CM's MK4 build by Wallace18

[wallace18]

I have a MK4 kit coming tomorrow by Stewart Transport. I am building it for a customer CM. It will be the 1st automatic MK4 I have built, but I have built a 33 and 35 with auto's. I am looking forward to this one as it will be a little different from the previous 6 MK4's I built. This will be my 18th kit overall. Here is a few details.

MK4 Complete Kit with a Blueprint 302 Carb with a 4R70W automatic transmission. Also S/S side pipes, headers, chrome drivers roll bar, wind wings, visors, floor-mats, P/S, P/B, Moser 3-link rear end, 4-wheel disc brakes, Vintage gauges, 17" wheel/tire combo, carpeted trunk, door panels, self canceling turn signals and some other goodies. It should be a really fun driver to cruz around in. I will post photos of the delivery tomorrow. :cool:

[Railroad]

Sounds just right!

[wallace18]

Stewart showed up right on time at 9:30. Kelly and I unloaded everything real quick. I was able to get it up on the lift and will start taking off the body and inventory this afternoon. Still waiting on Moser rear end and Blueprint engine/transmission package.

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[wallace18]

After lunch Fed-Ex delivered the Moser rear end. We took off the body and set it on the body buck. I was able to inventory 21 boxes. I am not a fan of the new inventory sheets or packaging. Old style lists were much more detailed and seldom was stuff missing from boxes that FFR checked off as being in the box. So far 5 boxes missing 1 or more items. Hope to finish up inventory tomorrow and get missing parts list to FFR on Monday.

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[wallace18]

Finished up inventory. About 20 missing parts. Emailed FFR. Mocked up and coated front aluminum panels. Assembled fuel tank as inventory sheet left a lot to be desired in detail. This way I knew I had all the parts. I feel sorry for new builders as how vague the inventory sheets are now vs precovid.
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[wallace18]

Not going to do much today. It is my anniversary, 24 years with my wonderful wife/brake bleeder, Marsha. LOL. Did just a bit. I installed front panels and marked all rear panels for drilling. I will really get after it tomorrow.

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[wallace18]

Good day today. Got to talk to FFR and Craig. Missing parts are on the way. I was able to mock up all the trunk aluminum, passenger side foot box, firewall, drivers and passenger floors. Also mocked up Power brake booster and Fox body pedal cluster. Slight modifications to frame and front drivers foot box aluminum to fit P/B.

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[wallace18]

Finished up mocking up drivers foot box. Both sides ready for Lizard Skin external coatings.

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[egchewy79]

so you drill and cleco all the footbox pieces, then remove it to spray lizard skin? brilliant! I'm sure it makes it so much easier to spray and eliminates all that taping.

[wallace18]

so you drill and cleco all the footbox pieces, then remove it to spray lizard skin? brilliant! I'm sure it makes it so much easier to spray and eliminates all that taping.

Yes, I just assemble the boxes once off the car with a few tech screws and coat. It has worked well for me over several builds. :cool:

[wallace18]

Another really good day. I was able to finish up mocking up all the rear cockpit aluminum. Also made my own firewall brace. I first coated the foot boxes, firewall and 2 floors with Lizard Skin sound deadener, then the ceramic heat coating. All the rest of the aluminum I coated with truck bed liner.

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[wallace18]

I put a second coat of bed-liner on the underside of the other aluminum panels. I then installed the firewall, drivers side front foot box panel and both floor panels. Installed pedal fox body pedal box, booster and frame mod. Installed front suspension, front brakes, rear end and rear suspension. Taking the weekend off.

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[wallace18]

Installed the steering rack, u-joints, steering shafts and bearings. Siliconed & riveted the passenger foot box, inner drivers foot box panels, cockpit sides and rear corners. Also installed the brake light switch in the pedal box and adjusted it.

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[wallace18]

Short day today. I had dentist visit and church lunch. I was able to install fuel tank and fuel filter. Also installed front brake flex hoses and line between both front calipers.

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[FF33rod]

Holy crap you're trucking on this one!

Steve

[wallace18]

Today I installed rear brakes, lines and started on wire harness.

