Advice on how to proceed

[JJK]

My kit arrived on October 31 with approximately two dozen items on the POL and another dozen or so on the MIK list. Here is what I have built so far, but I am concerned about jumping ahead too far as I have not built a FFR before and don't want to paint myself in a box.
I installed the front suspension, but am missing the Wilwood calipers and brakes. I understand these will ship from Wilwood when available.
I cut the tabs off the IRS spindles, drilled them out, replaced the studs in the hubs, and mounted the hubs to the spindles. I drilled out the mounting holes for the differential, but cannot proceed with the IRS until my IRS fasteners arrive.
I skipped the e brake as I do not have the IRS or rear Wilwood brakes yet.
I installed the Wilwood pedal box, hydraulic clutch and brake pedals, waiting on the RT accelerator pedal with Breeze matching Wilwood pad.
Installed the power steering rack, but missing one of the tie rod ends as well as the 1" DD tube for the steering shaft.
Installed the Breeze front battery box.
I am concerned about installing the passenger side foot box panels, as I wanted to complete the fuel and brake lines first, but I think I could do this without any consequences.
Missing parts for the fuel tank, but I don't think this matters since the IRS isn't installed yet.
I am uncomfortable running the fuel and brake lines without the IRS, fuel tank, or brake kits yet. Perhaps that is unfounded though and I would be fine.
Aside from the passenger side footbox, any recommendations on how I could proceed given that I could not complete several of the early steps?
As always, thanks to the forum for their assistance with things.
As an aside, my BPE 347FI shipped 12-21 and is currently in transit limbo. I hope to receive it within the next week, but I don't think there will be too terribly much to do with it for a while.
JJ

[edwardb]

You can fit, drill, and cleco all the aluminum panels. That alone takes some time. If you're going to have them finished (powdercoat or whatever) send them out to get done. If doing a finish of some kind yourself, you can do that. Probably don't want to permanently install any panels yet.

If you're having finish put on any of the metal parts (hood hinges, e-brake parts, etc.) round those up, prep and send them out. If doing a finish of some kind yourself, you can do that. When finished, you can make subassemblies as appropriate.

Do you have your dash and gauges? You can start working on that. Fit the gauges per your plan. Install the dash covering if that's in your build plan. Install the gauges.

If still waiting for parts, you can start cleaning up the body enough for it to fit or your planned level of finish. Fit and mock-up front and rear lights. Even with factory cutouts, requires some level of trimming.

Others may have some more ideas.

[JJK]

thanks Edward, several good points to keep moving

[i.e.427]

Good panel alignment take time. Start there and leave the outer panels off on the driver's and passenger footboxes until after carpet. Makes getting in there to add heat mat and carpet a lot easier. Next I always do fuel, brake lines and the electrical harnesses to the front and rear of the car. All much easier to do with the engine and transmission out of the car. You can fine many panel alignment tips here.


https://www.youtube.com/watch?v=wQvSakoI94A&t=3s

[Mike.Bray]

I wouldn't wait on FFR for fasteners for the IRS, it could be months. Head to your local Ace Hardware and get what you need so you can keep moving forward.

As mentioned there's lots of panels that can be fitted/drilled/finished.

Run brake & fuel lines as far as you can.

[rthomas98]

I wouldn't wait on FFR for fasteners for the IRS, it could be months. Head to your local Ace Hardware and get what you need so you can keep moving forward.

As mentioned there's lots of panels that can be fitted/drilled/finished.

Run brake & fuel lines as far as you can.

If doing this with the ACE hardware do it to have it in place for mock-ups and routing only. Replace with the Factory Five hardware once you get it. suspensions are not something you want to play with ace hardware type bolts, could lead to a serious breakage down the line.

[Mike.Bray]

If doing this with the ACE hardware do it to have it in place for mock-ups and routing only. Replace with the Factory Five hardware once you get it. suspensions are not something you want to play with ace hardware type bolts, could lead to a serious breakage down the line.

Why not? Ace sells grade 5, grade 8, and even SHCS. As long as the FFR specs are known I would not have an issue with it. Besides, I'm sure there's quite a bit of over design in the fasteners from the OEM (Ford).

[rthomas98]

Why not? Ace sells grade 5, grade 8, and even SHCS. As long as the FFR specs are known I would not have an issue with it. Besides, I'm sure there's quite a bit of over design in the fasteners from the OEM (Ford).

Just remember Ford over engineered them for a reason. Suspension is one place I do not skimp with my or my passengers lives. Dropping an A-arm at 50 mph is not my idea of fun and excitement.

