Dean's MK4 #9191 Build - FFCars.com : Factory Five Racing Discussion Forum
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post #1 of 42 (permalink) Old 11-15-2017, 02:04 AM Thread Starter
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Dean's MK4 #9191 Build

i will mot be posting every little thing, but will try to hit the unique and milestones. That said, I will start with some mundane.

Delivery Day, Sept 30, 2017


Pushing it down the street to the house


Body Moved to Buck


Ready to start Assembly


I'm looking forward to getting started Dean



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MK4 #9191, Gen 3 Coyote, T56, 2015+ IRS, ABS, 12.88 Wilwood's, FFR Tubular Front LCA's, FFR Spindles, 18" FFR Hilabrands

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Last edited by dhuff; 03-09-2018 at 02:28 AM. Reason: fixed display of pitcures
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post #2 of 42 (permalink) Old 11-15-2017, 12:07 PM
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Congrats Dean, good start!
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Mk 4 complete kit ordered 1/19/17, delivered 3/23/17 #9059-Dart 347/TKO 600 from Mike Forte, Forte's hyd clutch, KRC p/s, Kirkey high back seats, 2015 IRS, 17x9/10.5 Halibrand replica wheels, 12.88 wilwood brakes f/r. heater/defroster, dual chrome roll bars, FFMETAL new firewall fwd.
First start and go-cart 4/11/18
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post #3 of 42 (permalink) Old 12-01-2017, 01:09 PM Thread Starter
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Koni Double Adjustable Front Mounting Location

I purchased the Koni double Adjustable shock option and noted this AM that there are 2 mounting holes available for the top mounts as shown in this pic.



The manuals, forum search, and FFR instruction search did not provide an answer as to whether to use the top hole or the bottom hole. I am using the FFR tubular lower control arms if makes a difference.

Thanks


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MK4 #9191, Gen 3 Coyote, T56, 2015+ IRS, ABS, 12.88 Wilwood's, FFR Tubular Front LCA's, FFR Spindles, 18" FFR Hilabrands

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post #4 of 42 (permalink) Old 12-01-2017, 02:00 PM
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I've never seen that before. Wonder when that started?
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post #5 of 42 (permalink) Old 12-01-2017, 08:23 PM
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If you try to put it in the top hole will the spring seat fit between the mount ears?

FFR 5353K, 408W, TKO 500, 2015 IRS w/ 315 gear, Breeze QA1 DA coilovers front and rear, APE hardtop, Forte front swaybar
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post #6 of 42 (permalink) Old 12-01-2017, 08:39 PM Thread Starter
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These are the double adjustable Koni shocks which the manual says get installed with the body on the bottom.


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post #7 of 42 (permalink) Old 12-01-2017, 09:08 PM
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The two different hole locations on each side make it double adjustable, right?
The neck on your shock mount looks longer than my earlier mk4, as if it is suppose to be mounted in the upper hole. See attached picture.
Looks like the only difference between the mount holes is a little bit of wheel clearance and a slightly different wheel rate for the same springs. I'd try the upper and see if it works.
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post #8 of 42 (permalink) Old 12-01-2017, 10:32 PM
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Ah - let's see. dhuff and bhuff. Both from Olathe, KS. Maybe they're related?

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post #9 of 42 (permalink) Old 01-23-2018, 02:20 PM Thread Starter
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Front suspension and brakes are complete.






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MK4 #9191, Gen 3 Coyote, T56, 2015+ IRS, ABS, 12.88 Wilwood's, FFR Tubular Front LCA's, FFR Spindles, 18" FFR Hilabrands

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post #10 of 42 (permalink) Old 01-23-2018, 06:28 PM
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Quote:
Originally Posted by dhuff View Post
I purchased the Koni double Adjustable shock option and noted this AM that there are 2 mounting holes available for the top mounts as shown in this pic.

https://drive.google.com/file/d/1vQF...ew?usp=sharing

The manuals, forum search, and FFR instruction search did not provide an answer as to whether to use the top hole or the bottom hole. I am using the FFR tubular lower control arms if makes a difference.

