FFR Roadster

EFI 9-pin Connector

2010-01-17T08:46:19-06:00

The EFI interface to the dash is primarily made through a 9-pin connector, as illustrated below. [9-pin connections ]

Accelerator Pedal

2010-01-17T08:46:18-06:00

[Spacer added to pivot assembly of accelerator pedal] The FFR accelerator pedal requires some modification to work optimally with the EFI setup. Take the pedal apart by unscrewing the hex bolts that hold the pivot assembly covers. The pedal position must be set by removing the throttle cable arm and changing its pivot point on the rotating pin. Mount the pedal and note the cable arm movement which should stop just before the cross bar on the chassis.

Fuel Tank Access

2010-01-17T08:46:18-06:00

Background [Tank access positions] The OEM Mustang tank is strapped underneath the rear chassis tubing. Unless access to the fuel level sending unit and the in-tank EFI fuel pump is made available through the trunk aluminum panel, the tank must be dropped for any maintenance work.

Graduation Announcement

2010-07-16T15:31:44-06:00

The FFCars forum maintains an Official FFCars.com Class list of graduates as a discussion thread. While there are no strict definitions of what constitutes “graduation”, there is a consensus that the Roadster must be painted and legally registered to qualify. About 650 Roadsters have documented their graduation on FFCars.

Aluminum Treatment

2010-01-17T08:46:17-06:00

Anodizing vs powder coating Both processes treat metal that results in a smooth, protective surface. Here is a summary comparison of the two technologies. Issue Winner Comment Endurance tie anodized surface can scratch, powder coating can chip or crack Color Powder coating more color choices, colors do not fade, and color is consistent Fit Anodizing light, thin protective layer that does not change dimensions, panels will not crack if bent Metallic appearance Anodizing powd…

Body Badges

2010-01-17T08:46:16-06:00

The 3.1 Complete Kit includes three round 2 3/8” enameled metal badges with 3M trim adhesive tape on the back. One badge is placed on the steering boss center, and the other two are traditionally positioned on nose and lower truck, or deck area (see discussion below). These badges traditionally represent the make or manufacturer of the vehicle.

Automotive Electricity

2010-01-18T07:57:51-06:00

See also Switches, Relays, Fuses and Diodes and Wire Specifications section. Automotive electricity concepts can be easily understood using a water analogy. Imagine a water tank with an internal pressure pump connected to a pipe, narrowed at the end, that is positioned to drive a water wheel.

Battery Box

2010-01-17T08:46:15-06:00

[Battery box] The FFR Complete Kit includes a black plastic battery box mounted in the trunk compartment. This placement is difficult to access, requires a long battery cable back to the engine, and provides relatively poor weight distribution since the battery is high on the trunk floor.

Battery Box with Chassis Ground

2010-01-17T08:46:15-06:00

[Battery box] The Battery Box has previously been fit for installation, and then powder coated. Complete the installation: * bolt and rivet box * secure battery with holding rods * measure carefully for chassis ground bolt Drill a 5/16” and tap it for the ground bolt. This bolt will act as both a ground for the negative battery terminal, and as a chassis ground for the engine block.

Battery Switch

2010-01-17T08:46:14-06:00

[Battery switch] A battery switch (Breeze EzePak) is an added safety feature that cuts off power from the battery and also provides mild theft protection; anyone not familiar with the switch and its location cannot start the car if the switch is off. However, sophisticated thieves may be quite aware of the switch, so even a hidden switch offers limited protection. A keep-alive fuse bypass is added to switch circuit to keep enough power on to maintain the EFI computer memory (but not start the …

Bleed and Adjust Brakes

2010-01-17T08:46:14-06:00

[Bleeding brakes] The brakes operate via hydraulic pressure generated by pressing on the brake pedal which, in turn, activates the brake master cylinders. If air pockets exist anywhere in the closed system, proper operation is impaired. Therefore, the brake lines must be “bled” to remove any air and/or small pieces of grit that might block the flow of brake fluid.

Ford Boss 302 Engine

2010-01-17T08:46:14-06:00

[Ford Boss 302] In late 2006 at the important industry Specialty Equipment Market Association (SEMA) show, Ford announced the revival of the BOSS 302 V8 engine configured as a crate engine for the aftermarket. A crate engine, actually delivered in a large wooden crate, is essentially a “ready-to-start” engine without ancillary systems like cooling, ignition, fuel delivery, and so on.

Emergency Brake Boot

2010-01-17T08:46:13-06:00

[Brake boot] See also Emergency Handbrake section. The vinyl brake boot supplied with the FFR Complete Kit is designed to fit the Mustang-style handbrake mounted along the passenger side transmission tunnel wall. This boot can be slightly modified to fit the Lokar handbrake mounted on the transmission tunnel top by trimming some of the edges and pinning the fabric under the handbrake oval bezel.

Brake Cables

2010-01-17T08:46:13-06:00

[Brake cables] The emergency brake system uses cables attached to the rear calipers (see rotor and caliper installation) that are routed to the Lokar handbrake (see Emergency Handbrake). The cables have a very tight fit near the caliper spring-loaded hold. Carefully manipulate the cables (they cannot be easily bent) to get by the buttonhead bolt just below the caliper mount (see photo) and then secure the cables to the lower control arm.

Brake Lines

2010-01-17T08:46:13-06:00

Refer to the brake system overview in the pedal box discussion. Front lines [Brake line bulkhead] Hard brake lines ∼ front and rear ∼ do not use any sealant or washers to make a leak-proof seal. Brake fittings use mechanical pressure by tightening the locking nut against a carefully formed flare shape on the line itself, so the joint is entirely metal-to-metal. Therefore, the flare itself is a critically important part of system integrity and safety.

Hub and Brakes

2010-01-17T08:46:12-06:00

Overview [UCA assembly] See Spindle and Bracket for prior assembly steps. The hub and brake assembly has six primary parts: 1) spindle 2) hub attached to spindle shaft 3) rotor attached to hub 4) brake caliper bolted to spindle 5) brake shoes fitted into caliper 6) hub nut and dust cap Production Mustangs and other vehicles use dust shields between the brake rotor and the suspension assembly, mostly to protect the rotor from grease.

Breeze Engine Setup

2010-01-17T08:46:12-06:00

The aptly named Ford Racing crate engine (part of the Breeze EzePak) arrives in a wooden crate. Most residential deliveries will require lift gate service, which means that the truck lift gate can be slowly lowered to ground level to facilitate offloading of the 450 lb crate. If the crate pallet is placed directly on the shop floor it is difficult to position an engine hoist underneath it for the lifting operation.

Build Budget

2010-05-21T14:53:11-06:00

This pro-forma Mk3.1 non-donor build budget reflects kit and part prices as of April 2008, excluding shipping and taxes. Amounts are rounded to the nearest $100. Excludes build school, tools and supplies, vehicle registration fees, vehicle sales tax, builder labor cost (approximately 650 to 900 hours) and any other professional services (like welding, vehicle transport, suspension alignment and dyno testing). This represents a realistic cost estimate for the Roadster described on this site (se…

Build Objective

2010-05-21T14:58:03-06:00

A period-correct street oriented version of the 1965 AC Cobra (see Legacy of the FFR Roadster), incorporating current technology that improves performance and safety without impacting vintage look and feel, is our objective. See original 1963-67 Cobra specifications and the specifications for this build. Vintage details include:

Exhaust Headers

2010-01-17T08:46:10-06:00

Oxygen bungs [Welded oxygen bungs] Electronic Fuel Injection (EFI) requires accurate oxygen readings in the exhaust stream to function properly. At operating temperature, an oxygen sensor, mounted to sample the exhaust, becomes a miniature battery that generates a voltage based on the differential between the oxygen content of exhaust gases and the ambient air. Accurate monitoring of this differential permits the EFI computer (ECM) to compensate for various fuel grades, engine wear, and altitud…

Gauge Calibration Patch Panel

2010-01-17T08:46:10-06:00

[Patch panel] The vintage electronic gauge set requires calibration for three instruments: * speedometer for distance, as well as resetting trip and contrast options * tachometer for number of revolutions for proper reading * clock for setting time * fuel level for setting both full and empty conditions

Carpet Overview

2010-01-17T08:46:10-06:00

The carpet installed in the Roadster should be fire retardant and reasonably water/mildew resistant. Most commercial automotive grade carpet is made of nylon or rayon/nylon blends. Carpet should be installed after the body shell has been removed for painting, but before the finished shell is mounted back on the chassis. See also Road, Sound and Heat Protection and Heat and Vibration sections. Carpeting the cockpit and trunk requires slightly less than 10 square yards (automotive carpet is …

Clear Coat

2010-01-17T08:46:09-06:00

The final step, other than buff and polish, in the paint process is clear coating. Clear coat, as the name implies, is paint without pigment.