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[wallace18]

Had a few hours to work this morning. I finished up all the brake lines and mounted 1995 Mustang master cylinder. I mocked up and trimmed dash aluminum. Also installed some clamps on the front wiring harness. I am going to have a dental procedure this afternoon. Not sure if it will keep me from working a few days or not. Time will tell.:cool:

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[egchewy79]

Holy crap you're trucking on this one!

Steve

I remember looking over one of his threads when I first joined the forums, wondering to myself how he was getting so much done in such a short period of time.
I always tell my wife that my "next" build will be much faster :)

[wallace18]

I remember looking over one of his threads when I first joined the forums, wondering to myself how he was getting so much done in such a short period of time.
I always tell my wife that my "next" build will be much faster :)

When you have done 18 of them you get into a rhythm, LOL.

[wallace18]

Today I installed horns. Then mocked up dash layout. Then used DAP glue to install pad on dash. I will let time and a bunch of clamps finish up the pad glue job, LOL.:p

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[egchewy79]

just curious...do you consult w/ your clients about how they want the dash set up to look or how they want the interior finished?

[wallace18]

just curious...do you consult w/ your clients about how they want the dash set up to look or how they want the interior finished?

PM sent.

[wallace18]

Finished up dash, wired and installed. Tested all of dash stuff. A-OK. Installed some X-Mat on inside of fire wall.

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[wallace18]

Installed rest of rear aluminum panels. installed battery, hold down and cables. Filler rear end with proper fluids.

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[wallace18]

Cut holes in rear cockpit panel for speakers. Then I installed the sound deadening/heat mats inside the interior.

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[wallace18]

Tried to do some work this morning. I was able to finish up trunk matting. I also mocked up and trimmed transmission tunnel top. We had heavy rains last night and most of the morning. More rain on the way. Too humid in shop to do any more today. Did get a tracking # for the Blueprint engine/trans combo. Should be here tomorrow. Now waiting on FFR to send POL parts and then I can head towards the finish line, LOL. :cool:

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[wallace18]

While I was waiting on the Fed Ex truck I engine turned the radiator shroud and foot box removable cover. Also installed riv-nuts and mounted fan. Soon after the truck showed up.

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[wallace18]

Later I installed engine and transmission. I am going to have to move e-brake, trim some on the transmission and dust plate. Also I am going to have to custom make a rear transmission mount bracket. FFR unit hits transmission pan. All part of the fun, LOL.
Impressive #'s IMO for a base Blueprint 302.

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[wallace18]

I have lots of other stuff going on this week. I try to get some MK4 work in here and there. Today Marsha helped me bleed the brakes. Came out super with a great pedal! I installed some wiring to engine and trans. I removed e-brake and brackets. I will do a top of the tunnel style like North race cars used to sell. Also installed oil, water sensors and wires as well a vacuum line to power brake booster.

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[wallace18]

I was able to find time today to install TPS unit on Holley carb. I really feel this should have been included with the engine/transmission combo from Blueprint. I did email them to that point. For as much as my customer paid for that combo this should have come with it, as the transmission computer will not operate without it. Whew, that felt good getting of my chest, LOL. Install was not too bad but it did require patience and some tweaking to make it work properly. I am sorta waiting on some parts from Summit to help install the Automatic and other parts not included with the kit. I have obligations tomorrow and hope to work back on the MK4 on Friday.

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[wallace18]

Today I was able to make my custom tunnel mounted emergency brake handle assembly. IMO it is way better than the FFR unit and a must with the 4R70W transmission in this build. The handle came from a brake tube company of all places and was only about 47 bucks. I added a summit e-brake cable kit. Less than half the price of using LOKAR stuff. I also started the wiring for the 4R70W transmission and mounted the aftermarket computer. I am waiting on a cable shifter and some other stuff to try to get the transmision stuff done. Also still waiting on POL parts.

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[wallace18]

I am going to an oral surgeon today to have a bad #30 tooth removed. Not sure how long this will lay me up. Still waiting on some POL parts as well as shifter and such. :confused:

[wallace18]

Today I installed billet carb bracket, lokar throttle cable and wired TPS to transmission computer. Installed headers, RemFlex gaskets and Stage 8 bolts. Also started install of transmission cooler hoses. Still waiting on some POL parts from FFR.


