117_141229-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-PgT9m3p/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gDV8mt9/0/MWHtJpPLPjphfbRmQVGvcMqVhWrNPJw2hGFDkHLBD/X2/20251120_135339-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gDV8mt9/A)

After a few days I also lined up the louvers where I liked them. Marked the location for the studs, and glued/glassed/adhered them to the body.
I saw this trick of using painting sticks to hold the louvers in place. Worked out pretty nicely.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-nJzCLb7/1/LFq92TbCxKSB3jPSmsmFMBfggmrLsLTJSgZKTTbP7/X2/20251125_111036-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-nJzCLb7/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-JqBLf9p/0/KmqP8g23DFtSbhSDRXjGGqLF7gbtkhHjQ2Ps5g7tR/X2/20251125_111515-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-JqBLf9p/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-rsB9fVv/0/NCHFvnkQ3bnmRTQxLC7shpX9fFVFzwMFJrTZtVLwC/X2/20251204_140141-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-rsB9fVv/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-8MPCHXn/0/Kg26c7CGjrnhzQBJ7pC5rcvXhs5w6cRbTDn7jsD7k/X2/20251204_141049-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-8MPCHXn/A)

I could not get the fiber glass repair compound to look nice I think the studs are too close together along with the design of my body buck I just couldn't get any tools in there. And when the box says you have 10 minutes to work it is not kidding. But the work seems strong and holding well so I guess no one should be looking in there right?

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-wT9pZk5/0/L9CVnZvTmP496j5CvbCF8SqtPdVnRFppwcWHZVHkn/X2/20251204_162415-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-wT9pZk5/A)

I might try to sand some of the ugly swirls and lines down later. After that the next step is to flip the body over and apply some bedliner.

mrglaeser

12-25-2025, 02:30 PM

Time to undercoat the body. It was as messy as expected and little more.

First we took it off the buck, flipped it over, and supported it with some 2x4s wrapped in rags.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pnDRVnF/0/Ng2SdGwBCD5bXWq7v6XmLWLHjBHQ4rr96mtG85NtG/X2/20251213_165106-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pnDRVnF/A)

Then I we cleaned the body twice and I made my oldest scuff the underside of the body She wants to take her driving permit test in a week so we have a little leverage for a change -- actually she was quite a good sport about it and was willing to help.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-swZjKLR/0/K2qGV92hMNX84kq58fDCsKzWrPkcC4xD7fmXWcZ4v/X2/20251213_152113-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-swZjKLR/A)

I went through with a brush and established some boarders trying to leave an inch and half from each edge. But there was some running the made me wish I had taped instead. Not a big deal just an annoyance. Shouldn't have been lazy.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-swF3P6s/0/KbgTPJf8dTRSznCm5Bsg85ZRqxFshM8PPXM66MHsD/X2/20251221_122857-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-swF3P6s/A)

Then I got my youngest to do most the rolling work. At least for the first coat.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mGzRsjF/0/KD82z9fvRzN6qdxPDNzF6PxMjSk8rDFbt8FV6VxWT/X2/20251221_130410-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mGzRsjF/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-NHxC2g2/0/MVM6gC7MxGkmxqSbshFjsSmttgL8h883fmPpSk8R4/X2/20251221_135611-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-NHxC2g2/A)

Hopefully we'll get the body on in Jan and move on to fitting doors, hood, trunk, and windscreen.

Highplainsdakota

01-10-2026, 12:29 PM

BUDFIVE

01-13-2026, 12:12 AM

Brian, maybe I can help answer your question. Those fasteners are called Adhesive-ready studs or Bondable studs. I bought mine for the same purpose on McMaster Carr. I attached them with 3M HSRF (high strength repair filler).
223855

mrglaeser

01-13-2026, 08:44 AM

Hey Matt,

Nice work, your outpacing my build. Where did you get those bolts with mesh backing to fiberglass into your body? Also, what compound do you use to secure them to the fiberglass? Thanks a bunch.

Edit: The ones that you used to secure your side vents.

Brian

Brian, maybe I can help answer your question. Those fasteners are called Adhesive-ready studs or Bondable studs. I bought mine for the same purpose on McMaster Carr. I attached them with 3M HSRF (high strength repair filler).
223855

Hi Highplainsdakota - BUDFIVE answered for me! Thanks BUDFIVE. The specific part number from MC is 97590A569:
https://www.mcmaster.com/products/97590a569/
The 3M HSRF can be found at many marine sites and the price varies.

mrglaeser

02-09-2026, 12:13 AM

January has been pretty busy with both my teenagers in Hockey. I didn't play when I was younger and for the un-initiated I joke that a kid taking up ice hockey is like the whole family signing up for a new religion. We had four tournaments from the week between Christmas and New Years to last weekend. And I can't even guess how many games and practices. But things are winding down, 2 games left and then playoffs. Spring/Summer hockey are much less taxing.

