Homer's 30th Anniversary MkV Roadster Build

[Homer]

Hello Everyone, I finally got past the spam bots (with some moderator help) to get an account created on this forum. I've been a lurker on here for quite some time and felt it was time to finally give something back with my current build just under way. I'm not used to documenting during a build so I'll do my best, there are others on here that do a much better job!

A little background, I grew up on a small dairy farm in Homer, NY (thus the nickname), which is where me and my dad were always fixing things on the farm. My dad used to drag race a Chevelle in the 60s while in the Air Force and I got my fix by racing motorcross in my teens but we always wanted to build a hot rod together. My inspiration for the Cobra came when I first saw one in the movie "Bad Boys" back in the 90s. We went to a kit car show in Carlisle, PA, back in the 2007 timeframe and we got to sit in a bunch of different kits. Being 6'3" and not a bean pole narrowed our choice to B&B Roadsters which had plenty of legroom with a dropped floor pan. We had an old farm truck motor which we rebuilt and became the powerplant, me and dad had so much fun during that build. Many items from the farm were used in that car, like pieces of a cow mat for vibration dampening, you name it! ;) We're about to flip over 27k miles at the upcoming London Cobra Show.

After that, we pulled a '68 Chevelle out of my uncle's barn after he passed that sat there for 35 years. We restored it in his memory, complete frame off with a new LS3 powerplant and we have over 20k miles on it with multiple Hot Rod Power Tours under our belt.

We got our first look at the Type 65 (Gen 2) when we toured Factory Five, the MkIV Roadster was the current model. I was the lucky person in the tour that got to ride in the passenger seat while Dave drifted around the parking lot, I believe it was the first one that had a Coyote engine installed. The seed was planted though for the Type 65. Fast forward quite a few years and we finally ordered our Type 65 (Gen 3) back in 2022 with a pickup date in March '23. We drove to Wareham to pick it up in person and began building immediately. This is where the forum was priceless, the manual was good, Paul's build thread was even better! [My dad and I felt star struck when we met Paul in person 2 years ago at the LCS, answered all of our questions, thank you Paul!!] Between his expertise and Greg (Cobra Daytona Build-YouTube), we were able to get through the build and enjoy the journey. I used a Gen 3 Coyote with MT82 transmission from a wrecked 2019 Mustang GT. We have just over 300 miles since built and it's currently for sale, amazing car and stupid fast. Yeah, not the easiest car to get in and out of but I got pretty good at it and was comfortable once inside.

Once FFR announced the MkV and noticed the frame looked just like the Type 65, we knew we wanted to build one to replace our B&B Roadster. The B&B is great, but leaks a little oil wherever it goes and can't come close to the handling of the Type 65. Then the 30th Anniversary was announced and I put my name on the list not thinking for a minute that I would be one of the 30. Surprise again, I was #6!! We just picked it up on 05/30 and have begun the build process. Then we flew back up there for the FFR Open House to look at some of the MkV's, had a great time! This week, we'll be heading up to the London Cobra Show to hopefully get some more ideas and maybe see another MkV or two. Hope to put some more faces to the names on this board up there.

[Homer]

Ok, intro out of the way now on to the actual build. I'm not going to go into all of the specs of the 30th Anniversary as it's well documented on the website. I'm planning to use a Gen 3 Coyote again like we used in the Type 65. However, I'm going to go with a Tremec for this one, most likely the TKX. The MT82 was okay, 1st gear was useless though and it didn't like speed shifting at all which is a common complaint for that trans. We have a Tremec TKO in our B&B roadster and I like the way that shifts much better than the MT82. I did not order it with the heater/AC, I'm still on the fence. My dad thinks it's useless but I'm thinking long term if we ever get the hard top down the road. At minimum, we would need a heater box for the rare occasions you need defrost. Fortunately, no vehicle inspections in South Carolina so the car is never checked for things like that if it's not there. I went with the 17" wheels and dual, Chrome roll bars. We got the vinyl dash with glove box, I didn't realize it was plastic until I saw it. A little flimsy and I'll have to create a way to stiffen it, probably will make a filler panel from the bottom to the trans tunnel. Also, after meeting and talking with Mike Everson at the open house, I think I'm going to go with the Wilwood electronic parking brake.