Clutch

2010-01-17T08:46:09-06:00

The clutch mechanism is initially assembled in two parts: * clutch disc and pressure plate attached to the flywheel * clutch fork and release bearing attached to the bellhousing [Clutch] Disc and pressure plate The Breeze EzePak includes the clutch disc, pressure plate, and fasteners. One side of the clutch disc is marked flywheel side or equivalent. Position the disc correctly with a clutch pilot (also called alignment) tool.

Clutch Cable

2010-01-17T08:46:09-06:00

[Clutch cable] The clutch cable runs from the clutch quadrant in the pedal box, through the adjustable fitting in the footbox front wall, and then around the 302 exhaust headers to the clutch fork in the transmission body. Space is tight. The clutch cable should not contact or interfere with the steering shaft or wiring, and there should be enough clearance between the exhaust headers and the cable so that radiant heat is not a concern.

Cockpit Panel Assembly

2010-01-17T08:46:08-06:00

The cockpit is assembled from 14 aluminum panels: * FFR 10557: LH cockpit floor with tunnel wall (seat mount is not installed) * FFR 10558: RH cockpit floor with tunnel wall (seat mount is not installed) * FFR 12806: transmission tunnel front vertical wall * FFR 10823: rear cockpit vertical wall (behind seats) * FFR 13642: RH cockpit under door side wall * FFR 13641: LH cockpit under door side wall * FFR 14579 and FFR 14581: RH rear splash covers, upper and lower * FFR 14578 an…

Cockpit Overview

2010-01-17T08:46:08-06:00

[Cockpit overview] The Mk3.1 cockpit is compact and efficient. All controls are within easy reach. A steering column mounted self-canceling turn signal switch and high beam flasher (cannot be seen in photo) replaces inconvenient toggle switches. The battery cutoff switch is under the dash, but still a short reach for the driver.

Footbox Panel Assembly

2010-01-17T08:46:08-06:00

The right and left footboxes are assembled from 11 aluminum panels and two front cockpit firewalls: * FFR 14749 for the Wilwood pedal assembly (discard FFR 10904 mounted on the chassis) * FFR 10559: front firewall * FFR 12985: LH footbox dropped floor * FFR 10554: LH footbox outside vertical wall * FFR 10858: LH footbox outside top * FFR 10905: LH footbox inside vertical wall * FFR 10859: LH footbox inside top with FFR 14733 patch * FFR 10963: RH firewall extension * FFR 1313…

EEC-IV Diagnostic Trouble Codes

2010-01-17T08:46:07-06:00

Background In 1986, Ford's Mustang 302 cubic inch (5.0L) engine introduced Sequential Electronic Fuel Injection (SEFI) controlled by a fourth generation Electronic Engine Control (EEC), known as EEC-IV. A decade later, the 281 (4.6L) engine used a more powerful fifth generation EEC, or EEC-V, programmed to meet the federal On-Board Diagnostics (ODB) generation 2 (OBD-II) standards. The 302 engine in this build utilizes the older EEC-IV codes.

Complete Engine Bay

2010-01-17T08:46:07-06:00

[Engine bay #1]

Switches, Relays, Fuses and Diodes

2010-01-17T08:46:07-06:00

See also Automotive Electricity section. The automotive electrical system is a collection of wires — when bundled together referred to as a harness — that is regulated with relays and switches, and protected with fuses, to control various components, like lights, starter motor, alternator, and so on.

Mass-Flo EFI Electronics

2010-01-17T08:46:06-06:00

Overview [Overview] The electronic fuel injection system incorporates, in effect, a second harness assembly that must be installed and integrated into the FFR/Ron Francis electrical system harness. The FFR/Ron Francis harness enters the cockpit from the driver side, near the steering shaft. The EFI harness enters from the passenger side through the firewall extension grommet hole.

Terms of Use

2010-02-14T20:56:18-06:00

As a visitor to, or registered user of, Mk3Build.com or Mk4Build.com (Sites), you agree to the following terms and conditions. Copyright All materials contained on this site are protected by United States copyright law and may not be reproduced, distributed, transmitted, displayed, published or broadcast without the prior written permission of Kriss Motors Corporation (email ) or in the case of third party materials, the owner of that content. You may not alter or remove…

Covers and Patches

2010-01-17T08:46:05-06:00

A number of small aluminum pieces are provided in the Complete Kit. The following were previously installed as part of the aluminum fabrication: * FFR 14733: driver footbox * FFR 13855: used for ebrake cover, see Emergency Brake Bracket * FFR 12274: transmission tunnel patch, see Fresh Air Vents * FFR 13713: F-panel block-off plate

Radiator Cowling

2010-01-17T08:46:05-06:00

This section describes a new cowling design that replaces three FFR radiator panels: * FFR 10865: front nose guard * FFR 10907: LH front nose wall * FFR 10908: RH front nose wall [Cowling design] The Breeze hood hinge main brace rests on the square tubing that runs from the radiator cross tube down to the quickjack/body front chassis mount. This brace requires that the side radiator panels either be modified with slits to fit around the brace footings, or substituted with new panels fas…

Customizations

2010-05-21T14:56:40-06:00

Optional parts The following excludes hard and soft tops, tonneau, and car storage covers; see also orders. Alphabetical order by vendor; alternatives indicated by matching numbers, ie. => 1. OPTIONAL PARTS included in this Mk3.1 build Part Description Vendor, SKU Cost wheel well liners => 2 AC Interiors $185 traditional hood hinge kit Breeze EzePak ¹ seat mounts, tilt and adjustment Breeze EzePak ¹ hidden trunk hinges Breeze 35200 $129¹ trunk prop rod kit Breeze 35247 $…

Rear Axle and CV Joints

2010-01-17T08:46:04-06:00

The two rear axles, inserted into the “ears” of the differential, are packaged with the FFR Complete Kit, but the CV joints and various other IRS completion parts are drop shipped directly from an FFR supplier. [Axle and hardware] Layout the axle with the matching hardware:

Dash Overview

2010-01-17T08:46:04-06:00

History Vintage Cobra models — 289, 427, and other variants — offered a wide range of dash layouts, from street versions with a right-hand oval glovebox and grab bar to competition dashes with dymo-type switch labels and a blank right side. [427 Cobra CSX3282 dash][Vintage dash] The Mk3.1 Complete Kit's pre-cut dash mirrors the 1965-66 Cobra 427 street style instrument layout with (from left to right):

Dash Construction

2010-02-13T20:46:48-06:00

Black vinyl The Mk3.1 Complete Kit includes foam rubber-backed black vinyl covering material for the dashboard panel. [Cut holes in vinyl][Vinyl cover] On a flat surface, lay the aluminum dash over the back of the vinyl cover so that the white backing shows through the holes in the panel. Dash covering should be glued in place only after all gauges and switches have been trial fitted.

Dash Wiring

2010-06-17T18:27:58-06:00

The vintage style FFR electronic gauges and the Russ Thompson turn signal system must be integrated with both the MassFlo EFI and Ron Francis/FFR harnesses. None of these separate products were designed, out of the box, to work with each other.

Dash End Fit

2010-01-17T08:46:02-06:00

See also Dash Overview and Dash Construction sections. [Dash end] The ends of the vinyl-covered dash do not need to be secured to the chassis. After re-mounting the painted body, the dash ends may need to be adjusted to precisely fit under the body contour as it slopes down to the door opening.

Dead Pedal

2010-01-17T08:46:02-06:00

Background [Mk3.1 chassis showing the footbox tubing] The Mk3.1 cockpit is small, and foot space is especially limited. For longer trips, there is no comfortable rest for the left (clutch) leg and foot. To remedy this, many builders have installed dead pedals.

