Barnyard Re-Build

[mjp]

Edit: 3/3/13 Car back for sale see sale section - it hurts, but just not practical right now and MA laws are a PITA. I just don't have the time or patience to deal with the Mass RMV.

I bought this Mark-I FFR Roadster, in 2001 and completed it in 2004. Actually, "completed" would be a slightly loose term, it was finished enough to register and drive. I never put the carpet in and I painted it myself. Being my first paint-job, I had always planned to do it over-again, or have a pro do it, but wanted to road test it first. Unfortunately in Mass, we are not able to drive anything other than a "finished" car (not exactly a kit-car friendly state).

Unfortunately, I got tied up in graduate school and only got to drive it about 600 miles before it ended up sitting for a while. Then when I got out of school, I got a job in Boston and finding somewhere with a garage, to work on it, has been too expensive or complicated due to building permits. During this time, it was moved under a tarp outside and

I was going to sell it, but these have been my favorite cars since I was a kid and in the end I decided to make a re-build happen one way or another.

[mjp]

After sitting under a tarp the car has seen better days.

[mjp]

Some close-ups of the dirt and rust - taps are pretty tough on cars apparently...

[mjp]

Getting it started again after replacing bad starter motor.

video | Flickr - Photo Sharing!

[mjp]

I couldn't get a garage set up, but I poured a concrete slab and put up a portable garage. It will be an interesting rebuild in this setup, but better than nothing....

[mjp]

I've made more progress. I have started stripping the old paint. I am hoping to get most of the car done over the winter and am hoping to drive it again in the spring. So, before the weather gets bad, I want to get it painted. My goal is mid-September. Ideally, I'd prefer to paint it at the end of the build, but the weather around here is too unpredictable in early spring, so, I'm going to try this way. The paint striping is going slow though, I forget what type of paint I used, but wish I remembered; man is it tough! I've tried chemical strippers and razor blades, but the only thing that has made a dent is a DA sander. Still though, I'm almost 20 hours into it but only about half done. I'll try to post updated pictures tonight.

[dallas_]

Cool. A restored Mk I!

Keep us posted on your progress.

[M DOUGHERTY]

cool
ive done a couple assited builds in those tents.
it works.
better than getting rained on.
good luck
and keep us posted.

[NAVYDUDE]

What a great project to get back to !! It think its great you actually hung on to it ! the easy way out was just sell it for a loss and walk away a long time ago- I think its awesome you kept the dream going, keep working one day at a time and keep us updated-please.
Jeff

[CCRsAC]

Glad you decided to keep it and redo it. Keep an eye on the classifieds for left-over parts from current builds, which will give you an inexpensive way to rebuild it using FFR parts, while updating it along the way. In many cases, those parts are available for pennies on the dollar as builders elect to replace parts provided in their kit with others.

[TheFatKid]

That's very cool. I love the enthusiasm for tackling the project with the best conditions you can create. Where I live the concrete slab is actually the hard part to get approved, the building is easy.

If you're in the Boston area you're not too far from me. Since your garage resources are limited let me know if you need any tools/help/someone laugh with you etc...

Adam

[GW6929]

best of luck! always glad to see mk1s around!

Jim

[jspa]

I think it looks great like it is. Make it reasonably reliable then drive the hell out of it.

[M DOUGHERTY]

I just finished a MKI for a friend of mine who bought it in 2000, and only put 40 half finished miles on it.
Finally he dropped it off and had us finish it for him. Wow what a great car.
KISS KISS KISS
KEEP IT SIMPLE
I cant say it enough. his car is a carbed 302, 273 gears, wipers, heater, Russ T gas pedal
and auto meter/smith gauges, chrome roll bar, 5 lug, and Dayton wire wheels.
most of these parts were purchased over the years taking advantage of good deals as they showed up.
keep going it will be awsome in the end.
Later
mark D

[thebicman]

Its amazing how quickly things degrade when not used. I'm sure when your done it will look twice as good as before.

[RobbieD]

Nothing a pressure washer and some elbow grease wont fix...

[TXBLU]

Originally Posted by dallas_

Cool. A restored Mk I!

Keep us posted on your progress.

Originally Posted by jspa

I think it looks great like it is. Make it reasonably reliable then drive the hell out of it.

I think either wsay would be awesome! Good luck.

