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Old 10-04-2012, 06:42 PM   #1 (permalink)
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Wayne Build Thread

We had previously introduced ourselves in a thread when we received out MK4 complete kit, but I thought I would post a "Build Thread" for updates and questions.

For those of you that didn't see in our introduction post, my father and I are building a Mk4 Roadster together as a father son project. We each have restored many cars and bikes over the year separately, but not one together. My father is retired and I am a Mechanical Engineer by trade, now working in lean manufacturing.

We are planning a 'basic' build, with a 302 EFI, T5 and 3.55 8.8". We are adding power brakes, power steering, A/C, alarm and remote stereo system (as well as some smaller custom features).

The kit arrived 8/22/12 and today we are about at a roller (minus the power steering rack). Goal will to have the car ready by next spring season here in Texas. Paint scheme is planned to be British racing green or color similar to a silver blue poly metallic(Ford)








Also attached a picture of my other hotrod, a 68 Cougar, with 390 and TKO
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Old 10-04-2012, 07:14 PM   #2 (permalink)
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Good start, looks like you're well on your way.

Nice looking Cougar too.
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Old 10-04-2012, 10:57 PM   #3 (permalink)
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Tyler, I love the Cougar and you've done a beautiful job. But I would have restored it. But then I'm a purist.

John O

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Also attached a picture of my other hotrod, a 68 Cougar, with 390 and TKO
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FFR1293-289 slab side Mr Bruce body, 289 hi-po, Tremec TKO, 3-link 3.55 rear, spoked pin drive wheels, under car exhaust. A facsimile of CSX 2367.
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Old 10-05-2012, 01:47 AM   #4 (permalink)
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cool stuff, thanks for sharing. You will have some great memories. I hope my kids do the same when they get older... that is buy me a kit and build it LOL
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Old 10-05-2012, 02:19 AM   #5 (permalink)
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What a great way to spend time with your dad! Great build
Joe
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Old 10-05-2012, 01:01 PM   #6 (permalink)
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Thanks for compliment. Had it been a GT, GTE or XR7G, I may have restored it to original, but it was a X Code 390 2v with C6 and 2.73 open diff....red on red

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Tyler, I love the Cougar and you've done a beautiful job. But I would have restored it. But then I'm a purist.

John O
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Old 10-05-2012, 01:40 PM   #7 (permalink)
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Congratulations on your build project... it looks like the two of you are moving right along. At 82, my dad isn't too interested in being hands-on with my project, but he stops by every weekend, like clockwork, to check out my progress... often giving tips and keeping involved in his own way.

I'm going for an old-school look for my FFR, too, so will be painting it '66 Ford Ivy Green, a color you can see on John O's cars - he used it on both his 427 street body and now his 289 rebody and it looks awesome on these cars. Like John, I'm not doing stripes on my car.

Best of luck with your build!
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Old 10-16-2012, 09:47 PM   #8 (permalink)
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Update

We have been busy with MkIV. Here are a couple updates including the start of the extra trunk storage, Whitby A/C and relocated Shifter





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Old 10-17-2012, 02:15 PM   #9 (permalink)
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Looking great! Where did you get the relocated shifter?
Joe
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Old 10-17-2012, 03:18 PM   #10 (permalink)
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Looking great! Where did you get the relocated shifter?
Joe
X2

I love that
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Old 10-20-2012, 06:11 PM   #11 (permalink)
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Relocated / Mid Shift Update

Almost complete with the relocated shifter that I made. For those of you interested, I used a lot of parts that came with my kit.

The main bracket is 3/4" tubing and 3/16" flat stock.
I used the 3/8-24 threaded rod from the manual brake kit to locate the rod end bearing at the base of the shifter. The shifter handle I used is the one supplied with FFR and I cut off the mounting bracket and drill/tapped to accept a 3/8-24 rod end bearing. It is adjustable for height.
The connecting rod is from 5/8" solid round stock.

I located the pivot point of the relocated shifter in the same plane as the pivot point on my pro 5.0 shifter. It is adjustable side to side to achieve the best location. I also mounted the connecting rod as low to the trans tunnel braces so minimal height will need to be added to the trans cover.

The last thing I need is a few teflon or nylon washers between the shifters and connecting rod. There is zero flex in the pivot point of the relocated shifter or the connecting rod.




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Old 10-21-2012, 01:00 AM   #12 (permalink)
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Nice work Tyler keep us posted
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Old 10-22-2012, 01:15 PM   #13 (permalink)
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What have most people done to mount secondary fuse boxes (accessories/ AC) and relay boxes behind the dash? I want to has access to these quickly in case I need to change them.