That all said I did play a little in January.
I got the brightest red powder I could and powder coated a machined aluminum shifter. I love the color. I have no idea if it will hold up or not. But should be fun while it lasts.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gmSs7MM/0/LhtFMTcCVBJ72J5JBrS4pGNFx543b9NmMjBqJgwSs/X2/20251224_161434-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gmSs7MM/A)

I put together the door latches one Morning I found I was free to do my own thing.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-4kgXfts/1/NQkQRDvPWd7b5s2HxptMkFXzHbk2WkQTjLjXJgwcF/X2/20260103_111233-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-4kgXfts/A)

Another afternoon I found no one had me pre-scheduled I assembled the hood hinges.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-qcNGTLD/0/LhpW6sX8XGGMSZFd95Lb3N88CQrxvWLzzZtzZbSvw/X2/20260111_104504-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-qcNGTLD/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-Zk5kTjV/1/LvfPNNrRLL3jVFNDNXFpgLHCx2fnvLGmRfn3xVBZ9/X2/20260111_112439-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-Zk5kTjV/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-tw27qt5/1/LzCFL6LtmkQZMDRzwkgjtRTVDbQ6XzqSxs4kVq7xH/X2/20260111_113727-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-tw27qt5/A)

I also had a small setback in October I hadn't really mentioned. A lot of power steering fluid spilled onto my nicely wrapped headers. I tried to dab it out with various rags and paper towels, but most of it soaked in. When we started the car before it got too cold I was hoping it would slowly smoke off. But no luck. The PS fluid went up in flames causing my buddy to put it out with a fire extinguisher. Here is the basic after math.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-7k5JLsk/0/MKVFNzjgkLM7MHhjPgBWpC3CrkqWkdsJTPVLj4nzX/X2/20251125_103651-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-7k5JLsk/A)

Here is the ground after we moved the car lots of extinguisher powder everywhere - it was also all over the car.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-DLRk9Tr/0/MsXPVZzV4tFn8p83dMNGMXG6QGHgVhdKFbN9PZbKH/X2/20251123_183822-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-DLRk9Tr/A)

I cut the wrap off cleaned the engine bay and the chassis and today we finally rolled the car out and started it again. It was a semi successful test.

The good
-We ran the engine for 45 min and got it up to temp. No weird noises so far.
-Fan turned on as expected
-Sniper got in to learning mode and engine smoothed out so at least I know the sensors for the Holley work
-Volt meter works
-Oil Pressure gauge works
-Tach works
-Fuel gauge works

Bad
-Parking brake semi works
-Brakes only work once the pedal is depressed 80%+ of the way
-Temp Gauges (water and oil) didn't move

So if I can sort out the brakes and temp gauges then I think I can put the body on and maybe have a gel-coat summer?

Now I have two questions.
1.) Should I re-wrap the headers and J-pipes or get them cleaned and ceramic coated? I just need to get some more stainless steel ties.
2.) Does driving the car 10ft count as first Go Kart?

mrglaeser

03-07-2026, 08:56 PM

Just Shy of 1 month from my last post but today was a big day. Actually did a true Go-Kart today! Not too far, basically around the block, but more than 10ft forwards and backwards.

So in the last month I :
-Fixed the brakes by replacing the line lock which I found was defective and leaking plus a hardline attached to it
-Fixed the parking or rather just figured out how to adjust set it correctly
-Fixed the Water temp gauge, the oil temp gauge still isn't working but I'll trace that out tomorrow

EDIT: Here is a pic of the first tenth of mile on the Odometer. Also proved out the speedometer works.
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-gVkvN77/0/LkHVGX6vQ7x5Vw6wB2hRJBZbh8n6hhtpxDqknLhDb/X2/20260308_150910-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-gVkvN77/A)

mrglaeser

03-09-2026, 09:28 AM

Another distraction I've been playing with since summer is the fresh air vent ducts. I think the ones from the vendor who shall not be named is what most people use and maybe there is another option but I didn't find anything I liked really. But I've wanted to try my hand at 3D printing and thought this was a good opportunity to play and stretch myself.