Thanks
The bottom hole is used for the red Koni shocks. The top hole is used for the double action silver Koni shocks. Front and back. Which also must be installed with the body down. This was discussed on the other forum and confirmed with a call to Factory Five. Looks like you have them installed that way, so all good.

Quote:
Originally Posted by dhuff View Post
Front suspension and brakes are complete.
Unfortunately, your UCA's are installed incorrectly. The rear pivots should be on the top, and the zerks pointed up. The pictures in the instruction manual show it correctly, but unfortunately it's never mentioned that it's necessary to disassemble and re-assemble to get the proper orientation. You're in good company. Many have missed this. They come from the vendor assembled upside down for this application. Your upper ball joint is installed correctly, with the ball joint pointed out.

Note: While you're fixing this, it's generally recommend to have bolts go in from the top with the nut on the bottom. That way should the nut ever fall off, there's a chance the bolt will stay in place and avert an even worse situation. When you take the UCA's apart to flip the pivots over, put the bolts in from the other side.


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post #11 of 42 (permalink) Old 01-23-2018, 07:35 PM Thread Starter
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Quote:
Originally Posted by edwardb View Post
The bottom hole is used for the red Koni shocks. The top hole is used for the double action silver Koni shocks. Front and back. Which also must be installed with the body down. This was discussed on the other forum and confirmed with a call to Factory Five. Looks like you have them installed that way, so all good.

Thanks. i contacted Tech and go this answer also.


Unfortunately, your UCA's are installed incorrectly. The rear pivots should be on the top, and the zerks pointed up. The pictures in the instruction manual show it correctly, but unfortunately it's never mentioned that it's necessary to disassemble and re-assemble to get the proper orientation. You're in good company. Many have missed this. They come from the vendor assembled upside down for this application. Your upper ball joint is installed correctly, with the ball joint pointed out.

Note: While you're fixing this, it's generally recommend to have bolts go in from the top with the nut on the bottom. That way should the nut ever fall off, there's a chance the bolt will stay in place and avert an even worse situation. When you take the UCA's apart to flip the pivots over, put the bolts in from the other side.
OOPS. Glad you noticed. i put them in the way i knew the ball joint needed to go and thought the grease zerks pointed down would make then easier to reach so didn't think that they may come assembled incorrectly. i'm starting to realize i need to pay more attention to the pictures since they show things that are not mentioned. i will also put the nuts on the bottom as suggested. I will get this corrected.

Regarding the mount location of the pivot bar, i have the FFR spindles so i followed the "Complete Manual" which on page 37 says to use the side mount location not the top mount location.

Thanks Dean


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post #12 of 42 (permalink) Old 01-23-2018, 08:00 PM
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Quote:
Originally Posted by dhuff View Post
Regarding the mount location of the pivot bar, i have the FFR spindles so i followed the "Complete Manual" which on page 37 says to use the side mount location not the top mount location.

Thanks Dean
I didn't state that very clearly. Your cross shaft is in the right location. Wasn't talking about that. It's the swivels on the ends that are wrong. When you flip them over so that the zerks are pointing up, you'll see the pivots are off-center and are pivoting from the top half of the cross shaft vs. the bottom. Hope that makes better sense.

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post #13 of 42 (permalink) Old 01-23-2018, 09:10 PM Thread Starter
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Quote:
Originally Posted by edwardb View Post
I didn't state that very clearly. Your cross shaft is in the right location. Wasn't talking about that. It's the swivels on the ends that are wrong. When you flip them over so that the zerks are pointing up, you'll see the pivots are off-center and are pivoting from the top half of the cross shaft vs. the bottom. Hope that makes better sense.
Got it. Thanks Dean


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post #14 of 42 (permalink) Old 01-24-2018, 12:02 AM
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post #15 of 42 (permalink) Old 01-28-2018, 01:31 AM Thread Starter
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Corrected the upper control arms.






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post #16 of 42 (permalink) Old 02-02-2018, 02:52 PM Thread Starter
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Finished installing the IRS differential, suspension, brakes.







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post #17 of 42 (permalink) Old 02-12-2018, 02:41 PM Thread Starter
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Footbox, power steering rack, and steering shaft are now installed.