Eric

[mjp]

Thanks everyone it was really a lot of fun building it the first time around, hopefully it will be just as much fun the second time. I'll make sure to keep updating the thread as I go. Probably won't be a show car, per say, I'm leaning towards something to drive, but plan to make a few updates I wish I had done the first time around. Who know maybe the next time I rebuild it will be a show car, as they say, third times a charm

Originally Posted by CCRsAC

Glad you decided to keep it and redo it. Keep an eye on the classifieds for left-over parts from current builds, which will give you an inexpensive way to rebuild it using FFR parts, while updating it along the way. In many cases, those parts are available for pennies on the dollar as builders elect to replace parts provided in their kit with others.

Thanks for the heads up, will do!

Originally Posted by TheFatKid

That's very cool. I love the enthusiasm for tackling the project with the best conditions you can create. Where I live the concrete slab is actually the hard part to get approved, the building is easy.

If you're in the Boston area you're not too far from me. Since your garage resources are limited let me know if you need any tools/help/someone laugh with you etc...

Adam

Thanks Adam and congrats on the new arrival! Likewise, if you need an extra hand with anything, just let me know.

Originally Posted by jspa

I think it looks great like it is. Make it reasonably reliable then drive the hell out of it.

For sure and thanks!

[Riptide Motorsport]

Good stuff!!!

[CraigS]

This is too cool. Now in addition to two build threads (Sal and QSL) that I follow every day, I will have a redo thread to follow. Really glad you decided to keep it and get it running again. I know it will be worth it!

[mjp]

Well, here is an update then

As mentioned, I've been sanding the old paint off. I've made a lot of progress with a pneumatic DA sander, but all the small crevices and curves really need to be done by hand, so, I'd say I'm maybe 50% done. I expect a lot of block sanding and filling afterward as the DA isn't the most refined method, but it works! Probably good to touch up a few spots anyways.

I've left the windshield on for now so I can drill the holes for windshield wipers, before painting, while the car is still together. They just arrived in the mail. I decided to go with AFI marine wipers, as I installed them on a boat a few years ago and they worked really well. Also, I've heard mixed things about the lucas wipers. I did pick up some chrome bezels from moss motors as suggested in the the wiper FAQ. I'm hoping to use those as guides for the drill angle. Maybe will get to it tonight or tomorrow.

I'm really hoping to get the sanding done by Friday, I don't want this to take years, so, I'm trying to force myself to stick to deadlines this time. I think it's doable, but I may be taking off of work Friday...

Some recent pics (let me just say, wet sanding with a pneumatic sander makes a mess!):

[gtfireftr]

Where in MA are you located. Keep up the good work, you will be done before you know it

[JKleiner]

Glad to see you moving ahead with a restoration. While I applaud your dedication and efforts I'm afraid your DA method may have made that thing wavier than the Atlantic. I see lots of Slick Sand and long board work in your future Grasshopper

Good luck,
Jeff

[mjp]

Originally Posted by gtfireftr

Where in MA are you located. Keep up the good work, you will be done before you know it

Just south of Boston.

Originally Posted by JKleiner

Glad to see you moving ahead with a restoration. While I applaud your dedication and efforts I'm afraid your DA method may have made that thing wavier than the Atlantic. I see lots of Slick Sand and long board work in your future Grasshopper

Good luck,
Jeff

For sure, that's why I tried chemical strippers first. Unfortunately, this paint is pretty impervious. After two nights with chemical strippers, I managed to strip all of about 4 square inches of paint LOL. Razor blades would just break through the paint and dig into the body. I didn't feel comfortable with them at all. And soda blasting was out of my budget.

I should clarify my technique though, I did think of this in advance and have been pretty careful. I'm starting over a large section, with long, criss-crossing strokes (like block sanding), until the water starts to turn from sort of a foamy white, to a light blue. I then rinse it all off, and I can see vivid blue streaks where I've broken through the clear. After that, I am continuing with long, criss crossing strokes, but trying to focus on the dark blue areas, and repeat. Eventually, the water starts getting a dark blue foam, then I knot the clear is basically gone. At this point, I'm taking the sander and just ever so lightly brushing the surface. It's sort of like lightly brushing the paint off, inch by inch, just until I start to see the primer. Once I'm done with a large area, I'm taking a block and hand sanding, again, with long, criss crossing strokes to smooth it out. So far it doesn't seem to be too wavy, but I'm prepared for a lot of block sanding to come.

[mjp]

Just to update.

I finished sanding off the paint about two weeks ago. The front end and some of the sharp contours/edges were a nightmare and took some time.

