Brian's Mk5 Roadster Planning Thread

[brian.pautsch]

This is my Mk5 Roadster planning thread. I'll start a separate build thread when that starts in January 2026.

Background
I live in the Chicago suburbs, have 2 awesome kids in college (son is junior at Indiana Univ, daughter is freshman at Univ of IL) and an amazing wife who puts up with my hobbies.
This is my 2nd build. Back in 2021, I ordered a Ultima RS #141. I waited 1-1/2 yrs for the kit and spent 16 months building it (420 hrs + ~100 hrs of mods later).
I dropped in a Gen V LT4 crate motor + dry sump + G96.01 transaxle + AP Racing brakes + AiM computer + a ton of carbon fiber. It's an insane car. Scary fast.
I documented the build here: https://www.ultima141.com and sold it last month on BAT: https://bringatrailer.com/listing/2024-ultima-rs/

222079 222077 222080 222081

It's time for a new build! This build I'm keeping forever, so I'm not holding back at all.
Like probably everyone here, I've always loved the Shelby Cobras. I did my research and FFR seems to be the leader (in many ways) for these cars.
This will be a street car for weekend cruising and car shows. I like to drive my cars pretty aggressively and I'll probably do some fun laps at a local track, but nothing serious.

Any comments, suggestions, or advice is very much appreciated! (Questions are at the bottom)

Engine
Borowski Race Engines is building my engine.
351W (427 CI) Dart Block + AFR 220cc Renegade Heads + Diamond Forged Pistons + Jim Inglese Stacks
I know it's overkill, but I had 690-710 HP with the Ultima (2,300 lb car) and used it carefully. I'd rather have it and not use it. I'm probably compensating too? :)
I'll build out the components (serpentine, pulleys, etc.) with Billet Specialities parts: https://www.billetspecialties.com/Store/Accessories/engine-accessories/

Transmission
Tremec TKX 5 speed + McLeod Twin Disc + Quick Time Bellhousing + McLeod Billet Flywheel
The TKX has a mid or back shift location option. I'm going with the back location to be more period correct.

Paint/Exterior
I am planning a deep candy apple red paint job with black stripes. I'm already chatting with Jeff Kleiner (met him at SEMA this year).
I am also going to black out all the exterior parts (rollbars, side exhaust, mirrors, headlight rings, etc.)

Mk5 Kit
15125 - Left Hand Drive Chassis
13083 - 302/351W Mounts
34158 - Hydraulic Clutch Master Cylinder Kit
16793 - Headers: 351W stainless steel 4-port
17620 - Uncoated/Bare Steel Side Exhaust
17823 - 2015 Mustang-based IRA w/ KONI coil-overs, forged control arms, & CV axles
17150 - Front & Rear IRS Sport Shock Set
16668 - 2018 Mustang IRS 3.55 Center Section, Spindles, and Hub
16038 - 31 spline driveshaft for 302/351W/7.3L Godzilla with Tremec TKX/TKO transmission and 2015 IRS
16799 - Power Steering Rack Kit (requires pump and bracket)
16007 - Speedhut Vintage GPS 7 Gauge Set (mph)
16213 - Leather Roadster Seats, Black
16613 - Powder coated chassis – Black, includes powder coated roll bar
17632 - Powder Coated Driver Side 1.5" Rollbar, Satin Black
15355 - 12.88” Front Wilwood Brakes, Black Calipers, Drilled & Slotted
60849 - Wilwood 12.88” IRS Brake Kit, Black Calipers, Drilled & Slotted
16693 - Vintage Halibrand Replica Wheel & Mickey Thompson Tire Package, 18” X 9” Front and 18” X 11” Rear, 245/40R18 Front and 295/35R18 Rear
12239 - 14” Wood Steering Wheel
17728 - Mk5 Body with Cut-Outs
17743 - Vinyl Dash with Glovebox
17617 - 2" Wide 5-point Street/Competition Harness, Satin Black Buckles
15834 - GT400 Bullet Side View Mirror, Polished Aluminum, Convex
15834X - Additional GT400 Bullet Side View Mirror, Polished Aluminum, Convex
15470 - Paintable ABS Plastic Hood Scoop