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[wallace18]

Started on the Lokar shifter. I ended up using the top mount method. Also wired up Lokar neutral safety switch vs using transmission one. Some parts came in late today. I should be able to make more progress tomorrow.

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[wallace18]

I finished up wiring all the wires to the transmission for safety switch and sport shift mode. Also finished up shifter cable and adjusted everything for proper shifting. CM decided to use some new Cobra air cleaner and valve covers I had laying around. They look 100% better than the Blueprint chrome stuff, IMO. :p I am very particular about valve cover gaskets, hardware and ignition wire routing and clearance from headers. I installed studs and top of the line FelPro gaskets for the valve covers. Also install billet wire looms and heat socks so wires don't melt from headers. Looks and works so much better. Taking weekend off for a big car show.

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[JDLSantos]

Today I was able to make my custom tunnel mounted emergency brake handle assembly. IMO it is way better than the FFR unit and a must with the 4R70W transmission in this build. The handle came from a brake tube company of all places and was only about 47 bucks. I added a summit e-brake cable kit. Less than half the price of using LOKAR stuff. I also started the wiring for the 4R70W transmission and mounted the aftermarket computer. I am waiting on a cable shifter and some other stuff to try to get the transmision stuff done. Also still waiting on POL parts.

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Great project!!

I am curious about the handle brake, e-brake wire routing and the distand between the handle brake and the bracket that hold the e-brake wires

[wallace18]

Great project!!

I am curious about the handle brake, e-brake wire routing and the distand between the handle brake and the bracket that hold the e-brake wires

The handle came from Inline tube, the emergency brake parts came from a Summit e- brake kit. The cables are in the same bracket holes FFR uses. once you mount the handle you cut off the cables the appropriate amount. The brass connector sometimes has to be drilled out for cables to pass thru.

[wallace18]

Mocked up the top of transmission tunnel top. I used a cardboard template. Also mocked up under dash unit for radio, wired radio and speakers. Plays really nice! Not sure how you will here it with those side pipes, LOL. I also mocked up cover to enclose FFR e-brake opening. Hope to mount radio and cover lower dash unit tomorrow.


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[wallace18]

Installed the radio in the custom lower dash unit after I covered it in the same stuff the dash is covered. Also made a custom charcoal canister for the gas tank vent line. Finished installing passenger side transmission tunnel cover for FFR e-brake hole. I am running out of stuff to do on the chassis . Till the POL parts come in I am going to start trimming the body and fitting lights, ETC. tomorrow.


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[wallace18]

Worked on the hood, scoop, ETC. Bolted up the hood hinge assemblies and headlight assemblies. FFR needs to look carefully at their hole jigs for the hood. Holes were not even close to correct for the riveted metal brackets for the hood. Lucky I could fix it without much trouble. Taking tomorrow off. Friday will work on trunk and body.


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[wallace18]

I mocked up and drilled for gas cap, tail lights, headlights, Turn signals/parking lights, trunk handle and license plate light. Build on hold till Radiator, roll bar, P/S fitting, seat tracks come off of POL from FFR.

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[wallace18]

Since I was in a holding pattern waiting on POL parts, I was able to deliver a DF Goblin I sold to a customer in NC. Also picked up a Dune Buggy kit I ordered a year ago. While I was gone for 2 days my wife told me a box from FFR showed up. It was just the radiator. But better than nothing. Today I was able to mount the engine turned shroud, fan, Breeze radiator kit and mock up transmission cooler. I am waiting on some black radiator paint and some hoses. Taking the weekend off .


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[zee]

Man you're moving fast!

[Railroad]

I really like the engine turned fan shroud!

[wallace18]

Finally got the P/S pump fitting from the PLO list. This allowed me to get to finish up enough for a first start up. I was able to install transmission cooler, fan and lines. Install P/S hoses. Fill engine and transmission with proper fluids. Start up went great. I programmed TPS to transmission computer. Wired up fans so both come on with electric fan switch and also manual switch on dash. No leaks up front. Transmission shifts fine on lift. I hope to go-cart next week, then start on body. However the Moser rear end is leaking form differential cover. This is the 3rd new Moser that leaks right away. I wish they would use a better gasket. Lucky for me I had a new gasket in stock. I will fix it myself. Here is short video.