[JeffP]

Just remember Ford over engineered them for a reason. Suspension is one place I do not skimp with my or my passengers lives. Dropping an A-arm at 50 mph is not my idea of fun and excitement.

Like Mike said, Ace, and other stores like it ('DoIt Centers'), sell high grade bolts too. I'm sure Fastenal would have pretty much everything as well. Even my local Orielly's had a decent selection.

[CraigS]

When I did my irs retrofit I converted all the FFR bolts to fractional bolts and nylock nuts. The only ones left were the two that screw into the diff cover since it is threaded aluminum. Some came from McMaster and some came from local hardware store. Some were G8 but most were G5. 3 seasons of autocross w/ a 408W engine and 335/30-17 Hoosier A7 R-compound tires and never a problem.

[edwardb]

Call me conservative, but put me in the category of not being in a hurry to replace Factory Five supplied suspension hardware. It's a mixture of SAE and metric, mostly hardened grades, flanged heads, some distorted lock nuts, etc. I would say especially for new or inexperienced builders who may not know the nuances of the various bolt types, grades, etc. Just not something the uninitiated should be messing with IMO. My Ace is very well supplied with a whole aisle of hardware (and I know it all too well) but would have few if any of the larger sizes used in the suspension. I don't use hardware from my big box stores for my car builds. Most of it is lower hardness grades and frankly not the best quality. Fine for home DIY projects, etc. but not the suspension of my car. I buy a lot from McMaster, and likely would have what you need if you know exactly. But cost and shipping add up. Especially if you've already paid for it. I don't have experience with Fastenal. But from what I've heard, would be similar.

Here's a workaround that I've used several times. If all you're missing are bolt(s) from Factory Five, you can still assemble the suspension parts, including putting in the IRS center section, with temporary bolts of the proper dimension. Hardness grade doesn't matter. Typically the fit is quite tight, so putting nuts on isn't required. As the proper hardware arrives, replace the temporary bits and finalize. Just drive the temporary bolt out and install the ones received from Factory Five. Nothing else needs to come apart and typically it's an easy swap. Timing isn't critical until you're to the roller stage. I've done this several times and allowed me to hang the suspensions and keep moving.

[narly1]

Typically the fit is quite tight, so putting nuts on isn't required.

I like the idea of leaving the nut off as it serves as a reminder that the fastener used is only temporary and needs to be changed out for the correct one at some point.

Earl

[Mike.Bray]

If you want to install the IRS and keep moving forward as an engineer that is very familiar with independent suspension systems having actually designed and build several my advice would be to get some Grade 8 bolts & nuts and install everything. The truth is the factory probably uses Grade 5 so Grade 8 is a step up. You can get Grade 8 hardware from Ace or order it from McMaster (I agree to avoid the big box stores for quality hardware). Just be sure and apply Hook's Law (https://thefactoryfiveforum.com/showthread.php?42292-Why-the-Torque-Wrench-is-Your-Best-Friend) when you tighten them.

It's interesting someone mentioned dropping an A-arm at 50 MPH. Look at what is holding the IRS together and compare it to what is supporting the front spindle, the lower ball joint. Not much comparison really.

[narly1]

I think that the takeaway from all of this discussion should be that if one knows what one's doing, great, but if not you are better off relying on the engineering designed into these kits.

It also highlights the idea that if one is straying "off the reservation" (so to speak) as far as one's build goes that there may be safety factors to take into account.

This coming from a guy who in part makes his living selling sensors and instrumentation used for measuring force, torque and stress analysis.

Earl

[edwardb]

...The truth is the factory probably uses Grade 5 so Grade 8 is a step up...

Not the case. The large bolts Factory Five supplies for the IRS center section, front and rear control arms, spindle assembly, steering rack mount, brake caliper mounting bolts, are either SAE grade 8 or metric class 10.9. Not a guess. I just looked and confirmed. High percentage are flanged head. The only grade 5's in the suspension I saw were the bolts holding the coilovers at the top and bottom. Still beefy at 1/2-13.

I stick to my original advice. Replace/substitute only if you know exactly what Factory Five engineered for the kit.

[JeffP]

Edit - wasn't productive. apologies.

[JJK]

Thank you all. I spent an hour or so last night comparing the inventory list posted by Namrups (https://thefactoryfiveforum.com/showthread.php?44549-Inventory-parts-list) to the build manual as well as what parts were shipped in my kit and came up with a list of parts needed to complete the IRS assembly. Price is close to $200 since ordering so many small quantity items and nothing in bulk, especially since most of the hardware is class 10.9 metric which I cannot find in local stores. Before I ordered though I sent a note to FFR inquiring about the status of the IRS bolts. They told me they are in stock and will ship mine out. So, another data point for the greasy wheel theory in how FFR manages inventory and backorders. And now I don't have to buy parts I have already paid for once.