So I signed up for the free Fusion 360 Account and started playing around.

I wanted some tabs so I could use mounting stubs to mechanically connect the ducts to the body. My first versions I created longer, the walls were too thin, and there were way more tabs than needed. But I figured that out after printing a sample:

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-fsnwQtF/0/MWHmDqKb4Wd8S6fQ5GNVsrK6fBLMbrxrckJ4kMCj3/XL/AirVentProto_Angle-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-fsnwQtF/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-VTqFRjt/0/KXL5XMQsrJVdrWggWgKfD7FxMpr847XzKS4mHXRR6/XL/AirVentProto_Side-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-VTqFRjt/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mJXwTbH/0/M4gLPWBF2bcZMttSg7zGWnnz4FqtXn3BtKJ3x9QQL/X2/20250823_151812-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mJXwTbH/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-kJsK7KF/0/MMLJPHFjG9mmKrSPBpK4qTZvVBxjVKR6JKjgR9qJF/X2/20250824_112311-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-kJsK7KF/A)

I also screwed up the transition of the wall thickness between the round and oval areas so when the tape gave up on my mock up and the duct dropped and hit the floor it broke in two.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-495pBh5/0/KXgZLVxSXqx9fDFmZj26D87g4XqrDF37rjqZ62qPt/XL/20251107_190436-XL.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-495pBh5/A)

mrglaeser

03-09-2026, 09:28 AM

For attempted #2 I revised the part by thickening the walls, reducing the size of the oval, and shorting the over all length. This solve most the issues with the first prototype.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-9r2WJjP/0/Lr6z7TzXcgPF83QwLLQJggLf7WVRkg7tk6fkwkWLS/XL/FreshAirVentProto2_1-XL.png (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-9r2WJjP/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mkjv6T8/0/MxDtB6Sz2QCKRCjvg498vR92Ppsd3Xc7zRqnMkWDp/XL/FreshAirVentProto2_2-XL.png (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mkjv6T8/A)

Prototype 2(left) vs Prototype 1

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-t2cgXNt/0/KkcGmxV2LTq9nCjHPz4dKSRpFTCzTNpMRXVWGh6RX/X2/20251107_190247-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-t2cgXNt/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-mt5sGPG/0/NLDMrxHW63D7fmfhnScCgHbK4DPX8hrpDtS6ngz9c/X2/20251107_190313-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-mt5sGPG/A)

What I found with the Prototype 2. The walls are too thick it works but is a little in-flexible and cumbersome (also more costly to print as it uses more material than needed). Need something in between. The top and bottom tabs are also useless because you can't mount studs perpendicular to them. The round bump on the round portion of the duct was too big to pull the hose over. So I ground off the round bit along with the top and bottom tabs. I also cut a piece of aluminum and attached it to one side.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-TGq6NGw/0/MHwfMdX2dNfH56DPTSVQM98M89V9DHxSSP7vhWRHv/X2/20251120_100425-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-TGq6NGw/A)

mrglaeser

03-09-2026, 09:29 AM

Here is the end result on the car. I plan on using some strip caulk on final install to close the small airgaps left.

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-qgKNnZn/0/KRnmDSQxSJQDCJ57gSr26tsshSRJZZF7khT3nM8MD/X2/20260308_141608-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-qgKNnZn/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-pFTF3nm/0/Ms4mDrcdnFcSCvRH4Dbtpq5R47G6SsdLWsMgx3gqL/X2/20260308_141615-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-pFTF3nm/A)

https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-SFMHX8Q/0/LXxWnLMZvdSTQnch2hmrxMDNDVH8RzGcvD8WHZZzK/X2/20260308_141619-X2.jpg (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-SFMHX8Q/A)

I did re-do my 3D design one more time. So I'm debating printing them to see how they work because what I have should do the job nicely. Also at this point I've spent 3 times what it would have cost to just order the standard ones. But I figure the money was well spent in the enjoyment of the creative process.

Here is version 3. I'm happy to share the STL or Fusion Project files with anyone who would want them.

Prototype 3
https://photos.smugmug.com/Home/9999-Factory-Five-Roadster/i-GhqTWcG/0/LJWL48qXcTZx3wQ8JpBJwPLGZMpgQr68tm7Rjg9SW/XL/FreshAirVentProto3_2-XL.png (https://mattglaeser.smugmug.com/Home/9999-Factory-Five-Roadster/i-GhqTWcG/A)