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https://www.youtube.com/watch?v=9tUCsm2yNiM

[wallace18]

This morning I fixed the leaking rear end gasket. I pulled off the chrome cover. Cleaned the surfaces and installed new gasket with Black RTV on both sides. Refilled rear end with proper fluids.

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[wallace18]

After lunch I was able to clean up body and coat the underside with truck bed liner. Hope to go-cart tomorrow.
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[wallace18]

Did a front end alignment this morning. Then hooked up a set of well used Quiet pipes I have laying around to do a go-cart test. Car ran very nice. Shifts great. Will even bark the tires on full throttle shifts in lower gears. I am very impressed with this engine/transmission combo. Makes for a really nice driver's car. As with any go-cart test a few things crop up. A small gas leak at a fitting. Just had to tighten 1/4 turn, OK now. Water leak from Factory Five coolant fill tube. I am going to replace it with an aluminum one I ordered today. Also gas pedal too close to brake pedal. I will get an aftermarket pedal for more clearance. I have never been a big fan of kits pedal. I will do a go-cart Video once these punch list items are fixed. I seem to be coming down with some sort of cough/cold. I will be taking it easy this week till I get better. Thanksgiving and all that stuff. I am only 2 months into the build so it is right on schedule.

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[wallace18]

I am about 98% better now. I was able to fix the few items from my first go-cart test. I drove car about 4 miles today. Runs great. Here is short drive way video my wife Marsha took. Enjoy!. :cool: Hope to start on interior and body this week. Cod weather though here next few days. May not be able to due to cold weather. Glue no workin good in cold, LOL.



https://www.youtube.com/watch?v=GmeKgNimje4

[finleycraft]

Looking good, thanks for all the updates!

[wallace18]

Unfortunately the weather here is unseasonable cold. I can't do anything till the temps get above 65 or 70. So I just have to chill. No pun intended, LOL.

[wallace18]

Rough last 2 weeks for me. Got Covid 4 days before thanksgiving. Got over that. Then a unfortunate result from the covid was a terrible bacteria infection in my private parts area internally. Had to go to emegency room then 3 days in hospital. Got out 11am yesterday but at least 2-3 weeks of meds and rest before getting back to work. :(

[zarnold]

Terrible news, but good to hear your on the mend.

[wallace18]

After having to go to the hospital a second time for 2 days of antibiotics, I came home last Sat. I am 95% my normal self now, thank the Lord! I was able to install carpet and rubber seals so we can install body on this coming Sat. I have 3 other guys coming to help. I have some clean up of glue overspray and some caulking. Nice to get back to working on the MK4.:p

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[wallace18]

Last 2 days I got chassis ready for body install. Installed passenger seat, both sides seat belts. Got news that roll bar finally shipped. Still waiting on seat sliders for drivers seat. FFR not sure when they will come in. I ordered a set from Amazon. Can't wait forever on FFR. Tomorrow body on chassis!

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[wallace18]

The seat sliders from Amazon got here at 9:30 AM. I was able to install the driver's seat before we put on the body. At noon I had Bernie, Chris and all 3 of our wife's come over today . Us 3 guys put the body on the MK4. Then all 6 of us had Pizza and Dr. Pepper. Great day for sure.


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[wallace18]

Installed the front and back overriders. This located the body perfectly. Unfortunately there is 2 coolant puddles under the engine. One is the water pump gaskets are leaking. the second is coming out of the back of the engine and running down the dust plate between the engine and the transmission. There is no leaks at the intake or head gaskets. I am thinking possibly a leaking rear freeze plug. Contacted Blueprint and they agree with my diagnosis. So I get to pull the engine out.:( I will leave the transmission in the car. Should be an easy pull. I have coolant draining over night. 1 step forward and 3 steps back!

