Quarter Windows and Acrylic
Another somewhat trivial update. Expecting some more significant ones very soon. There’s a common theme to this update. Couple of the ideas are from other build threads. That’s the beauty of this community. Lots of shared creativity which I watch closely and pick and choose (and sometimes change a little…) for my builds.
First up, headlight covers. The kit comes with acrylic headlight covers (very last POL item for me) that need to be trimmed slightly to fit the openings. I’m going to wait for that until after paint just to make sure they fit exactly. They are attached with kit provided right angle SS pieces. Another builder posted a suggestion to use 10-32 SS rod end bolts from McMaster instead. Decided to go that way. These: https://www.mcmaster.com/2434k54. Require a couple of minor modifications. The 3/16-inch holes are unthreaded. I threaded them to 12-24, which is a somewhat unusual size. But 12-24 taps into them with any additional drilling, so that’s what I used along with 12-24 button head SS screws. Also used a 10-32 die to extend the threads all the way to the top. The shank will get cut off and probably need a spacer under the rod end. But have them ready for the next step when it’s time to install the covers. Makes for a nice clean look. Note that Peter Brock sells a somewhat similar setup on his website (bre2.net) so that’s another option. About the same cost.
https://thefactoryfiveforum.com/atta...4&d=1564074298
Next up, worked on the quarter windows. First was fitting the formed acrylic scoops. They're provided significantly oversized. Fit both sides to the outline on the body. Like the headlight covers, I’ll wait until paint is completed to confirm the exact fit, then drill and mount. BTW, fit each side individually. They’re slightly different.
https://thefactoryfiveforum.com/atta...5&d=1564074305
When the side windows are installed and running heat or A/C, in most cases you would not want this scoop to be drawing in outside air. So, the windows kit comes with an acrylic panel that’s intended to be placed into the opening for times like that. Couple of issues there. It’s intended to be held in with screws, which isn’t very handy since it’s likely to be taken in and out frequently. Plus the seatbacks are somewhat in the way for accessing the screws. Also, there’s a 1+ inch gap between the back of the window and the edge of the panel if placed on the inside of the body. I had made a note of how Erik Treves (the famous Hawk Coupe) addressed this on his build, so went back and reviewed that. He even posted a very informative video: https://youtu.be/Vj6pKvciQZI. These seal plus slide in and out without any mounting screws. Looks great to me, so unceremoniously stole this idea for my build.
First up though, found the kit provided acrylic panels were a little small to be set up this way. Plus it appears they were cut using a laser cutter, and the edges were burned in several places causing the liner material to be melted into the panels. Only around the edges and still could have been used. But picked up a couple 12 x 12 x 1/8 coated acrylic panels and cut new ones after making carboard patterns. Bent some aluminum angles for the corners, made a couple of pieces for the windows to slide into out of 16-gauge steel, and added some cushion and bulb seal. Sounds easy enough but does take some trial and error to get it all just right. I’m going to get the metal pieces powder coated and will hold the angles on the acrylic the same way the side windows are assembled with 10-32 SS button head screws. Very happy with how this turned out, and thanks to Erik for the inspiration.
https://thefactoryfiveforum.com/atta...0&d=1564074346
https://thefactoryfiveforum.com/atta...8&d=1564074330
https://thefactoryfiveforum.com/atta...9&d=1564074338
https://thefactoryfiveforum.com/atta...6&d=1564074312
https://thefactoryfiveforum.com/atta...7&d=1564074320
Finally, this is the first time I’ve worked with acrylic. I found numerous references that care must be taken when drilling holes as it’s possible to chip and/or crack the material, especially when drilling close to an edge. Learned that there are drill bits made just for this material, so Amazon to the rescue. https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1. Never a bad excuse for new tools. Only drilled the eight holes in these windows so far and seemed to work very well. Plus did a bunch of test drilling in scraps. Will use again for real for the scoops and the headlight covers. As the directions state, the right drill bit plus the right speed are important. If you don’t want to buy these, it is possible to drill with regular bits. But work up very slowly on the size with multiple bits, plus keep the speed down so they’re cutting and not melting.
After a week or so of very hot weather, which kept me out of the shop starting around noon every day, it’s cooled back off to our usual very nice Michigan summer weather. Have been able to get in lots of driving in the Roadster, in addition to the build.
New Headers, New Sidepipes, First Drives. Oh My!
Today was a big day. With my prototype headers and sidepipes installed (more later), drove the Coupe for the first time in my neighborhood. Started the Coyote after not running for quite a few months and it fired right up. Had a bit of a scare. Wasn’t getting any alternator voltage on the gauge. The alternator had to be out to get the headers on and off. So yesterday while reinstalling it, I forget the master switch was on and managed to touch the alternator power lead to ground. Sparked good as expected but didn’t see any damage so kept going. With the switch off of course. Now today no alternator output. Was afraid I fried something in the alternator (ugh) but then I remembered the alternator mega fuse I normally install. Sure enough it was burned and open. Did its job! Put in a new fuse and all good. With yet another lesson learned.
First impressions driving are all good. The Tilton HRB and clutch feel great. Smooth easy release. Really nice. The Wilwood brakes even though not bedded yet seemed strong. Power steering felt fine. T-56 shifts great and reverse lockout works with the car in motion. Initially didn’t have a speedo indication, but I just had the GPS antenna temporarily draped under the dash. Put it up on top and that’s working too. Need to find a permanent location. Radiator fan kicked on when it should have (around 190 F) and shut back off when it dropped back down. Interesting that Ford Performance went back to a more normal temperature curve on the cooling fan program with the Gen 3. I did throw a couple codes related to oil pressure. The pressure is fine (I kept a close eye on the gauge) but apparently the one sensor I removed (at Ford Performance agreement) is still active. Will dig into that. Tried the heater and it poured out hot air. Don’t have the A-C charged yet, so no test there. Checked everything over back in the shop, and no leaks or drips. The Gen 3 Coyote runs good, but still could improve some I think. Not sure if it’s still learning. Or likely will need a custom tune at some point. Kind of expect that. In general things are a little loud without any carpet or weather-stripping on the doors and hatch and windshield just taped in place. And since the splash guards aren’t coated yet, lots of pinging from dirt and gravel on the road. But it’s very driveable now. Only did 25-30 MPH in my neighborhood and found 3rd once. Bottom line, all good.