[edwardb]

This is going to sound like I'm making excuses for Factory Five. I'm not. Please don't flame me or throw out the "drinking the Kool-Aid nonsense." Just stating the situation. As many know (or may have forgotten) Factory Five went live with a complete new (to them) ERP system in September, 2022. For anyone that's been through such a migration, it's painful and usually not without issues. I know, I was in that business for most of my career. Clearly there have been some issues from that migration based on the number of posts like this one. Plus it seems they've changed how their kits are packaged, especially with hardware. POL items aren't new and has been widely discussed as Factory Five deals with global supply chain issues. But MIK items has clearly gone way up. In the five kits that I've received, I've only had a very few MIK items. Couple of the kits none. And I'm very meticulous with the inventory process.

I say this for two reasons: First, while it's certainly happened in the past, it's not typical and especially to this level. So for new builders that think this is how Factory Five has historically operated, that's not the case. Second, I'm positive that Factory Five will make it right and address the system issues. Beyond what I suspect they have already. History is on their side with excellent customer service. None of this makes dealing with it any easier, and I feel for builders going through this. But just felt maybe some context might help a little.

[Jeff Kleiner]

Well said Paul.

Jeff

[Mike.Bray]

Before I ordered though I sent a note to FFR inquiring about the status of the IRS bolts. They told me they are in stock and will ship mine out. So, another data point for the greasy wheel theory in how FFR manages inventory and backorders.

This is sad. I know FFR is a good company and build a good product and I really hope they get on top of this situation. My last POL item, after marking all of the fasteners off the list, are my door latches. I know they have them in stock and on December 19th I sent an email pointing this out and inquiring about mine. I also pointed out how I know new kits are being received complete with door latches while no word on mine. I received a reply the same day saying they would look into it. Nothing but crickets since then so I sent a reminder today.

[Mike.Bray]

This is sad. I know FFR is a good company and build a good product and I really hope they get on top of this situation. My last POL item, after marking all of the fasteners off the list, are my door latches. I know they have them in stock and on December 19th I sent an email pointing this out and inquiring about mine. I also pointed out how I know new kits are being received complete with door latches while no word on mine. I received a reply the same day saying they would look into it. Nothing but crickets since then so I sent a reminder today.

Update on my door latches. Dave Lindsey quickly replied to my follow-up email today. Factory Five showed they had shipped them with my shifter components back in August. I remember that shipment and the latches were not in the box. Everything for my car that is not installed is either on a shelf in my garage or in my office in the house. I also have a spreadsheet where I track everything ordered and if it has been received or not. I did a thorough search and I do not have them nor are they marked as received. I know I would have remembered them as they changed the design and I was/am interested in the new design.

Kudos to Dave though as FFR has agreed to ship a set out to me. I'm happy to give credit where it is due.

[JeffP]

Update on my door latches. Dave Lindsey quickly replied to my follow-up email today. Factory Five showed they had shipped them with my shifter components back in August. I remember that shipment and the latches were not in the box. Everything for my car that is not installed is either on a shelf in my garage or in my office in the house. I also have a spreadsheet where I track everything ordered and if it has been received or not. I did a thorough search and I do not have them nor are they marked as received. I know I would have remembered them as they changed the design and I was/am interested in the new design.

Kudos to Dave though as FFR has agreed to ship a set out to me. I'm happy to give credit where it is due.

I've had similar issues... never received my 17" rims. They claim they shipped them and provided tracking info - with delivery to someone else in another state. They got them shipped and then no spinners.. took another 12 weeks and a dozen emails until finally Dave S. took care of it.

[phils88gt]

I guess I should not brag. FFR actually sent me too much stuff. I did the honest thing and returned the things that I didn't pay for. Hopefully some of you guys got the them.

[JJK]

To update any others that may be waiting on parts, FFR told me two weeks ago they had the IRS fasteners back in stock and would ship some out to me. I got confirmation today that I will not be getting these, as they used what they had to fulfill even older backorders than mine. I don't disagree with serving those folks that have been waiting since July, but wish I was notified earlier. I ordered these from other vendors today for about $200 online. On another note, my Wilwood brakes were initially reported to be shipping directly from Wilwood, but FFR tells me they are in the process of stocking these themselves going forward. Not sure who will be shipping mine, but hopefully they are not overlooked in the transition.