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[Mike.Bray]

Installed the front and back overriders. This located the body perfectly. Unfortunately there is 2 coolant puddles under the engine. One is the water pump gaskets are leaking. the second is coming out of the back of the engine and running down the dust plate between the engine and the transmission. There is no leaks at the intake or head gaskets. I am thinking possibly a leaking rear freeze plug. Contacted Blueprint and they agree with my diagnosis. So I get to pull the engine out.:( I will leave the transmission in the car. Should be an easy pull. I have coolant draining over night. 1 step forward and 3 steps back!

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Ugh, I had the same thing. My freeze plugs are screw-in type and the O-rings were bad, machine shop didn't remove them when vatting the block. And I used the wrong gasket on the water pump which made for a good size leak out the bottom of the pump. That one was easy, the freeze plugs required pulling the engine.

Good luck with it.

[wallace18]

After pulling the engine. There was no leak from the rear freeze plugs as I thought. The water pump and thermostat housing all leaked. I took them apart. No sealer was used on any of the gaskets. Not sure why. I cleaned everything up and used Ultra gray silicone sealant on all new gaskets. I am waiting on hearing back from Blueprint. Even with 17psi on my coolant system tester I cannot see where the rear leak was coming from. There is a small trail from the rear driver's side cylinder head gasket area. However with tester on it overnight no leak has showed up. :confused:

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[wallace18]

After going back and forth with Blueprint, they told me to torque the cylinder heads and intake and reinstall the engine. While I was waiting on them I installed the roll bar and mocked up the grommets. Today I put engine back in and installed side pipes. Car started right up and runs great! No leaks so far. Time will tell for sure. I have my fingers crossed and said a few prayers. Now I can get going on the body stuff and maybe get this finished up for paint and body work by the end of January. :rolleyes:


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[wallace18]

No leaks on the floor so far! Yea!:) Today I installed and wired up front and rear lights. I use weather-pac connectors. I also installed fuel hose, mocked up rear and front spray shields. I will paint the shields with bed liner as soon as weather gets little better.

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[wallace18]

Finished up mocking up splash shields. Coated them with black truck bed liner. I pre-gapped trunk and installed with license plate light/holder. I started on driver's door. Weather getting very cold here next few days. Next Wednesday may be warmer. The week of the 8th seems to get warmer. Hope to get doors and hood done in next 2 weeks. Then windshield, mirrors and a few items and we may be done before the last week of January. It will be ready to go to paint/body shop.

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[wallace18]

Finished up both doors. Just roughed them in. Body shop will finalize the gaps and mounting. New strikers and door latches worked out well, IMO. Very cold here last few days. Tomorrow looks to be warmer. Hope to finish up hood, and windshield.

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[wallace18]

Finished up the hood. I slotted body underneath so the body and doors can line up. I mocked up side vents. Also sealed up inside front and rear wheel wells areas between body and foot boxes up front, body and chassis in the rear. Had to change a flat on my wife's Ranger. Then go get new tire, Ouch! Monday I will start on windshield. :cool:


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[wallace18]

Installed windshield, inside rear view mirror. Waiting on longer bolts for side mirror. Found out local body shop/paint shop will not do fiberglass cars. :( Owner will have to find shop near Naples to finish up car. Hope to have car done in next week or 2.

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[wallace18]

Installed door panels, door checks, lower door trim. Installed hood scoop hardware. Removed my builders steering wheel and installed new one from kit. Bad weather here today. I am batten down every thing. Possible tornados. Everyone stay safe that are in harms way.

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[wallace18]

Weather yesterday ended up not so bad for us here. Some small branches down and 2" of rain. Today I was able to install front and rear splash shields with tech screws. I also installed sun visors and wind wings. Getting very close to done. :cool:

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[wallace18]

Finished up some inside trim. Took it out for a good ride and had it weighed at a certified scale. 2400 lbs. Car ran great! Never went over 180 degrees and no leaks. Waiting on side pipe heats shields then it is ready to go to customer for body work and paint. Moved it to my small shop/garage.

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[wallace18]

Heat shields came in a couple days ago. It finally warmed up enough to install them. All done with CM's MK4. Hope to deliver it to him before the end of this month.

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[wallace18]

Yesterday I was able to deliver the MK4 to CM in Naples. It was a 600 mile round trip but worth it to see smile on Craig's face. He really liked how car drove and sounded. He is in process of finding a body/Paint shop to finish it up.


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