TXeverydayDad's Mk5 Roadster build - A new adventure begins

[TXeverydayDad]

It’s time to embark on my second build. Those who followed the previous build know that it ended quite abruptly after about 4 months of driving, as I hit a curb and ended up totaling the car. However, it was such fun to both build and drive that I decided to dive right in and ‘re-build’ the car. Since the frame was damaged beyond repair, and the bonded/riveted aluminum would not have been easy or visually appealing to remove and re-attach, I decided to start with a new build – a Mk5.

F5 had a last minute cancellation so I managed to get that spot and got a completion date 10 days from order. Cunningham (former Stewart) Transport will be delivering the car, sometime in the next few weeks.

Since this is my second build, I’ll be going in with more experience and familiarity with the parts and it’ll be fun to explore the differences between the Mk4 and Mk5. My kids are more excited about helping out with the build this time around as they know what the end product will be, so that will be fun.

This build will be very similar to my Mk4, with a few additions:



Complete Roadster Mk5 kit
Coyote Gen 4x, with TKX
IRS + 3.55 rear end
Power steering
Hydraulic clutch
Power brakes
Traction Control
Vintage gauges
Dual chrome roll bars
New polished exhausts (6 db quieter than my previous pair)
18” Bronze Sunburst wheels
Black Wilwood brakes
Front and rear sway bars
Carbon Fiber Dash
Black leather seats


The main change will be the addition of boosted brakes, using the F5 brake booster. The Wilwood brakes are excellent as is, but I prefer the feel of boosted brakes. Another change that I’m investigating is adding traction control. Given that the situation with my Mk4 would likely have been avoided with traction control, it’s something I want to add. I don’t have any real ideas yet how to do this, but it’ll be a good challenge. Finally, I’ve switched from the Halibrands to the Sunburst wheels. It’ll be a different look, but will hopefully be a good change.

Since my plan is to do my own bodywork and paint, it’ll be interesting to see how different the Mk5 body is in comparison.

I’ll also be a little more space constrained this time around as I have my crashed Mk4 in the garage as well, at least as I start the build. I expect parts of the Mk4 will start decorating the walls of the garage as time goes on…

Out of the ashes - a new adventure begins!

[Jeff Kleiner]

Sounds like a good way to get back on the horse! I'll look forward to following along :D Oh,and you're going to be very pleased with the new Mk5 body in comparison ;)

Jeff

[Blitzboy54]

Congrats on the new build. How much of your MK4 are you harvesting?

[TXeverydayDad]

Congrats on the new build. How much of your MK4 are you harvesting?

Thanks! I’ll be harvesting as much as possible, most importantly the engine/drivetrain. I’ll be inspecting all parts as I pull them off and use what I can and replace where needed. The nose with functioning lights will become part of my garage lighting in one way or another.

[edwardb]

Congrats on getting back on the horse. I can't imagine the emotions you went through after what happened. I think you're really going to like the Mk5. Not perfect (yet) but a very nice build with with many significant improvements. You probably know this already, but that power brake booster takes up quite a bit of space. Combined with a Coyote will be interesting. Good luck with the build.

[TXeverydayDad]

Congrats on getting back on the horse. I can't imagine the emotions you went through after what happened. I think you're really going to like the Mk5. Not perfect (yet) but a very nice build with with many significant improvements. You probably know this already, but that power brake booster takes up quite a bit of space. Combined with a Coyote will be interesting. Good luck with the build.

It’s an emotional hit for sure and I’m still processing. My wife actually found me sitting in the driver’s seat in the crashed Mk4 in the garage the other day, just processing. But by God’s grace I get to enjoy the process of building another one. Could have ended much differently. I’ve just started disassembly and it’s harder emotionally than what I expected, knowing how long it took to get it to this point. But I have an extremely supportive and wonderful wife and family by my side.

A question as I pull everything out - should I drain the TKX/coyote before lifting them out?