Again, my first time documenting a build so I'll try to post a few pics with some explanations along the way. Happy to help in any way I can and I've certainly received a TON of help for all of you on here!
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[Reddrig]

Looking at you first couple pictures, you look like your missing some bushing sleeves also? I was missing two lower control arm sleeves and one sleeve for the PS rack.

[DW66]

Hi Matt,
It was great seeing you and your Dad at Open House. I was shocked to see you there. My wife and I are not going to make it to LCS this year. Have fun see you next year. I'll be watching your build thread.

Dave

[Homer]

Looking at you first couple pictures, you look like your missing some bushing sleeves also? I was missing two lower control arm sleeves and one sleeve for the PS rack.

I had the front bushing sleeves, here were the main items that was on my backorder list when I picked it up on 5/30:

Power Steering Rack
Rear Spindles and Hubs
Bushings for IRS Install
Seats
Wheels
Roll Bars


Steering Rack is usually step #1 so I was disappointed that we didn't have it but didn't stop us from assembling the rest of the front end. At the Open House, they told me the steering rack/rear spindles and hubs had come in there. Sure enough, I received them last weekend! I'm not concerned about the seats/wheels/roll bars, that's a ways off at this point.

[Reddrig]

I had the front bushing sleeves, here were the main items that was on my backorder list when I picked it up on 5/30:

Power Steering Rack
Rear Spindles and Hubs
Bushings for IRS Install
Seats
Wheels
Roll Bars


Steering Rack is usually step #1 so I was disappointed that we didn't have it but didn't stop us from assembling the rest of the front end. At the Open House, they told me the steering rack/rear spindles and hubs had come in there. Sure enough, I received them last weekend! I'm not concerned about the seats/wheels/roll bars, that's a ways off at this point.

Your major items are the same as mine. I spoke to Travis today, he had no estimate on wheels or any of the larger items anyway. Hopefully the wheels make it in the next six weeks or so. I’m learning to jump around a little for my build. Have you received notification when a part ships from FFR? Or is it just showing up at your door?

[Homer]

Your major items are the same as mine. I spoke to Travis today, he had no estimate on wheels or any of the larger items anyway. Hopefully the wheels make it in the next six weeks or so. I’m learning to jump around a little for my build. Have you received notification when a part ships from FFR? Or is it just showing up at your door?

The only notification I get is from Fedex after FFR creates the shipping invoice. Usually, FFR will wait until there's a couple items they can throw in the same box before shipping but I've found them great to work with if you're stuck and need a part to keep going. They will send you what you need if they have it.

[Aleinsteingenius]

I will be building our Mark V about the same time as you. Also in NY except Long Island. We were also at the open house. I took so many pictures of the various Mark Vs there.

[Homer]

I'm a bit behind on posting as I've been on the road a bit recently, great to see some of you at the LCS!! Was really hoping there would be a finished MkV there, but no luck. Plan is to have mine there next year!

Assembled the lower and upper A-Arms, learned to keep checking FFR for updates to the manual. We printed out manual revision 1L since it's nice to have a hard copy, but FFR now has revision 1M online. There are updated pictures in 1M showing the forged lower arm as opposed to the previous version. For those of you who assembled a Type 65, you'll be happy to know that the ball joints install easily in the upper arms for the MkV. I was hoping the manual would have rough measurements to adjust the upper arms (like the Type 65 manual does) but it's not there. I talked to Nate at the open house and he believes the measurements would be the same so that's what I'll go with. This is just to get the alignment in the ballpark. Koni shocks were assembled and also installed with no issues.

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Next up was the spindles and hub followed by the Wilwood brakes. I've used Wilwood on the Chevelle and our current Cobra but first time installing on a FFR, went together with no problems and look great. Also got the sway bar installed, at the time I still didn't have the power steering rack.

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Since assembling the front end, I've received a lot of parts on the POL. Pretty much everything except for the wheels so I can finish the front end and complete the IRS as well. Plan on doing that during the July 4th weekend.