Free Options
12049 - Wind Wings
16808 - Trunk Gas Strut Kit
12469 - Brake Duct Wire Mesh Set
17872 - 4-Post Battery Cutoff Switch
12077 - Seat Track Kit, Driver Side
15659 - Assembled Side Louver Set

Additional Options
17814 - Mk5 Over-Rider Bumper Kit
60385 - A/C-Heater-Defroster Kit
15158 - Rollbar Grommet Set, Driver Side
16037 - IRS Front & Rear Swaybar
34168 - Brake Reservoir Kit
16427 - Hydraulic Clutch Throw-Out Bearing
17680 - EFI In-Tank Fuel System
14899 - Speedhut Vintage Oil Temperature Gauge
17712 - Remote Brake Booster

Other Items
Dynamat or Siless sound deadening
DEI heat shielding
Cobra emblems (front, rear, steering wheel, mats)
427 Cobra side badges
Parking brake
Dead pedal?
Hidden sound system w/ Carplay
Hidden USB ports
Cupholders?
Heated seats

Questions
1. Clutch package: Forte recommends their External Clutch Kit for serviceability. Thoughts? Or stick with FFR Hydraulic Clutch Master Cylinder Kit? Or other (e.g. Tilton)?
2. Forte recommends their Mechanical Throttle Linkage. They said theirs feels better and lasts longer. Thoughts?
3. Side Exhaust: I'm going to black it out, so they don't need to be stainless steel, but do you still recommend SS?
4. Opinions on the EFI In-Tank Fuel System? I'm still reading through the forums. As long as it meets the fuel pressure needs, I should OK?
5. Anything else you recommend? Radiator fan shroud, Radiator cowl cover, Aftermarket radiator fan, Oil cooler.
6. Any Mk5 hood clearance issues with 351W block + Jim Inglese Stacks? Air flow good?

Thanks!

[edwardb]

Welcome! Awesome Ultima RS. The FF Roadster is a totally different car, but then you know that. Sounds like an excellent build plan. Responses to some of your questions:

1. I've used Forte's external hydraulic clutch system on a few builds. It's OK (although pricey IMO) but the last couple builds I've used an internal throw-out bearing. Which I highly recommend. For me -- smoother, lower effort, self-adjusting, easier to install, cheaper. This is debated a lot so you'll have to decide I guess. Many, including Forte, bring up the "If it fails you have to take everything apart" warning. I get that. (1) Mine haven't failed. (2) Just like replacing a clutch. Everything has to come apart for that too, but doesn't seem to get the same concern. Interesting. If you do go that way, Tilton is BY FAR the best choice. I'm not sure what brand FF is selling. But go with the Tilton HRB to reduce your chance of any issues.

2. I haven't used Forte's piece. Made up my own before his was available. But highly recommended.

4. Sorry FF, you can do better than their in-tank setup. They're all widely available components and you can customize exactly to your build including what plumbing you use.

5. Yes, radiator fan shroud. The Mk5 has a narrower gap at the top of the radiator than previous models. I'm not sure Breeze (the usual supplier) offers one yet or whether it's necessary. I'm not putting one on my Mk5 build for now. I'm OK with the kit supplied fan. Some say it's loud. Maybe it is. I can't hear it. Oil cooler depends on your engine and intended driving. For more mostly street typically not required. You may want to look at a small PS cooler though. I typically install one just to be safe.

Good luck and welcome to the fun!

[Aleinsteingenius]

It sounds very similar to the build I am doing except for the engine. I have the Forte external clutch kit sitting here waiting for me to put the engine in. Welcome to the MK V family.

[Jeff Kleiner]

Hey Brian,
It's been good talking with you. Just a couple of comments:

Regarding the TKX...which one? Do the math on the available ratios. IMO the 3.27 first gear is much too low so I suggest you go with the 2.87. That leaves you to decide between the .81 (2.87:1 overall) or .68. (2.41:1 overall) fifth gear.