For the brake booster, I’ve just seen the videos from F5 and I don’t have a frame of reference for the Coyote in the Mk5. It’ll be interesting to see how/if it comes together. There’s very little information about the unit. Seems to be an Iruna 6160000 but I haven’t found any technical info about it yet. Maybe something will come with the unit? Either way I’ll be documenting everything as I go.

[Nigel Allen]

Really impressed with your energy to get straight back into building. I certainly wish you all the best and will be following the journey. Pretty sure you will need to drain the TKX prior to removal, as oil will run out the rear when tilted.

Cheers,

Nige

[Jeff Kleiner]

The booster will fit with the Coyote, and now that FFR has made some revisions to the chassis fitting a battery along with the booster is no longer a challenge.

Jeff

[TXeverydayDad]

The booster will fit with the Coyote, and now that FFR has made some revisions to the chassis fitting a battery along with the booster is no longer a challenge.

Jeff

That’s great!

[edwardb]

This is why I said what I did about the Coyote installation and brake booster together being a "challenge." I didn't said it wouldn't fit. Only a head's up. As I see it, there will be two considerations: (1) The cold air intake routing off the throttle body. Every intake part provided in the FF Coyote installation kit (90-degree silicone adapter, MAF tube, air filter) may not fit. The usual 90-degree turn down into the area between the front of the engine and the radiator may not work because of space taken by the booster. With a smaller air filter I was able to route the cold air intake differently on my Mk5 build and maybe something like that. Granted that's an Aluminator with a CJ intake which has its own fitment issues. But a similar solution could work. Multiple pictures and descriptions in my build thread. (2) Likely there isn't room for a "Mustang style" expansion tank and plumbing like many of us do with a Coyote installation. FF shows using a standard overflow tank setup which works OK for many builders. Likely that will be the only option.

227417

I've done power brakes on a couple builds and agree it's nice. I support your desire to make it part of this build and meant nothing negative by my comment. These builds frequently are about problem solving and I was trying to share what I've learned from several Coyote installations. Wishing you nothing but the best with your new replacement build.

[TXeverydayDad]

This is why I said what I did about the Coyote installation and brake booster together being a "challenge." I didn't said it wouldn't fit. Only a head's up. As I see it, there will be two considerations: (1) The cold air intake routing off the throttle body. Every intake part provided in the FF Coyote installation kit (90-degree silicone adapter, MAF tube, air filter) may not fit. The usual 90-degree turn down into the area between the front of the engine and the radiator may not work because of space taken by the booster. With a smaller air filter I was able to route the cold air intake differently on my Mk5 build and maybe something like that. Granted that's an Aluminator with a CJ intake which has its own fitment issues. But a similar solution could work. Multiple pictures and descriptions in my build thread. (2) Likely there isn't room for a "Mustang style" expansion tank and plumbing like many of us do with a Coyote installation. FF shows using a standard overflow tank setup which works OK for many builders. Likely that will be the only option.

227417

I've done power brakes on a couple builds and agree it's nice. I support your desire to make it part of this build and meant nothing negative by my comment. These builds frequently are about problem solving and I was trying to share what I've learned from several Coyote installations. Wishing you nothing but the best with your new replacement build.

I really appreciate your input and the heads-up, and I didn’t interpret anything in your comment as negative. I took it as one builder looking out for another, which I sincerely appreciate - please keep the comments and suggestions coming. Yours and others’ experienced eyes on my build is something I value highly.

Since i’ll have everything on hand, I’ll probably drop the engine in early in the process to confirm layout. Good to know what I should look out for.

[Mike.Bray]

A question as I pull everything out - should I drain the TKX/coyote before lifting them out?

You don't have to, you can use one of these for the rear of the TKX. https://americanpowertrain.com/shop/transmissions/transmission-install-tool-and-seal-protector/?srsltid=AfmBOoolS50yHI1S6LbCcpIBVpNst766z6Q-gcvWm6VF4bd7IgSanAp8

Just add some duct tape for insurance.