Making Decisions

2010-01-17T08:46:02-06:00

[Decision tree] Organizing and understanding the basic decisions to be made in launching a home-built car project can be both daunting and confusing. It may be helpful to think through the broad, fundamental decisions before getting into the hundreds of possible customizations and options.

Run Diagnostic Codes

2010-05-02T07:29:14-06:00

[Equus 3145 code reader] The computer included with the Mass-Flo EFI system uses various sensors to manage and report on all aspects of engine operation, from cold start to WOT (Wide Open Throttle). The computer reports out digital codes, in either 2- or 3-digit format, that can be easily read by connecting a code reader such as the Equus 3145 to the self-test connector under the passenger side dash.

Differential

2010-01-17T08:46:01-06:00

[Differential pumpkin] The 3.1 Complete Kit differential is drop shipped “dry” (without oil) about six weeks after initial delivery with the case vent packaged separately in a plastic bag. [Mounting platform] When the 3.1 Complete Kit with IRS was first released, it was shipped with a 3.55 ratio Eaton Detroit Truetrac limited-slip differential in an iron housing and aluminum cover. The Truetrac helical gear design substantially reduces gear friction, does not require a friction modifier ad…

Distributor

2010-01-17T08:46:00-06:00

[Distributor] Before final installation of the distributor, mount the coolant temperature gauge sensor (see Sending Units). Check that the engine is at Top Dead Center (TDC) on the compression stroke for cylinder 1 (front passenger side). Coat the distributor gear with a moly-based lube and install the distributor with the rotor aligned with the cylinder 1 plug wire post. Cylinder 1 is identified by an etched 1 on the side of the distributor bowl.

Distributor Timing

2010-05-26T07:23:56-06:00

As part of the EFI assembly, the distributor should already be positioned at approximately top dead center (TDC). After the first start, warm up the engine to the normal operating temperature and turn the engine off. For optimal performance, the timing on the distributor must be set more precisely than the initial positioning. The exact setting is often worked out in a trial-and-error procedure, but 14-16° BTDC (before top dead center) is a good starting point for the Boss 302 engine according…

Doors and Bottom Trim

2010-01-17T08:45:59-06:00

[Door trim]

Flywheel Dowel Pins

2010-01-17T08:45:59-06:00

includesnot [Dowel pins] Some Ford Racing 302 engine models do not include three centering dowel pins inserted into the flywheel. If required, the pins are part of the Breeze EzePak. Place the flywheel on a level flat surface, and support the sides so the flywheel can be hammered without moving.

Chassis Weep Holes

2010-03-24T13:08:39-06:00

Drill 1/4” weep, or drain, holes in the bottom of the main chassis tubing. These holes will help keep moisture out of the interior of the chassis tubing that can leak in through rivet holes and other small openings. The chassis tubes are not coated on their inner diameters, and will rust from the inside out if moisture is trapped for extended periods of time. The purpose of the weep holes is to minimize standing water in the tubes; some surface rust on the tube interiors is inevitable, but …

Do You Really Want One?

2010-02-14T09:53:47-06:00

[February 2009 Moochfest] Building the FFR Roadster for most is a fascinating, absorbing project, filled with challenges (and - yes - frustrations, too), that ultimately yields a great sense of personal achievement and satisfaction. Driving a 1965 AC Cobra replica may be, for some, a very different experience than the build itself.

Driving Technique

2010-01-17T14:00:06-06:00

The FFR Roadster does not handle like a mass-market sedan or even a high performance sports car, e.g. a Porsche, BMW, or Jaguar. Most FFR builders are not professional drivers, and many have limited, if any, track experience. Handling characteristics should be appreciated in a step-by-step, cautious manner.

Engine Drop-in and Drive Shaft

2010-01-17T08:45:58-06:00

Mounting preparation Before dropping in the engine, bolt the A-frame transmission platform onto the chassis positioning tabs, and also attach the transmission mount under the end of the T5 transmission. After the transmission is seated in the Cobra, two bolts, attached from under the chassis, will pass through holes in the A-frame platform and screw into the underside of the transmission mount.

Driver Footbox Finish

2010-01-17T08:45:58-06:00

[Driver side footbox carpet] There are many ways to finish the driver side footbox which is bisected by curved tubing along the dropped floor. This tubing creates an awkward and useless triangular space in the left front corner. The tubing can be left exposed for a functional racing look, or covered for a street appearance. Footbox space is limited, with little room between the right edge of the accelerator pedal and the inside wall. With sound and heat insulation, the space narrows even m…

Ear Protection

2010-01-17T08:45:57-06:00

Apart from frequent attendance at rock concerts, driving a Roadster is perhaps the loudest thing one can do in daily living. While some enjoy the raw sound and the power that it implies, most owners will wish to prevent long-term hearing loss and the annoying ear ringing, or tinnitus, that can result from high decibel exposure.

Emergency Brake Bracket

2010-01-17T08:45:57-06:00

The Complete Kit includes an OEM Mustang emergency brake which is mounted on the passenger side of the transmission tunnel on a bracket welded to the chassis that protrudes through the transmission wall. Since this build will replace the OEM ebrake with a Lokar ebrake mounted on the transmission tunnel top, the bracket will be removed, and the hole in the transmission tunnel wall will be patched.

EFI Wiring Harness

2010-01-17T08:45:57-06:00

An EFI installation is, from a wiring perspective, much more complicated than a carb engine setup. The following drawing outlines the approximate engine bay connection points for the Mass-Flo EFI harness. Numbers refer to the Mass-Flo documentation of the harness layout.

EFI Fuel Lines

2010-01-17T08:45:56-06:00

The Breeze EzePak EFI Fuel Line kit contains all the rubber hose and fittings required to plumb the EFI system. Use Loctite Pipe Thread Sealant (PST) on all tapered pipe fittings. Refer to the fuel lines and filter section for an overview of the fuel delivery system.

Emergency Handbrake

2010-05-21T14:57:45-06:00

OEM Mustang brake handle [OEM Mustang ebrake] The Mk3.1 Complete Kit includes the Ford Mustang emergency brake handle and older pre-SN95 brake cables. Due to the flat handle mounting system used in the Mustang, this OEM ebrake is mounted on the passenger floor abutting the right transmission tunnel wall with the cables routed under the chassis tubing.

Alternator

2010-01-17T08:45:55-06:00

3G, 95 amp model In the mid-1990s, Ford replaced the 2G alternator, implicated in some car fires, with a more powerful and better cooled 3G model. Except at low RPM, the 3G outputs approximately 25% more amperage than the older 2G, more than enough to handle the requirements of the Mk3.1 Roadster.

Engine Bay Panels

2010-01-17T08:45:55-06:00

After powder coating (or anodizing), test fit engine bay panels with temporary fasteners (cleco) prior to final riveting :!: 65-70. If desired, a rubberized undercoating will minimize the ping sound of road debris on the floor panels. Mark the chassis tubing pattern on the floor panels (just like the procedure for marking the rivet drill holes) and mask it. Then spray the panel underside (see Road, Sound and Heat Protection) with a rubberized coating. Do not get the rubberized coating where t…

Engine Block Holder

2010-01-17T08:45:55-06:00

[Engine block holder] The first task involving the Ford Racing 302 engine (part of the Breeze EzePak) is to swap out the oil pan. This requires mounting the engine on an engine stand so that it can be rotated 180° for a proper oil pan attachment.

Engine Mounts

2010-01-17T08:45:54-06:00

[Engine mounts] The FFR 3.1 Complete Kit includes two engine mounts that bolt to the Ford Racing 302 engine. Note that the two mounts are similar, but not identical. Before bolting to the engine, trail fit the mounts on the chassis as shown in the photo at right.

