MPTech: Building my Factory Five Roadster

After researching for almost a year and joining the Gateway Cobra Club in St. Louis, MO, I began formulating my Build Plan. I saved links and Word documents full of forum topics, and many pages of notes in a binder. My plan went thru many revisions and updates (and is still evolving as new information is discovered and I learn more). this is my latest version (but even a couple items here have changed since I started the actual build).

This was as-of January 2011, just prior to ordering my kit from [URL="http://www.factoryfive.com/"]Factory Five Racing[/URL].


[B][SIZE="6"]MPTech’s Build Plan[/SIZE][/B]
A modern / sport-version of the 1965 AC 427 Cobra S/C (Semi-Competition), incorporating current technology and engineering that improves performance, safety, convenience, comfort, and reliability without impacting the vintage look and feel of the original. Primarily built for street-use and cruising, but could be tracked if desired.
[LIST][*][B][U]Kit[/U][/B] - Factory Five Racing – MK4 Roadster.[*][B][U]Engine[/U][/B] - small block Ford 302 ~ 300 HP.[*][B][U]Transmission[/U][/B] - 5 Speed Manual, T-5 w/midshift mod.[*][B][U]Suspension / Differential[/U][/B] - independent front and rear suspension, with limited-slip differential.[*][B][U]Wheels / Tires[/U][/B] - Halibrand-style vintage wheels with pin drive racing spinners.[*][B][U]Steering / Brakes[/U][/B] - manual steering, 4 wheel power disc brakes. [*][B][U]Electronics / Wiring[/U][/B] - donor engine harness / Painless wire harness.[*][B][U]Interior[/U][/B] - as close to authentic as comfortably possible, amenities will be hidden / subtle.[*][B][U]Body[/U][/B] - Blue with White stripes, using CSX3016 as the original to be modeled after.[/LIST]
[SIZE="4"][B]The Goal: a modern version of the original CSX3016.[/B][/SIZE]

[IMG]http://i9.photobucket.com/albums/a78/MPTech/PIC1.jpg[/IMG]

[B][U][SIZE="5"]Kit[/SIZE][/U][/B]

Objective: Vintage-look, performance (street-legal) race-car, built for street use. Well-engineered, safe, fun-to-drive, and reliable. Reasonably comfortable for short cruises, but could be driven for longer periods. Moderate build cost with choice of build parts and ability to upgrade others later. Looking for what I consider to be the Best: value, quality, and engineered Kit available.

[B]Factory Five Racing - MK4 Roadster Base kit[/B] [I](plan to order this month)[/I]
combination Base Kit with selected donor and new parts.

[IMG]http://i9.photobucket.com/albums/a78/MPTech/Kit.jpg[/IMG]
FFR MK4 Roadster example

Ordering Options:
• Powder Coated Chassis
• Tubular Front Lower Control Arms
• Independent Rear Suspension Kit (standard width w/ Koni shocks)
• Headers (302 ceramic coated 4-port)
• Roll-bar (driver-side Chrome)
• Roll-bar (passenger-side Chrome)
• Blank Dash panel
• Vintage Halibrand Replica Wheels (17’ x 9” front, 17” x 10.5” rear)

Don’t plan to use:
• Seats (selecting after-market seats0
• unpainted side-pipes (purchased chrome/silver ceramic coated side-pipes)
• smog pump bracket (not needed)
• battery box (not needed)
• pre-drilled dash panel
• air-filter (not needed)
• steering wheel (already have one)
• and I’m sure many other misc parts

Donor Parts:
• ’95 Mustang GT Front spindles / Disc Brakes / Vaccu-boost (Bought)
• ’95 Mustang GT Gas Tank and Fuel pump (Bought, but may replace gas tank)
• ’95 T-Bird IRS rear knuckles, disc brakes, and rotors (re-drilled to 4.5”) (Bought)
• ’98 Mustang Pedal Box (Bought)
• ’93 Mustang 302 engine (roller), engine wiring harness, and computers (Bought)
• ’03 T5 Transmission w/S-10 Midshift conversion (Bought)
• ’92 - 97 Lincoln Mark VIII differential

[B][U][SIZE="5"]Engine[/SIZE][/U][/B]

Objective: Small-block Ford V8, about ~ 300 HP, street-use, EFI for performance and reliability, donor, reasonable cost, common parts, economically upgradeable for additional performance, ease of maintenance, and decent gas mileage (lol).

[B]‘93 Mustang Roller 302[/B] (rebuilt) (Bought)
• GT-40P ported heads
• FMS F-cam
• Explorer intake (Mustang intake 58mm TB, Explorer 65mm)
• 24lb injectors + Pro-m meter calibrated for 24s
• MSD 6al ignition
• new water pump
• new 3G Alternator 120 amps
• Flywheel + new RAM clutch

[IMG]http://i9.photobucket.com/albums/a78/MPTech/Engine.jpg[/IMG]
302 SBF EFI example (w/ 4 into 1 headers) (a beautiful example, unfortunately not mine (but my goal)

Upgrades:
- 4 into1 headers, ceramic coated.
- Side pipes Chrome ceramic coated. (Bought)
- Aftermarket pulleys/brackets. (Bought)
- “Cobra powered by Ford” valve covers. (Bought)
- ARP Fastners
- ARP Ultra-Torque (lube for torquing bolts, here so I don’t forget it)
- Canton Oil Filter Remote Locator w / AN steel braid hoses and fittings
- ~ Motor mounts(?)