But the real news here is the headers and sidepipes. Now that I have a working setup, will finally give more details. Most know the stock Factory Five sidepipes are loud, a little on the rough side (at least mine were), unfinished, and the transition is maybe less than ideal. I considered a couple of options, but really wanted to stay with the dual pipe traditional look of the Daytona Coupe. Due to the uncertainty, I purposely didn’t order headers with my kit and figured I would address the header/sidepipe situation later. So fast forward some months into my build, and I was pleasantly surprised that Georgie from Gas-N contacted me and asked if I would work with him to develop a header/sidepipe setup for the Gen 3 Coupe. Would I? You bet. I’ve used Gas-N side pipes on each of my Roadster builds and they’re perfect. Look great, sound great, and last. The prospect of that same quality on my Coupe build was something I didn’t have to think about very long.
There have been a number of steps to the process, and I won’t go through all of them. Georgie developed a twin pipe design and I received the prototypes several weeks ago. Note these are stainless, just like the Roadster pipes. But for this stage, not polished. Then we used “Frankenstein headers” to determine the proper configuration of the headers with the side pipes in their intended location. Once locked down, those were sent back to Georgie to use as patterns for the prototype headers. Couple of weeks later, these arrived.
https://thefactoryfiveforum.com/atta...0&d=1564525864
Now installed. And by the way, for those who have busted knuckles and said words Mom said not to use while putting in Roadster headers, the Gen 3 Coupe isn't too bad. The driver side is still tight, but all are reachable. The passenger side is mostly a piece of cake. All but a couple can be reached with a ratchet, extension, and universal joint. I used RemFlex gaskets and high-temp RTV silicone (Permatex 81878) on the bolts. This combination has been rock solid in #8674.
https://thefactoryfiveforum.com/atta...5&d=1564525915
https://thefactoryfiveforum.com/atta...6&d=1564525926
https://thefactoryfiveforum.com/atta...3&d=1564525900
https://thefactoryfiveforum.com/atta...2&d=1564525892
Note these are the first prototypes. Now that they been checked out, Georgie will make a new pair with his legendary stainless steel polished finish. No huge rush because these are fully functional. Did my first drives today with them. Note I don’t have the side hangars on yet, so there’s a little movement of the pipes that will be reduced when those are added. Check out the videos. They're short. But really happened and you get the idea.
https://youtu.be/24kZChAlKeI
https://youtu.be/boH-3-BD52g
https://youtu.be/QCdUdj6n3eM
https://youtu.be/mFHHqadaREs
If interested, you can check with Georgie on price and availability of this new option for the Gen 3 Coupe with a Coyote. Next up, visit the paint shop for my estimate (oh boy…) and scheduling. This will also be the first time I try to fit it into my 14-foot SE. We’ll see how that goes.
Coupe and 14 Foot Serpent Express
Brief update after the crazy last couple of days. Today I tried the Coupe in my 14 foot Serpent Express (SE) trailer to see if it will fit. Short answer. Not really. Probably not a surprise but not exactly for the reason I expected. After driving it in and stopping short of the cover frame in the front, found a pretty major issue. The door wouldn’t open. Doesn’t clear the side escape hatch. Kind of hard to get out and back in that way. So drove it all the way against the front. Like this:
https://thefactoryfiveforum.com/atta...0&d=1564626686
Now the door clears. Just barely:
https://thefactoryfiveforum.com/atta...9&d=1564626679
Sticks out the back as I expected. This I had figured out previously with a tape measure. Found the covering is flexible enough that it will still zip closed.
https://thefactoryfiveforum.com/atta...8&d=1564626670
Conclusion: Ok to use the trailer for transport before it’s painted. After it’s painted? No way. Can’t have the paint touching anything, specifically in the front. But stopping short, can’t get in/out of the door. Winch is an option, but still the interior (e-brake, shifter) will be inaccessible unless the DS window is off. Even then it’s still sticking out the back. I had resigned myself that at best I would have to tie the door up above the hatch spoiler area and tow it with it hanging out. Still affords reasonable protection. But not so much security. Bottom line: Ok temporarily, but not for the long term. Looking at options.
On a happier note, while I had it out and running, took my wife for a short spin around the block. Still rough and noisy, but she really liked it. Likes the seats, the added footbox space, the 4-point seat belts with pushbutton latches, the roof over her head without wind (think hair...), and the prospect of heat for those cold drives. A/C is a bonus. I think we have a winner. Officially have two miles on the odometer.
What are the dollar amounts?
Quote:
Originally Posted by
edwardb
Thanks for the encouragement guys. Still talking but not sure it's going to work out. We'll see. The shop has had some bad experiences with Roadsters (that's all they've painted) and grossly underbid them. I know about several of the situations. But that hasn't been the case for the two they've done for me. I just seem to be getting the brunt of that. I full expected the Coupe to be pricey, and I want a first class paint job. But going from 150 hours estimated (my Roadsters) to now 350+ (with all the glass fitted and mounted in both cases) is off the charts. They're now saying they would only charge for the actual time, and it really is only an 'estimate.' But my trust is shaky at best.
Curious about how many dollars are being quoted.
fred