Engine Bay and Finishing Panels

2010-01-17T08:45:54-06:00

The engine bay, in addition to the footboxes, is assembled with 7 panels: * FFR 10864: LH engine bay wall “F” * FFR 10863: RH engine bay wall “F” with patch FFR 13713 * FFR 10861: LH splash guard (not shown) * FFR 10862: RH splash guard (not shown) * FFR 10865: front nose guard (not shown, see replacement cowling) * FFR 10907: LH front nose wall (not shown, see replacement cowling) * FFR 10908: RH front nose wall (not shown, see replacement cowling)

Engine Start

2010-05-21T14:57:25-06:00

Prior to the first engine start, add all necessary fluids: radiator coolant, engine oil, transmission fluid, rear end differential oil, and brake fluid. Check carefully for leaks. Add a small amount of 90-91 octane gasoline to the tank and temporarily cap off fuel tank hose to reduce fumes. If the driver seat is not in, temporarily secure it in place.

Fasteners

2010-01-17T08:45:53-06:00

Definitions US/English fasteners US and English fasteners are described by material, head style, and type followed by or preceded by the diameter dash thread count (machine threads only) X length. The diameter and length are in inches except small sizes that usually notated with a # sign, like #12, with a thread count. Nuts used the same diameter and thread count, but obviously drop the length variable. The Society of Automotive Engineers (SAE) maintains a common standard for bolt sizes defin…

FFR Assembly Manual

2010-02-10T07:11:35-06:00

[FFR Assembly Manual cover][FFR Assembly Manual digital version] 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 distrib…

Fiberglass Shaping

2010-01-17T08:45:52-06:00

If duct tape or shipping labels remain on the shell, remove them. Use acetone to remove any sticky residue (but only on unsanded gel coat surface). Wash the shell with soapy water and towel dry. Do not apply any wax to the body. Fit doors, trunk, and hood just enough to facilitate transportation to the painter; the hood, which is slightly oversized, can be left off the body at this stage.

Coolant Fill Port

2010-01-17T08:45:52-06:00

[Coolant fill] The Breeze EzePak simplifies the FFR cooling system configuration by providing a T-fill and bottom fed, two-quart overflow bottle combination that efficiently runs from the thermostat port, through an elbow tube, into the T-fill with pressurized cap, and on to the top of the radiator.

Filler Neck

2010-01-17T08:45:52-06:00

[Filler neck] At the shell preparation stage, connect the metal fuel filler neck (see also Gas Tank discussion) with the supplied rubber hose to the fuel cap, and then attach the ground wire to the chassis. Disconnect the hose and ground wire before removing the shell for painting.

Painted Body Mount

2010-04-06T21:31:33-06:00

[Completed go cart][Fender shim] All operating systems and the interior finish, with the exception of the under-door panels and carpet, should be completed before the painted body is mounted for the final time. Once the body is on, check all panel edges and bulb seal to make sure that the fiberglass is seated properly. Check the position of the dash ends. These will be tucked under the body contour and held in place behind the door hinges. Initially, make sure that the dash ends are not obst…

Fire Extinguisher

2010-01-17T08:45:51-06:00

[Fire extinguisher] A recommended safety accessory is a cockpit-ready fire extinguisher. Since the transmission tunnel is used for the re-positioned handbrake, and the front of the tunnel needs to open to allow access to the battery cutoff switch, the best location for the extinguisher is on the slanted tunnel end piece between the two seats.

Firewall Attachments

2010-01-17T08:45:51-06:00

[Mounted firewall components] The following components are mounted conveniently on or near the engine bay firewall (from left to right): * EFI fuel regulator (wires from EFI fuse pass behind regulator) * chassis ground for EFI harness and engine block (only EFI ground connection shown) * brake fluid reservoirs * battery switch * EFI fuse; positive connection to battery switch, negative to chassis ground * rear harness (pass through from pedal box to transmission tunnel) * solenoid…

Front Footbox Panel

2010-01-17T08:45:50-06:00

[Front panel detail] Assembly of mechanical controls begins with the front driver side (DS) footbox panel. The panel that is pre-attached and shipped with the chassis must be removed and replaced with the panel designed for the Wilwood pedal assembly (FFR 14749).

Footbox Panel Modification

2010-01-17T08:45:50-06:00

[Modified footbox side panel] The engine bay side panel of the driver footbox must be modified for rear harness and brake reservoir hose pass-through.

AC Cobras For Sale

2010-02-13T07:07:58-06:00

The following consolidated listing from online sources covers complete vehicles only. Partial builds, raw kits, and parts are excluded.

Preliminary Front Alignment

2010-06-16T13:17:06-06:00

A preliminary front end alignment must be made with tires mounted on the front and rear. Note that FFR front alignment specifications are slightly different for independent rear suspension builds. Ride height The FFR recommended Roadster ride height is 4.5”, although a different height may be optionally set. The following alignment adjustments are made assuming a 4.5” ride height. Ride height is measured from the bottom of the main chassis tubing to the road surface.

Front Harness

2010-01-17T08:45:49-06:00

[Front harness] The Ron Francis front harness connects to the main harness in the pedal box area and passes through a grommet in the front the driver side footbox. Run the front harness up along the top chassis strut, notch the driver side F-panel, and continue the harness along the left side of the strut down towards the radiator left bottom edge.

Front Koni Shocks

2010-01-17T08:45:49-06:00

Overview [UCA assembly] The Mk3.1 Complete Kit includes custom-engineered Koni brand adjustable coil-over shock kits. The larger red shock body requires 2.5” x 8” springs with 500 lb front and 750 lb IRS rear tension specifications. Refer to new FFRfront Koni assembly instructions that apply only to Koni shocks.

Fuel Lines and Filter

2010-01-17T08:45:49-06:00

The fuel system, including hard and soft lines, connects the fuel tank to the electronic fuel injectors, as outlined in the diagram. [Fuel system overview] Fuel pump [Breeze fuel pump] A fuel pump, which generates positive pressure in the fuel lines, forces gasoline to the engine. The higher gasoline pressure in an EFI system raises the boiling point of the fuel, and increases engine efficiency. As a result, EFI engines run slightly hotter than normally aspirated (carb) ones.

Fuel Pump

2010-01-17T08:45:48-06:00

See also Gas Tank, Fuel Lines and Filter, Dash Overview, Wiring Overview, and Rear Wiring Harness sections. The following diagram shows the electric fuel pump sub-system linked into the EFI Mass-Flo harness and computer. [Fuel pump wiring detail]

Mass-Flo Fuel Components

2010-01-17T08:45:48-06:00

The Mass-Flo intake manifold was installed on the engine block previously. With the engine now seated in the engine bay, the EFI assembly can be completed. All openings on the intake manifold should be covered with duct and/or masking tape to prevent screws and other small parts from falling into the engine.

Ron Francis Fuse Box

2010-01-17T08:45:48-06:00

[Fuse box] The FFR/Ron Francis harness system includes a fuse box mounted directly in back of the pedal assembly and attached to the underside of the footbox top chassis tubing. First, mount the fuse box to the face plate (the relays may need to be slightly pulled up to move the plate into position). Second, clamp the fuse box plate in its approximate position as shown in the photo. Then, layout the main harness to make sure it clears the firewall opening on the drive side.

Fuse Box Modifications

2010-01-17T08:45:47-06:00

In order to integrate the Ron Francis/FFR and MassFlo EFI electrical systems, the FFR fuse box must be significantly modified. [Fuse box modifications] In the diagram above, the dashed gray line indicates that the functionality has been eliminated by either removing the fuse, cutting the incoming wire, or both.

Fuse Box Wiring

2010-01-17T08:45:47-06:00

See also Integrate Harnesses and Fuse Box Modifications sections. The following diagram shows the Ron Francis/FFR and Mass-Flo EFI fuse/relay block connections and how they integrate with each other, and with switches, gauges, and harnesses. [Fuse wiring]

Trunk Floor Gap

2010-01-17T08:45:47-06:00

Depending on body and chassis tolerance variances, the rear of the body shell may not match up precisely to the end extension, or lip, of the trunk floor panel, creating a small gap of about one inch. If left open, this gap compromises the trunk interior because moisture and road depris can penetrate the otherwise closed compartment.

Footbox Gap Fills

2010-01-17T08:45:47-06:00

[Front fill gap][Front fill gap] Before putting on the body, a few small gaps in the panel construction should be filled. The cutout for the brake lines in the front wall of the driver side footbox has an L-shaped filler plate. Make any required modifications for special brake lines, and rivet in place.