Cooling System
- New Radiator (tbd, Breeze cooling system)
- 427 overflow tank (Bought)

Fuel System
- New Gas Tank (tbd, have donor, but really considering new)
- Fuel pump / management system (donor)

[B][U][SIZE="5"]Transmission[/SIZE][/U][/B]

Objective: 5 Speed manual transmission, good low end gears, 5th gear for hi-way driving, reliable, street use, and fun-to-drive.

[B]’03 T5 transmission w/ S-10 mid-shift conversion[/B] (Bought and mid-shift conversion completed)
Stock gearing:
• 1st: 3.35:1
• 2nd: 1.99:1
• 3rd: 1.33:1
• 4th: 1.00:1
• 5th: 0.68:1
• Rev: 3.15:1

Upgrades:
- MGW Short-throw shifter w/ silver (Race) handle
- MGW dust boot
- Stang Shifter Gasket
- Forte’s Clutch Fork extender
- Solid Differential Mounts
- Shortened driveshaft

[B][U][SIZE="5"]Suspension / Differential[/SIZE][/U][/B]

Objective: good ride and handling, street use, adjustable, common parts, maintainable, PosiTraction rear-end.

[B]FFR front Upper & Lower Control Arms w/ Koni coil-over shocks.[/B]

Donor (Bought)
- ’95 Mustang GT Front Spindles / Disc Brakes

New
- New Rotors & pads
- Rebuilt calipers
- Breeze Lower Control Arm Bushing Set (TBD)


[B]FFR Independent Rear Suspension w/ Koni coil-over shocks.[/B]

Donor:
- ’92 - 97 Lincoln Mark VIII Aluminum pumpkin
- IRS Trac-Loc diff
- ’95 T-Bird IRS rear spindles/knuckles & hubs (Bought)
[INDENT] - New OEM Ford bearings
- Hubs re-drilled for 4.5 inch lug pattern & New wheels studs
- VPM Poly Bushings[/INDENT]
- ’95 T-Bird IRS disc brakes calipers with re-drilled rotors (Bought)

Upgrades:
- 3.55 diff gears
- Diff Carrier mounting bolts (grade 8)
- Silicone CV boots (North Racecars)
- Aluminum Differential Bushing Kit [url]http://www.vintageperformancemotorcars.com/[/url]
- Driveshaft safety loop
- ~ Sway bar (?)

[IMG]http://i9.photobucket.com/albums/a78/MPTech/PIC2.jpg[/IMG]


[U][SIZE="5"][B]Wheels / Tires[/B][/SIZE][/U]

Objective:
[B]wheels:[/B] retain the vintage look of the original 427’s, common size, and fits without any customization or clearance issues. Allows future upgrade to larger brakes.
[B]tires:[/B] street (DOT) tires that provide good handling and grip characteristics. As wide as possible, without fitment issues. Common size at a reasonable cost.


[B]17-inch Vintage Halibrand Replica Wheels[/B], w/ 5 lug bolt on with machined spinner and cosmetic cover.
17 x 9 front
17 x 10.5 rear
[IMG]http://i9.photobucket.com/albums/a78/MPTech/Wheels.jpg[/IMG]

Tires:

[B]Kumho Ecsta XS[/B]
245/45R17 fronts (rim 7.5” – 9.0”, section width 9.6”, tread width 8.2”, diameter 25.7”)

315/35R17 rears (rim 10.5” – 12.5”, section width 12.6”, tread width 11.5”, diameter 25.7”)
[IMG]http://i9.photobucket.com/albums/a78/MPTech/Tires.jpg[/IMG]


[B][U][SIZE="5"]Steering / Brakes[/SIZE][/U][/B]

Objective: good steering and braking characteristics, simple to setup and maintain, general street use.

• Flaming River Steering Rack.(FR1520 15:1) (Bought)
• 4-wheel power disc brakes, donor Mustang Vacu-boost and disc brakes w/ 10.8” front rotors, rear T-Bird rotors / discs. (Bought)
• Donor Brake / Clutch Pedal Assembly, with pedal bender mod (Bought)
• Breeze Clutch Cable Adjuster & Quadrant Kit. (Bought)
• Russ Thompson Throttle Pedal.
• Breeze Offset Steering Rack Bushings
• Lokar E-Brake kit

Possible Upgrades:
• ~ SAI Mod – Whitby’s (? tbd)
• ~ Bumpsteer mod (? tbd)
• ~ larger / better brakes (later)
• ~ Splined Quick Release Steering Wheel Hub kit (Breeze)