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post #18 of 42 (permalink) Old 02-20-2018, 01:57 PM Thread Starter
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Solicited input on foot box modifications.
https://www.ffcars.com/forums/17-fact...iucations.html
https://thefactoryfiveforum.com/show...dvice+Foot+Box

Turns out that the newer FFR sheet metal that I have provides almost as much room as possible when using a coyote motor. As a result I have decided to go with the foot boxes as FFR provided.


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post #19 of 42 (permalink) Old 02-26-2018, 02:32 PM Thread Starter
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Passenger foot box complete




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post #20 of 42 (permalink) Old 02-26-2018, 02:49 PM Thread Starter
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i purchased a new 2004 furl tank and need to identify the parts indicated on the included picture. Does anyone have the part numbers or Ford's name for these parts?

thanks Dean
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post #21 of 42 (permalink) Old 03-12-2018, 05:14 PM Thread Starter
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Solid quadrant and fire wall adjuster.

Solid quadrant and fire wall adjuster.
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post #22 of 42 (permalink) Old 03-29-2018, 03:15 PM Thread Starter
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Installed Fuel Return into Tank

Added fuel return to tank. Return discharges into the pump sump to minimize fuel starvation on low fuel levels.
Plan to install the tank tomorrow.
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post #23 of 42 (permalink) Old 04-03-2018, 04:36 PM Thread Starter
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IRS Differential Vent Installed

IRS Differential Vent Installed. Used the stock part, trimmed off both ends to fit. Used the first step of a double flare to bulge the end of the plastic tube to help hold the hose on.
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post #24 of 42 (permalink) Old 04-25-2018, 02:50 PM Thread Starter
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Fuel Lines Installed

Fuel lines from the tank to the engine compartment are complete. No couplings used.
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post #25 of 42 (permalink) Old 07-17-2018, 04:18 PM Thread Starter
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Hydo Boost, ABS,and Brake Lines Installed

Hydo Boost, ABS,and Brake Lines Installed
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post #26 of 42 (permalink) Old 07-17-2018, 04:19 PM Thread Starter
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Hydo Boost, ABS,and Brake Lines Installed

More brake line pics
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post #27 of 42 (permalink) Old 07-19-2018, 02:57 AM
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looking good!

#7619 MKIV IRS complete kit, non donor
351 tko 500
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post #28 of 42 (permalink) Old 09-01-2018, 01:35 AM Thread Starter
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Heater Mounting

Choose to mount the heater more substantially that threading self tapping screws into plastic. So, i got some 1/8' x 1/2" steel bar, drilled and tapped for 8 #8 screws. Drilled, tapped, and countersunk 4 #6 screws to hold the bars in place. The 8 screws were put into the bar from the back side with Locktite to keep them from backing out as the nuts are tightened. Also added a piece of bar to fill the gap instead of using a gob of silicon seal as suggested in the instructions.
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post #29 of 42 (permalink) Old 09-02-2018, 01:36 AM Thread Starter
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Front ABS Sensor Brackets

Started out with the Russ Thompson front ABS sensor brackets but I am using 2007 front ABS sensors which did not fit the Russ Thompson brackets. The 2007 sensors take a 5/16" bolt instead of 1/4", and the flat spot is turned at a different angle from the mounting location. Started by modifying one of the Russ Thompson brackets and decided that a winder piece of aluminum would be needed. The pictures shows the 2 Russ Thompson brackets (on the left) and the 2 that I made, and a mounted sensor.
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post #30 of 42 (permalink) Old 09-16-2018, 10:02 PM Thread Starter
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E-Stopp brake with T56

Anyone use an E-Stopp parking brake with a T56? I have a later MK4 with Wildwood’s. There are 2 brackets that the cables can go through. I was considering cutting off the front one to push the E-Stopp as far back as possible. Would that provide sufficient clearance?

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MK4 #9191, Gen 3 Coyote, T56, 2015+ IRS, ABS, 12.88 Wilwood's, FFR Tubular Front LCA's, FFR Spindles, 18" FFR Hilabrands

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