Gas Tank

2010-03-15T10:08:34-06:00

Background [Mounted tank] The 3.1 Complete Kit includes a 1987-1998 OEM style Mustang gas tank in a fuel-resistant black finish with a high-impact black plastic debris shield, moisture drainage holes, and the following related parts: * steel mounting straps and fasteners (see photo at right for position) * fuel level sending unit with gasket and locking ring * fuel vent with gasket * 3/8” send lines matched to filter * click-on tank to filter nylon fuel line, click-on filter to barb …

Gauge Calibration

2010-06-06T14:55:03-06:00

The classic electronic gauges included with the Complete Kit are private labeled for FFR by SpeedHut. Use the patch panel to calibrate these FFR electronic gauges: * clock * tachometer * speedometer * fuel level The oil pressure, voltmeter, and water temperature gauges do not require calibration.

Gauge Wiring

2010-06-17T18:24:14-06:00

See also Dash Overview, Dash Construction, and Dash Wiring sections. The diagram outlines connections for the FFR electic (or electronic) gauge set manufactured by Speed Hut for Factory Five that is an option with the Mk3.1 and Mk4 Complete Kit.

Gel Coat Body

2010-01-17T08:45:45-06:00

The black surface of the unfinished FFR body shell is gel coat, a pigmented .015” resin layer that protects the vinylester shell. The body at this stage is thus generally referred as “gel coated” or “in gel coat”. [Wax paper helps to mount the gel coat body] The gel coat body must be mounted on the chassis prior to final prep and paint, then removed, and finally mounted again after the body has been painted. The gel coat mounting is required to properly attach the windshield (also called the wi…

Gel Coat Test Drive

2010-01-17T08:45:45-06:00

[Prep of gel coat before test drive] Before the body shell is removed for painting, test drive the Roadster extensively. There are many repairs and changes that are much easier to do before the final painted body installation. Because the hood section is slightly oversized (it will be sized to fit during the painting process), leave the hood off during the road test.

Go Cart Test Drive

2010-01-17T08:45:44-06:00

[Test drive] The “go cart” stage describes the Roadster when it can operate under power but where the body and various assemblies, like lights, wipers, and fuel cap, are still off the chassis. Testing the go cart is important since some problems can be much better addressed without body and supporting panels in the way.

Electrical Grounds

2010-01-17T08:45:44-06:00

[Chassis ground] Fiberglass body vehicles, like the Mk3 Cobra, have a disadvantage when it comes to wiring: the body cannot be used as a common ground, which means that all grounds must be directly connected to the metal chassis. Without a proper ground, the electrical system will not work.

Road Handling Adjustments

2010-01-17T08:45:44-06:00

Now that the Roadster is built, licensed, and road tested, it is still only 99% complete. The remaining 1% — debugging and fine adjustments — may take time to diagnose and correct. About 500 miles of driving, at less than 75 mph, will be required to make sure that brakes, clutch, engine, and other systems are working properly in a variety of conditions. The EFI computer will also need some time to calibrate properly, and the vehicle in general needs to “settle in”. Periodically check critical…

Safety Harness

2010-01-17T08:45:43-06:00

[Rear belt roll] See also Seat Belts section. The shoulder belts are purposely cut long, and the excess material should be rolled up and stored so that it does not interfere with the use of the trunk. The side and anti-submarine belts should be securely fastened in place.

Headlamp Adjustment

2010-01-17T08:45:43-06:00

[Headlamp alignment] There are two adjustment screws located under the chrome trim ring of the headlight assembly. Vehicles with improperly aligned lights may fail state inspections. Remove any heavy items from the trunk. The car should have about 7-8 gallons of gas in the tank and testing should be conducted with the usual driver in the driver's seat to reflect the average effective curb weight.

Headlight Switch Connections

2010-06-17T18:25:58-06:00

[Headlight switch detail] The Complete Kit includes a push-pull type of headlight switch that connects directly to the Ron Francis harness. To properly operate the Russ Thompson turn signal assembly, the switch 2 power feed from the fuse box side must also be wired into a distribution block on the dash.

Heat Shields

2010-01-17T08:45:42-06:00

[Heat shields] A notable distinctive feature of the 1965 Roadster is the racing-style exterior side pipes. Experienced drivers will know how to enter and exit the cockpit without getting severe calf or shin burns, but passengers will not realize how dangerous the pipes are, especially when getting out of the seat, an awkward procedure for most.

Hood Hinge

2010-01-17T08:45:42-06:00

[FFR hood hinge] The FFR hood hinge assembly for the Mk3.1 mounts behind the radiator with a two-arm design that uses gas struts to support the hood. Over time these struts can exert a pulling pressure on the hood piece which may result in a warp or deformation of the original contour.

Hood Scoop Modification

2010-01-17T08:45:42-06:00

[Hood scoop] The FFR hood piece incorporates the air scoop in a single mold whereas vintage Cobras featured a separate scoop riveted to the hood. FFR sells a separate vinylester scoop that replaces the single mode to replicate the period-correct appearance. The template guide below shows rivet placement.

Horns

2010-01-17T08:45:41-06:00

[horn button] See also Dash Overview, Dash Construction, Wiring Overview, Front Harness, Fuse Box Wiring and Dash Wiring sections. The Mk3.1 Complete Kit includes dual high and low note horns mounted on the engine bay X-member. The horn button is inserted into the dash panel.

Independent Front Suspension

2010-06-06T14:59:47-06:00

Parts Each front wheel independent front suspension (IFS) has the following components: * Lower control arm assembly, standard (non-pin drive) 15” width, FFR Photo * Front Lower Control Arm Bushing Kit, Breeze Photo * Upper control arm assembly, FFR Photo * Front spindle assembly, FFR Photo * Front brake kit, FFR Photo * Koni coil-over shock kit, FFR Photo

Ignition Switch

2010-01-17T08:45:41-06:00

The key-operated ignition switch is one point where the Ron Francis/FFR and EFI harnesses are joined (see also Integrate Harnesses and EFI 9-pin Connector discussions). The FFR ignition switch has four terminals labeled as follows: * IGN * ACC * BAT * S

Inspection and Body Removal

2010-01-17T08:45:40-06:00

Check chassis The FFR chassis is manufactured on a jig but no two chassis are exactly identical. Tolerances should generally be within an 1/8” or so. Carefully adjust the four jack stands holding the chassis so that they are exactly under the main round tubing and spaced equally. Make sure that all jack stands are set at the same height (any height is fine, but they all need to be the same).

Road, Sound and Heat Protection

2010-01-17T08:45:40-06:00

Anodizing or powder coating aluminum panels provides general protection against corrosive chemicals, road salt, flying pebbles, and other normal road debris. The Mk3 can be additionally protected by applying various spray-on or glue-on products in a number of vulnerable areas. Heat insulation, especially on the interior surfaces of cockpit footboxs and firewall, eliminates driver hotfoot and generally lowers cockpit temperatures in hot weather. Sound deadening, especially on the interior cockpi…

Auto Insurance

2010-01-17T08:45:39-06:00

Like a daily driver, the Roadster will require motor vehicle insurance. Minimum coverage requirements vary by state, and a preliminary review can be accomplished by visiting the appropriate state department or registry of motor vehicles. In general, you will need liability, personal injury, uninsured motorist, and collision/comprehensive coverage on the value of the Cobra itself. In most cases, the insurance levels carried on daily drivers should provide a guide for Roadster limits.

Intake Manifold

2010-01-17T08:45:39-06:00

[Intake gasket] A special EFI intake manifold for the Ford 302 engine is included in the MassFlo EFI system, part of the Breeze EzePak. Inspect the intake manifold for metal chips and depris; clean carefully with acetone. Also, remove the duct tape protecting the cylinder head mating surface that rises from the lifter valley on the Ford 302 (the engine has been rotated 180° since the oil pan installation so this is now facing up), and clean with acetone.