The sander worked well, very smooth on the gel coat, but did dig up the body filler areas a bit. So, I ended up sanding them down a bit more and building them up again. I also spent some time on some of the areas that could have used more work the first time.

One area I was never happy with was the doors. I just reinstalled the doors, windshield, body bolts and probably spent half a day fiddling with shims to get the doors aligned as best as possible. They were still off. The first time around I was afraid to use too much body filler, but looking online, at what others have done, I decided to be more aggressive this time. I think I used a quarter gallon of Rage Gold on the doors alone and I'm still not done! Unfortunatley, I'm now about out of rage gold, so, I am waiting until I can find some. I ordered some online and hopefully it will be here soon... but I'm also looking locally.

I have the critical body work done, so, I could move on to slick sand and painting within the week or two. However, there are a lot of upgrades I'd like to do, that I always regretted not doing (and reading ffcars doesn't help!). I'd like to roll the cockpit edges and fill the wheel wells. Also, it would be nice to finish the underside of the hood and trunk. I also always hated finding a spot for the hood, so, I did end up ordering a breeze hood hinge, and while I was at it, I hated the cheap FFR trunk hinges, and after seeing how bad they had tore up the paint (not to mention one broke), I decided to order breeze trunk hinges as well. So, they still need to be installed... I also like the Breeze roll bar, but I don't have a welder. I guess I could get one, but getting 220v out to the garage would be tough and I don't think a 110V would do. So, still thinking about that one...

So, right now I'm debating whether to do what I can in the next two weeks, then paint, or just do body work until November or so and then shelve it and paint it in the spring. It's sort of a tough decision as I know I'll never be completely happy anyways, so, maybe better to get it done, but at least some of the upgrades would definitely be nice to do. It may depend on when I can get the filler. If I can get it soon, I do have time to work this weekend (usually I've been too busy weekends) and then maybe take off two days next week. I think 4 full days I could knock out a heck of a lot, but if get delayed waiting for filler, I may hold off.

[MPTech]

Cool project.

Are you considering removing the body at this stage?
If you do, look at the DS footbox expansion and the new PS footbox. Your feet and your passenger will thank you!

[mjp]

Originally Posted by MPTech

Cool project.

Are you considering removing the body at this stage?
If you do, look at the DS footbox expansion and the new PS footbox. Your feet and your passenger will thank you!

The body is coming off for final body work and painting. Whether or not it is painted now, or in the spring, I'll put it in storage for the winter, off the car. Over the winter the plan is to work on the chassis, brakes, engine etc... basically anything that does not require warm weather.

The footbox looks like a good idea, but too many things to buy! We'll see.... I guess one way to look at it is that luckily I'm short and most passengers are hesitant to drive with me in a "normal" car anyways

[DAVE LITHWAY]

MJP, I bought a Mark I (#1495) out of a barn five years ago and have now just about finished with a total restoration. Amazing how moisture can work on steel and aluminum parts! Just drove it up to northern NH and back for a cruise with a group of Cobras, and can tell you that your efforts will pay you back big time! Keep at it.

Dave

[retownsendjr]

Way to dig in!
Are you going with the same color?
Rich

[mjp]

Originally Posted by DAVE LITHWAY

MJP, I bought a Mark I (#1495) out of a barn five years ago and have now just about finished with a total restoration. Amazing how moisture can work on steel and aluminum parts! Just drove it up to northern NH and back for a cruise with a group of Cobras, and can tell you that your efforts will pay you back big time! Keep at it.

Dave

Cool, do you have a build thread? I'd like to see that. I agree driving them is a lot of fun! ,Although, so is building them!

Originally Posted by retownsendjr

Way to dig in!
Are you going with the same color?
Rich

No, not that I didn't like it, but time for a change. I guess I get sick of color quick (one reason of many to paint it myself). Heck, knowing me, odds are I'll be sick of the next color by the time I paint it LOL. Right now, I'm leaning towards black. I also really like pearl orange with white stripes, atomic orange, with white or silver, carbon fiber metallic, darker blue, lighter blue, with white or silver stripes, dark reds, i.e. candy apple or merlot etc... I guess I should decide soon.... I do like the idea though of a solid, non-metalic, just for touch up reasons. As I said, I'd like to drive this and not really worry about it much. So, being able to touch up a nic or scratch here or there would be good. For solid colors, darker tend to look better I think. So, black, dark blue, merlot etc.. but we'll see.