Planning ahead, I purchased an Aeromotive fuel pump (part#18638). I was going to go with the Pro M hanger and Walbro fuel pump that I used in the Type 65 and many others have used but I was shocked at the price - it more than doubled!! Just the hanger is $399!!!! I emailed them just for fun asking why the increase in just over 2 years but they did not reply, thus the Aeromotive purchase. I already test fit it in the tank and it will work just fine. I also contacted Mike Forte, great guy to work with and I'll probably get the flywheel on back from him. I've never used an external slave cylinder before for the clutch, have always used internal TOBs on my builds with no issues. So this will be new to me.

I also purchased an engine that I'll pick up next week, a Gen 3 Coyote with only 25k miles on it.

[Homer]

Catch up time, me and my dad had 3 full days to work on the car over the holiday weekend and got a lot of accomplished - it's now a roller!

First thing we installed was the IRS, never a fun job but we got it installed. My advice would be to use drift pins similar to what Paul has used in his builds. I always seem to have problems with the forward sleeves sliding out of the bushings by a 1/4" or so. Will have to keep an eye on them in case they do work their way back in over time and retorque those bolts.
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Then we installed the lower controls arms, axles, spindles, etc. Had to open up some of the opening a 1/16" or so and file some holes a little to get the bolts to fit but all in all, not too bad.
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Followed by the Wilwood brakes, installed easily. The suggested shims worked perfectly for centering on the driver side and had to add 1 shim on the passenger side. Also put on the ebrake, certainly is close to the shock but the wires to control it don't see to have a problem being routed away from it. Will just have to come up with a good way to secure it.
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Gas tank was next, as described earlier, I'm using the Aeromotive edition which fits in the tank well. To install the tank, I put a thin piece of foam between the tank and the frame so it's not metal to metal. Probably not necessary but would eliminate any possibilities of strange squeaks down the road.
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[Homer]

Assembling the rear end was easy compared to the steering. Fortunately, my dad has a lot more patience than I do. Getting that turn signal cam lined up perfectly takes a lot of time. As others have done, had to use different configurations of shims and washers to get it right. The middle shaft does need to get cut down to 12.5", it doesn't mention that in manual version 1L but it does mention it version 1M. Another reason to keep checking for newer versions of the manual online. Had to do some filing to get the 3/4" shaft to fit in the 1" outer. Still, final installation with the belleville washers took some force to get it in there. End result was good though, put the steering wheel on there and don't feel any binding at all.

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Zip tied the dash in place, will have to cut a slot for the turn signal stalk and somehow make it look good. Strange that the hazard switch is not accessible at all, you have to reach up and behind the dash panel to activate. Not that I regularly use the hazard lights but would have preferred that to be elsewhere or give me another option. I'm also curious how the dash will mount on the hoop and if the screws are accessible after the body is in place. I'd like to keep that removable if I can.

[Homer]

I picked up the engine last week, came from a 2022 Mustang GT with ~24k miles on it, looks almost new!!

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I've since removed the MT82 transmission, clutch and flywheel. Also, the engine mounts, exhaust manifolds, etc. Will be ordering the Tremec and everything else I need from Forte soon.:D

[Reddrig]

Assembling the rear end was easy compared to the steering. Fortunately, my dad has a lot more patience than I do. Getting that turn signal cam lined up perfectly takes a lot of time. As others have done, had to use different configurations of shims and washers to get it right. The middle shaft does need to get cut down to 12.5", it doesn't mention that in manual version 1L but it does mention it version 1M. Another reason to keep checking for newer versions of the manual online. Had to do some filing to get the 3/4" shaft to fit in the 1" outer. Still, final installation with the belleville washers took some force to get it in there. End result was good though, put the steering wheel on there and don't feel any binding at all.
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Zip tied the dash in place, will have to cut a slot for the turn signal stalk and somehow make it look good. Strange that the hazard switch is not accessible at all, you have to reach up and behind the dash panel to activate. Not that I regularly use the hazard lights but would have preferred that to be elsewhere or give me another option. I'm also curious how the dash will mount on the hoop and if the screws are accessible after the body is in place. I'd like to keep that removable if I can.

I was able to get my turn signal to finally line up also, but I’m really considering a different option. I’m just not a fan of that signal switch, I see a failure down the road with the build quality and engineering of it. And by the way you’re just down the road from me. Really nice work you do!