Integrate Harnesses

2010-01-17T08:45:39-06:00

The Ron Francis (Francis) harness supplied in the FFR Complete Kit and the MassFlo EFI (MassFlo) harness supplied with the Breeze EzePak must be integrated at several points for optimal performance (see fuse box modifications for wiring diagram):

Rear Suspension

2010-03-14T13:50:45-06:00

Alternatives There are four possible rear suspension configurations for the Mk3.1 Roadster: * 4-link solid axle (FFR Mk4 Base Kit includes rear axle brackets, fasteners and axle straps to mount a Mustang 8.8” rear solid axle and brakes which must be supplied separately) * 3-link solid axle (FFR Mk4 Complete Kit) * 5-link solid axle (Levy Racing) * independent rear suspension ($2,250 upgrade to FFR Mk3/Mk4 Complete Kit)

IRS Control Arms, Spindle and Rotor

2010-01-17T08:45:38-06:00

Spindle finish The spindle provided by FFR is unfinished, unlike all the other IRS parts. Prepare the spindles and spray paint them black prior to installation. [Finish the spindles] LCA orientation [Check LCA orientation] Assemble the upper and lower IRS control arms. Make sure that the left and right LCAs are attached to the correct side of the Cobra. If the shock mounts are above the LCA (as in the photo), this is not the correct orientation. The lower shock mounting must have the bolt …

Kit Car Manufacturers

2010-01-17T08:45:37-06:00

This is a listing of AC Cobra replica kits only. Distributors, spec builders, turnkey vendors who supply a complete vehicle, and so-called rolling chassis finished vehicles sold without installed engine/transmission are not included. Foreign manufacturers are also excluded due to shipping and other logistical issues.

Hood Latch

2010-01-17T08:45:37-06:00

The hood is secured in place with two keyed latches. The vintage placement is at the rounded corners, but this may warp the fiberglass edge slightly over time. A practical position is approximately 12.00” from the centerline and 2.25” down from the hood edge which makes it possible to open the latches from one side of the Roadster.

LCA Assembly

2010-01-17T08:45:37-06:00

[Design comparison] LCA fit has been a troublesome issue. FFR engineer Jim Schenck led a redesign effort to reduce friction in the joints with a changed inner pivot sleeve combined with a fluted polyurethane cap that reduces surface area and allows better movement of grease throughout the LCA bushing.

Legacy of the FFR Roadster

2010-02-14T09:58:29-06:00

In the aftermath of World War II, many car manufacturers, especially European ones, experimented with the relatively less expensive roadster or spyder configuration: a topless two-seater sports car. A British company, Auto Carriers, Ltd. that marketed under the AC brand, introduced the Ace Bristol Roadster in 1954 that is generally considered to be the “grandfather” of the FFR Roadster.

24 Hours Le Mans

2010-01-17T08:45:36-06:00

See also Legacy of the FFR Roadster and Shelby and Cobra Development sections. 24 Hours of Le Mans (24 Heures du Mans) is the world's oldest sports car endurance race. Run on public roads since 1923, Le Mans took on special significance in the 1960s when the dominance of European manufacturers, especially Ferrari, was challenged by Ford in several classic, and violent, match-ups.

Reference Library

2010-05-26T14:14:54-06:00

FFR supplementals * FFR announcement of Mk4 roadster PDF 02-10-2009 * FFR Assembly Manual Table of Contents (for Mk3.1) * FFR Wilwood pedalbox instructions, 2008 mount design PDF 07-16-2008 * FFR Wilwood pedalbox instructions, 2007 mount design PDF 09-17-2007 * FFR Koni front coil-over shock assembly PDF 07-03-2007 * FFR Koni IRS coil-over shock assembly PDF 07-03-2007 * FFR bolt-on passenger roll bar instructions PDF 12-06-2004 * FFR listing of Mk3.1 Complete Kit mounted compon…

License Plate Wiring

2010-01-17T08:45:35-06:00

[License wiring] The Ron Francis rear harness includes two wires ∼ black and tan ∼ that connect to the license plate light on the trunk. These wires split off from the passenger tail lights near the right back corner of the chassis and fuel tank.

Exterior Lights

2010-01-17T08:45:35-06:00

[Front lights][WeatherPack connectors] New WeatherPack connectors for front and rear exterior lights greatly facilitates the mounting and removal, if necessary, of the body shell. See also Wiring Overview and Electrical Grounds discussions. Cut off the existing light connectors on the Ron Francis/FFR front and rear harnesses. Split off the black ground wires and route to separate grounds.

Cockpit Lock Box

2010-01-17T08:45:34-06:00

[Lock box] Because the Mass-Flo EEC computer is positioned behind the passenger side of the dash, there is not room for the traditional glove box (unless one is installed for show only, with very limited storage space). To compensate for the lack of secure storage, a rectangular lock box can be placed on the outside wall of the passenger foot box.

Lucas Wipers

2010-01-17T08:45:34-06:00

The wiper system, manufactured by Lucas, is driven by a wiper motor that rotates a spiral cable back and forth that, in turn, drives a circular gear housed in a wheelbox. Before installing the wiper assembly, make sure that the wiper motor is securely clamped to the firewall, and test the fast/low operation of the motor (cockpit ON-OFF-ON switch was previously wired).

Maintenance Checklist

2010-01-17T08:45:33-06:00

✔Engine, transmission, exhaust Comment radiator hoses check rubber joins for leaks plastic fan housing, blades check for cracks clutch cable at footbox check clearance with exhaust headers, no heat damage, proper seating at footbox panel clutch cable at transmission open clutch cover, check fork/cable end for fraying header bolts secure water pump belt tight, no wear header-to-side pipe exhaust bolts check torque exhaust side bracket check bracket-side pipe weld …

Unpack and Inventory

2010-01-17T08:45:33-06:00

Chassis setup * place FFR body/chassis shipping assembly on four jack stands (or dollies) :!: 38 ”furniture dollies”” * remove all duct tape from the body and clean any residue off with acetone * notch 40x2x4 lumber at approximately 35” (measure precise span across the cockpit midpoint) for a body brace to prevent fiberglass stressing under the doors when body is moved; some give in the brace is necessary to allow enough flex to remove the body

Master Cylinders

2010-01-17T08:45:33-06:00

See also Pedal Box Preparation and Brake Fluid Reservoirs sections. The Mk3.1 Complete Kit includes two Wilwood 3/4” bore master cylinders that are specifically designed for remote fluid reservoirs. This low profile design allows the master cylinders to be installed in the relatively tight space immediately in front of the driver side firewall.

Understanding Wheels and Tires

2010-01-17T08:45:32-06:00

See FFR Assembly Manual, page 108, for ride height measurement specifications. Wheel dimensions are all taken from where the tire bead seats on the rim although the wheel lip can extend out an inch or more. Therefore, actual wheel widths are slightly larger than the published specification. Similarly, the actual wheel diameter is slightly larger than published specification since measurements are made from the flat seating area, not the extended lips.

Side and Rear Mirrors

2010-01-17T08:45:32-06:00

[Mirrors] The Mk3.1 Complete Kit includes two mirrors, both configured to mount on the body shell as shown in the photo. While the top of the dash hoop location for the rear mirror is period-correct (see Legacy of the FFR Roadster), the original AC Cobras had no side mirrors!

FFR Mk4

2010-03-08T17:46:11-06:00

[Mk4] On January 30, 2010, FFR announced the Mk4 which began shipping in March 2010. The development of the Mk4 is consistent with FFR's incremental upgrade strategy, and the Mk4 addresses a number of weaknesses identified over the years by the builder community.

Oil Analysis

2010-01-17T08:45:31-06:00

In addition to the EEC computer's diagnostic codes and a visual inspection of the Roadster for leaks, loose bolts, and so on, an oil analysis provides a nondestructive chemical view of what is happening inside the engine. Oil analysis generally involves a number of different tests:

Oil Pan

2010-01-17T08:45:31-06:00

Background [Breeze 35041 Oil Pan, Rear Sump] The Ford M-6007-X302E (Boss 302) crate engine ships with a rear sump pan that fits most Fox body cars. However, Mk3 performance is optimized with a specifically pan designed for autocross and road race applications. The Canton Racing pan, part of the Breeze EzePak, uses the Ford Racing 302 dipstick and pickup.

Order History

2010-01-17T08:45:31-06:00

Over-rider Bumpers

2010-02-10T06:39:33-06:00

[Quick jack][Over-rider back view] For appearance options, see bumper and opening comparisons. The Mk3.1 Complete Kit includes quick jack bumpers. This build will substitute over-riders for quick jacks to emphasize our street-oriented concept.