I was thinking on making a bracket to mount them facing downward so looking up under the dash, they would be easy to see, or another option is to mount them to the firewall/bracket with velcro so your can just reach up and remove them to change fuse/relay and reattach.
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Old 10-22-2012, 02:24 PM   #14 (permalink)
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Don't know how much room you'll have, but with the firewall forward and the heater core in the middle, I have plenty of room behind the glovebox.





My new Glovebox (and a little something extra)
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Old 10-22-2012, 03:23 PM   #15 (permalink)
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That would be ideal, no neck bending or flashlight needed. However I have AC behind my dash, so i was thining about designing a mount that would hold my AC relay bundle & fuse box, and a 12V constant and switch fuse panel for accessories that I can remove by feel, and have enough extra wire to pull it out and diagnose any issues basically sitting in the passenger or driver seat, then just velcro it back in position. I may also consider a more rigid mechanical connection than velcro


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Don't know how much room you'll have, but with the firewall forward and the heater core in the middle, I have plenty of room behind the glovebox.


My new Glovebox (and a little something extra)
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Old 10-25-2012, 02:25 PM   #16 (permalink)
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Update - Engine Wiring

Trial fit all the engine wiring and and tried to hide as much wiring as possible. Closing in on first start date.....

Unsure if I will keep the upper intake semi gloss black or get it powdercoated silver....thoughts?



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Old 12-18-2012, 02:15 AM   #17 (permalink)
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Long Overdue Update

Just wanted to post an update on progress of my dad and I's build.

Had our first start 10/27 and first go kart ride on 11/12.

Here are some photos of some of the updates we have made:

Bluetooth remote stereo in trunk with amp and 6X9's in bulkhead.
I fabricated my own frame to hold the stereo, amp and speakers.




Hidden controls for AC/Heat:


Powdercoated Chrome Drive system:


AC Condenser:


Dad and I on his birthday:
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Old 12-18-2012, 02:17 AM   #18 (permalink)
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The speakers will have an expanded steel or rigid mesh/grille over them to protect them. Will coverage with headliner/acoustic material.

Also, can anyone tell me the stock CFM for the 16" electric fan?
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Old 12-19-2012, 01:02 PM   #19 (permalink)
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Hydroboost installed for PS and PB. Includes Heidts valve.

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Old 01-28-2013, 11:05 PM   #20 (permalink)
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Update before paint

We are looking to get the car into paint this week and hopefully it ready for the Texas cobra meet in San Marcos in April.

XL Access Panel before bending.


Need to add AC cover


Minimalist Dash:


Body goes on:



Getting more attention:


Relocated shifter, cup holders, relocated E-brake


Added combination USB and 3.5mm jack directly to rear mounted head unit. Charges iphone as well.
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Old 01-29-2013, 02:29 PM   #21 (permalink)
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Unsure if I will keep the upper intake semi gloss black or get it powdercoated silver....thoughts?
Keep it black! I like how they go with the covers in black. Here's what I've done with mine so far.




-Kyle
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Old 01-29-2013, 05:05 PM   #22 (permalink)
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Question Valve covers

kgkeys:

You have [what I believe] is a very rare set of valve covers . . . any ideas where they came from, the ones that are cast as "Powered by Ford" (No COBRA)?

You are the only {other} person I know of that has these valve covers.

Doc
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Last edited by Big Blocker; 01-29-2013 at 05:14 PM.. Reason: redirected post to another builder
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Old 01-29-2013, 08:04 PM   #23 (permalink)
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Quote:
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kgkeys:

You have [what I believe] is a very rare set of valve covers . . . any ideas where they came from, the ones that are cast as "Powered by Ford" (No COBRA)?

You are the only {other} person I know of that has these valve covers.

Doc
I'm fairly certain they came off of an earlier (maybe an '84?) [EDIT: looks like 83-85. Apparently '82 was similar but had shorter bosses?] carbed mustang. I'm pretty certain they aren't rare. [EDIT: They may by rarer than I thought, but they still seem to sell pretty cheap and look nice!] There's a bare set on e-bay for $40 right now. I got mine on Craigslist for $35 from the same guy that sold me a Trak-Lok carrier for my MK VIII diff.

I wire wheeled them, sprayed them satin black, took down the fins with an orbital sander, then sprayed them in clear. I know I'm going to have to run either two low profile caps or work up an angled extension tube to clear the EFI upper. (That's the next thing someone was going to point out.)

EDIT: found a pic of some in stock form


-Kyle

Last edited by kgkeys; 01-29-2013 at 08:19 PM.. Reason: added picture
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