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Build Manual

Kriss Motors

Mk3Build.com and Mk4Build.com (home page) are independent, non-commercial informational sites with free access provided by our sole sponsor, Kriss Motors. Kriss Motors, an automotive digital publisher, has no ownership interest in any Roadster-related vendor or manufacturer, including Factory Five Racing. As a visitor, you are subject to these Terms of Use. This site is optimized for 1280 x 800 screen resolution. Access to certain information requires free registration. If you are already registered, login to access restricted areas of this site. Email comments to info@krissmotors.com.

Mk4 introduced

The evolutionary upgrade of the Mk3 Roadster, the Mk4, went into production in March 2010. While this Manual extensively covers the Mk3 model, most of the material here applies equally well to the new Mk4.

Getting started

Introduction

This build site covers the construction of an all-new — that is, non-donor — Factory Five Racing (FFR) Roadster, generally referred to as the Mk3 or Mk41)(see also Legacy of the FFR Roadster). FFR, now a leading kit manufacturer, introduced its prototype Mark I in 1993, followed by the Mark II in June 2002. Over 4,000 Mark I-Mark II kits were sold by May 2004 when the Mark III (Mk3) was announced. In September 2007, FFR began shipping its Mk3 Complete Kit which was upgraded to the Mk3.1 Complete Kit version in January 2008. In May 2009, FFR manufactured chassis number 7000. FFR sells about 600 Roadster kits per year. In January 2010, FFR announced the Mk4 featuring a refined body mold (see FFR Mk4) which began shipping in March 2010.

The :-T symbol estimates the duration of a specific step or task, and :!: page notations refer to the FFR Assembly Manual (see Manual contents).

To eliminate hundreds of possible part configurations discussed on Factory Five forums, two complete kits

  1. Factory Five Racing Roadster Complete Kit with IRS option
  2. Breeze Automotive EzePak Master Mass-Flo EFI™ for the Mk3.1 Complete Kit (with Ford Racing Boss 302 engine)

will simplify sourcing, save shipping costs, speed up what can be a frustrating search for items with arcane numbers and obscure descriptions, and insure that individual components work well together. Prior to FFR's introduction of its Complete Kit, builds typically required a time-consuming tear-down phase of a donor car, like a 1990 Mustang, to harvest parts.

Decisions

Planning

¹ The FFR Mk3 Manual is based on a donor build and, although updated in early 2008, not does fully reflect the new Mk3.1 Complete Kit. Still, it is a useful reference for the build. The 2010 Mk4 manual has better coverage of non-donor builds.

Work area setup

* prepare workspace with adequate lighting², ventilation, storage³, power, and table top work area

² Illumination with 4-light 4-foot fluorescent lights works well, see work area tool recommendations.
³ 3.1 Complete Kit parts are packed in about 25 boxes requiring 200-250 cubic feet of storage space.

Building Process

Kit staging

Aluminum fabrication

Crate engine

Front suspension and rack

Independent rear suspension

Mechanical controls

Pedals

Steering and footbox

Brakes

Electrical

Overview

Mounted components

Dash and controls

Wiring integration

Sub-system detail

Fuel delivery

Engine bay

Engine drop-in

Electric components

Electronic fuel injection

Cooling system

Exhaust

Summary

Cockpit

Go cart

Gel coat

Shell preparation

Interior finish

Exterior finish

Graduation

Safety assurance

  • test all safety equipment
  • headlamp adjustment
  • adjust clutch and brakes, if necessary
  • inflate tires, 26 PSI front, 24 PSI rear
  • comprehensive test drive

Legal requirements

Ceremonials

Driving

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Appendix

Appendix includes Roadster specifications, build resources, vendors, and other helpful links. If you have not registered yet, click here.

Reference library

Reference Library includes PDF documents, FFR supplemental instructions, and related material. If you have not registered yet, click here.

1) Identified by “RD” at end of chassis number; Mark I and Mark II are stamped with “K” instead. First production Mark I, FFR 1011, was sold by FFR in 1995, registered in 1996; the Mk4 was introduced in 2010.
 
start.txt · Last modified: 2010/05/21 14:49 by Kriss Motors
 
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