Paint Selection

2010-01-17T08:45:30-06:00

After the shell has been completely shaped and sanded, several coats of primer, paint and clear coat are applied. Outstanding results can be achieved in a home-based paint booth, but most builders choose a professional fiberglass painter with specific experience doing FFR Roadsters.

Paint Process

2010-01-17T08:45:29-06:00

[Gel coat] See also Fiberglass Shaping section. Professional painters following different pathways to the same outcome, but all involve adding chemical layers over the vinylester shell. Metal-Morphous, the painter used in this build, applies a polyester gel coat as the first step, before the primer. Many painter do not apply a gel coat as the first layer.

Paint Plan

2010-05-21T14:57:05-06:00

See Road, Sound and Heat Protection, Hood Scoop Modification, Paint Selection, Customizations, and Fiberglass Shaping discussions for background on other decisions such as undercoating and body shell changes. Apart from ordering the FFR Complete Kit itself and its associated major components, the paint process is probably the biggest procurement challenge. Most builders do not have the facilities nor the special equipment necessary to create a professional shell finish, so the cost-efficient …

Panel Preparation

2010-01-17T08:45:29-06:00

General process * trace chassis tubing locations and panel-to-panel overlaps with Sharpie * remove panels, and with rivet template and auto punch (Breeze), mark rivet hole pattern * drill rivet holes and, where previously indicated for body clearance, trim panels * using drilled aluminum panels as templates, drill chassis holes and trial fit sheet metal with temporary Cleco fasteners * make trim and bend modifications as necessary to achieve a tight fit

Parts Inventory

2010-01-17T08:45:28-06:00

Pedal Box Preparation

2010-01-17T08:45:28-06:00

See also Master Cylinders section. Overview [Brake line layout] The 3.1 Complete Kit includes a new Wilwood pedal box setup with two master cylinders (MC) — separate cylinders for front and rear brakes — each connected to a remote fluid reservoir.

Graduation Photos

2010-05-21T14:52:36-06:00

After the Roadster is washed and waxed for the first time, plan a graduation photo session. See also Motorcar photography step-by-step PDF. Setting Find a contrasting, but not clashing, background that is interesting, but not too busy that it distracts from the Roadster itself. Unless you are a professional photographer, avoid stark same color backdrops. For example, a red car should not be shot against a bare red brick wall, but an ivy-covered brick wall might work well.

Professional Alignment

2010-01-17T08:45:27-06:00

A precision alignment requires tools that are typically beyond the home builder. Due to the sensitivity of the IRS design, a professional alignment is highly recommended. See also Preliminary Front Alignment and Preliminary Rear Alignment sections.

Passenger Footbox Finish

2010-01-17T08:45:27-06:00

[Raw footbox] Compared to the challenges of the driver footbox finish, the passenger side is less complex because there no pedal assembly, fuse box or other protruding operational components. However, the exterior side wall incorporates chassis infrastructure that diminishes the useful space.

Mk3Build Format Summary

2010-01-17T08:45:26-06:00

This is regular text. a title the box contentsused for most photographs titlethe box contents

Steering Rack

2010-01-17T08:45:26-06:00

Overview :!: 51-54 [Steering rack] The 3.1 Complete Kit includes a 15:1 manual steering rack customized for FFR by Unisteer. Steering stability, specifically the tendency of the FFR Roadster to exhibit bump steer, has been a troublesome engineering issue for many years.

Radiator

2010-01-17T08:45:25-06:00

In FFR documentation, radiator mounting is vaguely described with several options. A critical consideration is vibration: the fragile radiator structure must be insulated from hard road bumps. For this reason, flexible hoses are used for the top inflow and bottom outflow water connections.

Radiator Fan

2010-01-17T08:45:25-06:00

[radiator fan] See also Radiator, Prepare Radiator Shroud, Dash Overview, Dash Construction, Wiring Overview, Front Harness, Fuse Box Wiring and Dash Wiring sections. The Mk3.1 Complete Kit includes a radiator-mounted fan. The following diagram shows the fan sub-system linked into the EFI Mass-Flo computer.

Radiator Hoses

2010-01-17T08:45:24-06:00

[Radiator hoses] See also Coolant Fill Port section. The flexible radiator hose (FFR 13883) is joined to the radiator, engine block, and coolant fill ports with reinforced 2.5” rubber adapters secured with hose clamps. FFR supplies 7 feet of corrugated metal hose, more than enough to make the necessary connections.

Prepare Radiator Shroud

2010-01-17T08:45:24-06:00

The Breeze EzePak includes an aluminum shroud that separates the fan from the radiator body and creates a wider and more efficient cooling system. [Marking the cirle] Ignore instructions included in the shroud shipping box (from the manufacturer) and so do not use the small angle brackets, plate or rolled aluminum. The shroud looks like a large baking pan, with tabs on one end. Position the fan so that the wire pigtail points towards one of the tabbed ends, and center the fan carefully on the …

Preliminary Rear Alignment

2010-01-17T08:45:24-06:00

A preliminary rear end alignment must be made with tires mounted on the front and rear. Shocks should be removed from the rear to enable manipulation of the upper and lower control arms. Ride height The FFR recommended Roadster ride height is 4.5”, although a different height may be optionally set. The following alignment adjustments are made assuming a 4.5” ride height. Ride height is measured from the bottom of the main chassis tubing to the road surface.

Rear Wiring Harness

2010-01-17T08:45:23-06:00

[Rear harness] The Ron Francis rear harness connects to the main harness in the pedal box area, passes down by the firewall, and along the driver side of the transmission tunnel. The harness is then routed to the left (as viewed from the rear of the vehicle looking towards the front) of the driveshaft safety loop, under the trunk chassis struts, to the top of the fuel tank. At the rear of the chassis, the harness splits to the left and right for exterior lights.

Rear Cockpit Wall Finish

2010-01-17T08:45:23-06:00

[Vinyl covering on strut] The rear cockpit wall carpet is cut as a single large piece that incorporates four slits for the seat belt pass-through into the trunk anchors. A short portion of the chassis infrastructure cuts across the right and left sides of the rear wall, leaving small gaps between the aluminum panels and the protruding strut. These gaps should be filled with silicon and aluminum tape. The wall is insulated with a sound and vibration as well.

Registration and Title

2010-01-17T08:45:23-06:00

Vehicle registration is entirely a state, not federal, government matter. Your state of residence is the sole determining factor on how easy or difficult it will be to register and title a FFR Roadster. The Roadster tends to fall between the cracks of the regulatory system: it is not a classic car manufactured, say, 25 years ago, nor is it a “new” car that is federalized to meet current safety and emission guidelines.

Footbox Removable Cover

2010-01-17T08:45:22-06:00

[Footbox cover] The driver side footbox holds some essential components, including the main Ron Francis fuse box and front harness connections, pedal assembly, master brake cylinders with remote reservoir hoses, and the brake adjustment balance bar. If the footbox top cover is permanently riveted in, access for adjustment and maintenance is significantly limited.

What is a Replica?

2010-05-21T14:56:18-06:00

[Cobra ad] In general, a replica is a reproduction of a vintage or esoteric vehicle at a price point well under what the original might be worth. Replicas can be either professionally assembled or sold in kit form for home builders. Often a replica of a vintage car will substitute current technology for old components, especially where safety or sourcing issues arise.

Brake Fluid Reservoirs

2010-01-17T08:45:22-06:00

See also Master Cylinders section. Hydraulic brakes require a gravity fed line, so the primary objective of remote location is to ensure that the top fluid level of the reservoirs is always above the master cylinders. A secondary objective is to allow reasonably easy access for fluid refills.

Roll Bars

2010-01-17T08:45:21-06:00

Installation of the roll bars is a three step process: * drill and fit the roll bars to the chassis mounts with the body off * with the unfinished body on, drill (if not pre-drilled by FFR) and shape the roll bar body holes for a proper edge fit to the roll bars * with the painted body on, install the roll bars and finish with trim rings

Driveshaft Safety Loop

2010-01-17T08:45:21-06:00

Driveshaft safety loops are designed for a single purpose: to retain the rotating driveshaft should the universal joint or other drivetrain component break or come loose. The safety loop prevents a whirling mass of metal from penetrating the cockpit and causing, as one might imagine, significant bodily injury.