The FFR hydraulic clutch option #34158 is for the pedal box and doesn't lock you into an external slave like Forte offers or a hydraulic throw out bearing. If you buy an engine/trans package from Blueprint or the Coyote package through Factory Five AT you get a hydraulic TOB but since you're doing neither the end choice will be up to you. Personally, I'm not a fan of the hydraulic throw out bearing but that's me. If you go with Forte's external you'll want to change your master to a 13/16" rather than the FFR supplied 3/4". I can't speak from personal experience on the 3/4" master with the hydraulic TOB but one of my customers couldn't get enough throw using it with a Blueprint package and had to go up. Maybe Paul will chime back in to offer his experience.

Forte's mechanical throttle linkage will require some additional fabrication and ingenuity to work with the stacks but it'll give you a good place to start..

The Breeze radiator cowl cover won't fit or be applicable to the Mk5 but yes to a radiator shroud. Oil cooler is not necessary for a street car

If you plan to black out the side exhausts they'll have to be ceramic coated whether SS or mild steel. That being the case there's no reason to spend the additional $$ for SS.

Take the wheels but you can do a whole lot better for tires than the Mickey Thompsons.

There's more but that will get you started.

Jeff

[brian.pautsch]

edwardb - Thanks for the detailed and honest reply. Wow...Build #6 for you? Very cool.

I just added question #6: "Any Mk5 hood clearance issues with 351W block + Jim Inglese Stacks? Air flow good?"
Jim said it'll fit, so I'm not worried...but I'd love to hear other builders experience.

[edwardb]

I can't speak from personal experience on the 3/4" master with the hydraulic TOB but one of my customers couldn't get enough throw using it with a Blueprint package and had to go up. Maybe Paul will chime back in to offer his experience.

For both of my builds with the Tilton HRB throw-out, using their worksheet, a 13/16" master is the correct size. Provides the right amount of throw for the pedal and the right travel distance for the clutch. Tilton 60-6104 HRB in my Coupe with a T-56 now with nearly 10K miles. Tilton 60-6102 HRB in my Mk5 with a TKX waiting for it's turn.

- Paul B.

[brian.pautsch]

Jeff Kleiner - thanks for the tips and advice! Maybe I can take some of the money you're saving me and bribe you with a paint job. :)

TKX - Great point. I'm ordering a "Tremec TKX 5 speed TCET17765 2.87 1.89 1.28 1.00 .68 ratios". I like these ratios for low end and highway cruising.

Clutch - That helps clear things up a lot more. Thanks.

Forte's mechanical throttle linkage - I spoke with Will at Forte and they said it's not designed for the Mk5, but other customers have got it to work. I'll give it a shot.

And thanks for the advice on everything else. This is exactly what I was hoping to get from the FFR community.

[Jeff Kleiner]

edwardb - Thanks for the detailed and honest reply. Wow...Build #6 for you? Very cool.

I just added question #6: "Any Mk5 hood clearance issues with 351W block + Jim Inglese Stacks? Air flow good?"
Jim said it'll fit, so I'm not worried...but I'd love to hear other builders experience.

Ping Mike Bray. His is Mk4 but the engine to hood relationship is the same.

Jeff

[brian.pautsch]

Looks like Breeze has a few Mk5-specific products:
https://breezeautomotive.com/?product_cat=&s=mk5&post_type=product

Rad parts:
70807 Radiator Fan Shroud Kit for Gen 3 Coupe and Mk5 Roadster
70812 Radiator Shroud Kit for FFR Mk5 Roadster or Gen3 Coupe with Flex-Wave 105390 Electric Fan

Seat parts:
70815 Seat Riser Block Kit for Mk5 Roadster

[Kevin-C]

A couple of my favorite add-ons.

1. Microflex self-canceling turn signals and steering column. microflexlabs.com (https://microflexlabs.com/)

2. Dakota Digital cruise control. dakotadigital.com (https://www.dakotadigital.com/)

[Jeff Kleiner]

A couple of my favorite add-ons.

1. Microflex self-canceling turn signals and steering column. microflexlabs.com (https://microflexlabs.com/)



Column mounted self canceling turn signal is standard issue on the Mk5.

Jeff

[brian.pautsch]

This community is great! I just spent 35 min chatting with Mike.Bray on the phone. He shared a lot of knowledge with me based on his build experience. Thanks, Mike!

[rickster991]

Welcome to the madness!