FFR Assembly Manual
Assembly Manual cover for Factory Five Racing 1965 Roadster Mk3
Digital version of the Factory Five Racing 1965 Roadster Mk3 Assembly Manual
FFR first developed an assembly manual in 1995 to cover donor-based builds. The current version of the Mk3 manual retains that heritage so that some sections focus on Mustang donor issues which are no longer relevant to Complete Kit builds. An electronic version of the 2F edition of the manual was released in February 2010 with substantially the same content, supplemented with color images and updates that were previously distributed separately from the manual.
The print and digital versions of the manual are available directly from the online FFR Parts Catalog.
Annotated Table of Contents
The following Table of Contents excerpt is from the 268-page Revision 2F, January 2008 edition of the Assembly Manual, copyright ©2008 by Factory Five Racing, Inc., and replicated here strictly for educational purposes under the fair use doctrine as incorporated into the Copyright Act of 1976, 17 U.S.C. § 107. All rights reserved by Factory Five Racing, Inc.
Annotations added by Mk3Build.com were not reviewed or approved by Factory Five Racing.
A new digital version of the Mk3 FFR manual was released in February 2010. Annotations below refer to the printed version.
Annotations:
Does not apply to non-donor build
May not fully reflect Mk3.1 Complete Kit parts or assemblies
May not fully apply to the build described on this site because of alternative parts or assembly method
| HEADING | PAGE |
|---|---|
| Statement of non-liability | iv |
| Foreword | v |
| Tools and supplies list | vii |
| CHAPTER 1 - Donor parts and parts needed | 9 |
| Donor parts and the Mustang 5.0 | 10 |
| Donor part selection tips | 10 |
| Disassembly of a Mustang donor for parts | 13 |
| Donor part preparation | 26 |
| Cleaning and detailing | 34 |
| Not using a donor | 35 |
| CHAPTER 2 - Step by step chassis build-up | 37 |
| Unpacking your replica kit | 38 |
| Removal of body & aluminum | 38 |
| Aluminum removal and preparation | 39 |
| Engine bay aluminum | 40 |
| Front suspension installation | 41 |
| Front upper A-arms | 42 |
| Front coil-over shock assembly | 44 |
| Steering shaft | 49 |
| Steering rack installation | 51 |
| Rear-end (refer to Appendix F for IRS) | 54 |
| Suspension torque specs chart | 58 |
| Fuel tank and fuel filter | 59 |
| Fuel filter | 60 |
| Pedals | 61 |
| Master cylinder & push rod | 63 |
| Cockpit aluminum | 65 |
| Aluminium floor panels | 65 |
| Tranmission tunnel front vertical wall | 65 |
| Driver's foot box | 66 |
| Passenger foot box | 68 |
| Cockpit rear wall | 70 |
| Transmission tunnel U-joint cover | 70 |
| Transmission tunnel rear corners | 70 |
| Fuel, brake and battery lines | 70 |
| Rear brake line | 71 |
| Front brake line | 72 |
| Fuel line | 73 |
| Battery relocation kit | 75 |
| Engine preparation | 77 |
| Alternate drive pulley | 78 |
| Engine/transmission/drive shaft | 79 |
| Accelerator cable | 82 |
| Clutch cable | 86 |
| Mass air meter, fuel vapor canister | 86 |
| Radiator, hoses & fan shroud | 87 |
| Wire harness and EEC-IV | 91 |
| Rear harness | 92 |
| Transmission harness | 93 |
| Headlight harness | 94 |
| Dash harness | 95 |
| Engine harness | 98 |
| Gauge pod installation | 101 |
| Ignition and turn stalk | 102 |
| Aluminum trunk & side walls | 102 |
| Emergency brake handle and cables | 105 |
| Transmission top cover | 108 |
| Wheels, tires and ride height | 108 |
| Checking the running gear | 109 |
| Foot box top cover | 110 |
| Roll bar drilling | 111 |
| Body cut-outs | 112 |
| Roll bar cut-outs | 112 |
| Gas filler hole | 113 |
| Windshield cut-outs | 113 |
| Side exhaust cut-outs | 114 |
| Turn signal and tail light cut-outs | 115 |
| Side louver cut-outs | 115 |
| Headlight cut-outs | 116 |
| Hood scoop cut-out | 117 |
| Trunk license plate light hole cut-outs | 118 |
| Hood pins | 118 |
| L-shaped hood handles | 119 |
| Body mounting | 121 |
| Rear quick jack bumpers | 123 |
| Side body mounts | 123 |
| Front body mounts | 124 |
| Front quick jack bumpers | 124 |
| Body prep and painting | 125 |
| Rubber seal on aluminum | 127 |
| Final body mounting | 128 |
| Rear cockpit corners | 128 |
| Trunk hinges | 131 |
| Trunk latch | 131 |
| Side louvers | 132 |
| Fuel neck and gas cap | 133 |
| Windscreen | 137 |
| Hood pins | 139 |
| Doors and hinges | 140 |
| Check straps | 143 |
| Under-door aluminum | 143 |
| Side view mirror | 145 |
| Radiator aluminum | 147 |
| Side exhaust | 149 |
| Roll bar | 152 |
| Rearview mirror | 153 |
| Gauges and dash | 154 |
| Front wheel splash guards | 159 |
| Rear wheel splash guards | 160 |
| Headlight assemblies | 161 |
| Turn signal lights | 166 |
| Tail-lights | 167 |
| License plate light and bracket | 168 |
| Seat installation | 169 |
| Carpet installation | 172 |
| Seat harness installation | 173 |
| Final seat installation | 174 |
| Emergency brake boot installation | 174 |
| Shifter installation | 175 |
| Nameplate | 176 |
| Finishing touches | 177 |
| Headlight alignment | 177 |
| Alignment specifications | 179 |
| CHAPTER 3 - Performance reference material and technical support | 180 |
| Technical support | 181 |
| Factory Five Owners Group | 181 |
| Registration and titling | 182 |
| Wheels | 183 |
| Performance modifications | 184 |
| Helpful reference material | 194 |
| A final note about completed cars and car builders | 196 |
| Appendix A - Templates | 197 |
| — Carpet | 198 |
| — Rear tail lights | 199 |
| — Headlights | 200 |
| — Front turn signal lights | 201 |
| — License plate light | 202 |
| — Side exhaust cut-out | 203 |
| — Fuel neck flange | 204 |
| — Body buck | 205 |
| — Driveshaft | 207 |
| — Alternate drive pulley | 208 |
| — Fuse panel mount | 200 |
| Appendix B - Donor parts list | 210 |
| Appendix C - Roadster standard pack list | 213 |
| Appendix D - Big block instructions | 225 |
| Appendix E - 3-link instructions | 234 |
| Appendix F - Independent rear suspension | 240 |
| Appendix G - Torque specifications | 259 |
| Appendix H - Mustang specifications | 261 |
