Stix's Coupe Build - Striped Steel - Page 5 - FFCars.com : Factory Five Racing Discussion Forum
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post #121 of 128 (permalink) Old 04-09-2019, 11:45 PM Thread Starter
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Minor update, I got the differential out of the Factory Five as-designed mounts and raised it about 3" with a jack to get the coupler I made installed.

You can see my driveline is pretty much one giant inline group of stuff.


Here's a closer view of the coupler from above installed and how much the diff was raised.


Finally, a back view showing the new position I need to make mounts for:



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post #122 of 128 (permalink) Old 04-16-2019, 09:55 PM Thread Starter
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Here's first cut at the axle angle with a 4.5" or so ride height. I'll know better once I get the whole powertrain height and position finalized, but we're looking good for now:


Next up is the height of the engine end at the mounts and then seeing how to snake the front driveshaft in. If that shows good I'll weld in a new frame beam for the new differential height and redo the engine mounts before starting to cut up the front suspension area to make room for the front diff.


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post #123 of 128 (permalink) Old 05-18-2019, 07:28 AM Thread Starter
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Thought experiment time:
I've been reading about multiple people trying to quiet down the exhaust volume, Slimline 30" being sold out (my original option), etc and I wanted to get an idea of what I could do with yet another non-standard idea. Since I had time at my computer after getting a CNC job started at work, I played around with using a muffler and tucking it in the Coupe recess and begin seeing how it would work.
Obviously this isn't a finished product. I haven't verified the dimensions on the car itself but I pulled actual sizes from a few mufflers online, chose circle and oval pipe sizes based on rough numbers for flow, and started up our CAD software. Here's the result after a couple hours.




You'll need to ignore the left side since I'm leaning towards a tri-Y header design to widen the powerband and clearly it sticks forward of the actual body opening right now. The bottom element is a side skirt that would be enabled with my widebody setup and having to put in some wheel arch flares to fit the tires completely.

As stated, completely a thought experiment but since I haven't had time to touch the actual car, this was the next best thing for an engineer.

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post #124 of 128 (permalink) Old 05-18-2019, 12:57 PM
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I think this would not look good on an original looking car however, you are redefining your coupe completely and for your car I think it would look really cool.

John

Building when I can, sigh....


Coupe #386,17" Team III 245 FR 315 RR, 3-link, T5, 4 wheel disk, power brakes/steering. Fast EZ EFI
First start Sept. 18 2013
First go kart Sept 19 2013


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post #125 of 128 (permalink) Old 05-24-2019, 11:25 PM Thread Starter
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Thanks for the input John. I know it's not standard or authentic looking so I'm still having to weigh how much of it I want to consider.
----

A bit of a progression on the thought experiment. I measured some on the actual body and tried to better match them in 3D. I also added some wheels and the flares I'll need to support my other changes. I colored the body silver/steel/grey to better match how it'll be to reflect my thinking.


In other news, since I was able to spend a few minutes of time in my garage after doing some yard work, I notched yet another frame member near the transmission mount location so it would clear the CV joint of the front driveshaft. Looking even closer now although it'll need a custom length in the end. The lowest point of the CV cup is flush with the bottom plane of the chassis and the current diameter driveshaft just clears the transmission mount plate

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post #126 of 128 (permalink) Old 06-21-2019, 08:26 AM Thread Starter
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I've been thinking more about the front suspension and assembly and decided to spend a whopping $50 to help make some progress. That let me order front hubs for a recent Ford Explorer AWD model since they check a couple requirements. First, they're splined for front axles (27 splines), second they're 5x4.5 or 5x114.5 so they share the same wheel PCD as the 2015+ Mustang GT IRS hubs, third they have the same hub diameter meaning the same wheel bore with hubcentric rings and the ability to rotate tires, and an added fourth... they're super inexpensive if a bearing fails.


They did come with the downfall of having a larger diameter hub section where the brake rotors go meaning the Wilwood aluminum rotor hat wouldn't fit. The hub also has what I found to be a 5/64" radius at the bottom which added some fun to make things flat. The Factory Five hubs and knuckles are much smaller in diameter, helped in large part by not needing an axle and splines going through it.


All in all, I had to increase the rotor hat hub bore from about 3.05" to 3.23" along with an inboard chamfer to clear the hub radius. Not terribly complex but holding that in the lathe proved fun since I couldn't chuck it up internally since that was the machined area. Next up is stacking the hub, rotor, and wheel together to figure out the stud replacement lengths and pressing those in with ones that match the rear (unlike the FFR instructions which press out the rears to match the fronts.


I'm also modeling up new rear suspension A-arms to support the longer rear axles. More on that later

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post #127 of 128 (permalink) Old 06-26-2019, 10:29 PM Thread Starter
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Visual update for the front:


Next up on this is starting to design the knuckle to support this particular hub and caliper setup as well as figuring out the ackerman steering and tie rod placement.

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post #128 of 128 (permalink) Old 07-03-2019, 12:51 PM
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Looking good, sounds like you have the skills and knowledge to git er done.
I guess that's how you eat an elephant, one bite at a time!

Mike
Miami, FL
65 Coupe #439, Complete Kit, 3 Link, 4.6 SC Terminator Cobra Motor, MMR TKO 900, Megasquirt 3
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