Neutral Safety Switch

2010-01-17T08:45:20-06:00

[Neutral safety switch] The FFR/Ron Francis harness has a provision for clutch safety switch, a feature that prevents the engine from starting unless the clutch pedal is pressed. Unfortunately, the FFR/Wilwood pedal box setup does not include a clutch safety switch.

Body Seals

2010-01-17T08:45:20-06:00

Seals are used to help create a tight bond between the metal chassis/panels and the fiberglass body shell. The Complete Kit includes four body seals for this purpose: * thin foam tape for use on flat facing chassis square tubing * rubber edge seal for use on aluminum panels * trunk edge seal for the trailing edge and rear cockpit wall * expandable weatherstrip to fill various gaps

Seat Belts

2010-01-17T08:45:20-06:00

The Complete Kit includes Simpson 5-point H-style seat belts. Two points are attached in the rear with the belts passing through a cutout in the rear cockpit wall. Another two points are attached on either side of the seat, and the last point, the fifth, is a thinner belt attached to the floor in front of the seat, often referred to as a crotch or anti-submarine strap.

Seats

2010-01-17T08:45:19-06:00

[Seat plate] The Mk3.1 Complete Kit includes two seats (with leather as an option). The Breeze seat mount, included in EzePak components, uses two plates, one attached to the cockpit floor, and the other bolted to the underside of the seat. A slight incline (seat tilted back) increases rider comfort. Refer to detailed Breeze instructions for assembly details.

Sending Units

2010-06-16T15:42:30-06:00

Three of the vintage electronic dash gauges ∼ speedometer, coolant temperature, and oil pressure ∼ require remote data from the engine or transmission which is collected via a sending unit, a specialized sensor. Speedometer [Speedometer sending unit] The speedometer sending unit is inserted into the T5 transmission, on the driver side, through a small hole (which has a plug for shipping).

Shelby and Cobra Development

2010-01-17T08:45:18-06:00

The following history, courtesy of RM Auctions of England, was developed for the October 28, 2009 auction of CSX3006¹. Development of the 427 Cobra Although Carroll Shelby’s 289 Cobra was well proven in competition, by the mid-sixties it was becoming clear that something more was needed. Every year, more power was needed to stay competitive, and Ford’s 289 had reached its reliability limit at around 380 or 390 horsepower.

Shifter Knob, Boot, and Bezel

2010-01-17T08:45:18-06:00

See Transmission Tunnel Cover section. After the carpet is completed, position the rubber boot and bezel correctly over the cutout in the transmission tunnel top, and secure with metal screws. [Shifter][Shifter in cockpit]

Driving Shoes

2010-01-17T08:45:18-06:00

The Roadster driver footbox is cramped, with the accelerator pedal typically placed very close to the right transmission interior wall. For many drivers, everyday shoes may either be too large or heavy for optimal road handling. [Piloti Spyder driving shoes]

Side Exhaust Pipes

2010-04-05T21:38:22-06:00

The Roadster is a hand-crafted vehicle with a chassis welding tolerance of about 0.20”. In practice this means that certain parts that demand precision alignment, like the suspension, will require careful, and often tedious, adjustment. Side pipe alignment, which is very sensitive to small differences in header angles, will likewise require a trial-and-error process to achieve a straight appearance.

Solenoid

2010-01-17T08:45:17-06:00

The starter solenoid, also sometimes called the starter relay switch or starter relay, receives two current inputs: a large one from the battery and a small one from the ignition switch. See also Switches, Relays, Fuses and Diodes section. [Solenoid] When the ignition switch is turned to start, the small electric current closes a contact (acting as a switch) and relays the large electric current to the starter motor.

Heat and Vibration

2010-01-17T08:45:16-06:00

While the aluminum panels may be left bare, like the trunks were in the vintage Cobras, or simply covered with the FFR relatively thin carpet, insulating layers will significantly lower road noise caused by chassis vibration and reduce heat generated by the engine and exhaust pipes. See insulation discussion.

Fender Spats

2010-01-17T08:45:16-06:00

See spat template. Removable fender spats can be cut from clear 8 mil static cling plastic sheeting. A 30” x 10' roll with paper backing, ordered from Sign Warehouse, is enough material to last for years of peel-off-and-discard usage. The advantage of removable spats is that paint protection does not come at the expense of marring the finish with snaps or other attachments, and offers greater flexibility than permanent spats which may not be appropriate for all venues (like car shows).

Mk3.1 Specifications

2010-05-26T06:56:19-06:00

The following specifications describe this build of the FFR Mk3.1 with the Breeze EFI Master EzePak featuring the Ford Racing Boss 302 engine. ALL NEW PARTS WERE EXCLUSIVELY USED. Vehicle * 2460 lbs. curb weight (approximate) * front/rear weight distribution 46.9/53.1% * wheelbase 90” * overall length 158” * front track 58.5” * rear track 58.5” * overall height 48.0” * overall width 70.5” * ground clearance 4.50” front, 4.75” rear at full curb weight * fuel capacity 15 g…

Spindle and Bracket

2010-01-17T08:45:15-06:00

[Spindle and bracket assembly]

Guard Panels

2010-01-17T08:45:15-06:00

Wheel wells The wheel well design incorporates front and rear splash panels to fill in the space between the tubular chassis and body shell: * FFR 10861: LH front splash guard in wheel well (also referred to as elephant ear due to shape) * FFR 10862: RH front splash guard in wheel well (also referred to as elephant ear due to shape) * FFR 14585: LH rear splash guard in wheel well * FFR 14586: RH rear splash guard in wheel well

Build Manual

2010-05-21T14:49:17-06:00

[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 a…

Starter

2010-01-17T08:45:14-06:00

[Starter] The starter is wired directly to the solenoid. The larger terminal (A in photo) attaches to a large red cable that goes to the battery side of the solenoid switch (technically, the battery cutoff switch side). A smaller yellow cable goes from the small terminal on the starter (B in photo) to the opposite terminal on the solenoid.

Steering System

2010-01-17T08:45:14-06:00

See also Russ Thompson turn signal system. Parts Each manual steering system has the following components: * steering rack with inner and outer tie rod ends and fasteners, FFR Photo (FFR polyurethane steering rack bushings will be replaced by Breeze aluminum bushings) * aluminum rack mounting bushing kit, Breeze Reference * nickel-plated lower steering shaft, FFR Photo * steering rack shaft adapter 9/16-26 spline * collapsible upper steering shaft with friction washers * steering …

Supply Inventory

2010-01-17T08:45:13-06:00

Tap Drill Measurement Table

2010-01-17T08:45:13-06:00

Screw ThreadCommercial Tap DrillOD, PitchRoot diameterSize or numberDecimal equivalent1/16 - 64.04223/64.046972.04453/64.04695/64 - 60.05631/16.062572.060152.06353/32 - 48.066749.073050.067849.07307/64 - 48.082343.08901/8 - 32.08443/32.093740.092538.10159/64 - 40.108132.11605/32 - 32.11571/8.125036.120230.128511/64 - 32.13139/64.14063/16 - 24.133426.147032.146722.157013/64 - 24.149020.16107/32 - 24.164616.177032.178212.189015/64 - 24.180610.19351/4 - 20.18507.201024.19594.209027.20193.213028.203…

Terminal Blocks

2010-01-17T08:45:12-06:00

[Terminal blocks] Terminal, or distribution, blocks and their related connectors are an efficient way of handling complex wiring layouts. Blocks come in various configurations. For dash wiring, the best choice is a double-row block arranged with two opposing screw-down connection points electrically linked to each other with a small metal plate. Double-row blocks some in various lengths.

Terms

2010-07-15T17:01:44-06:00

See also abbreviations Numbers * 1320 - Distance, in feet, of a 1/4 mile * 19 lb, 24 lb, 30 lb ... - indicates pounds of fuel per hour for fuel injectors * 1.6 RR - 1.6” Roller Rockers * 3G - alternator without external fan on SN95, higher output * 302 - also called 5.0 or 5.0L, a small block Ford engine; in 1968 shorter connecting rods boosted displacement to 302 cubic inches; Ford discontinued this engine in 1996 * 315/60 - tire size example * 351 - Ford engine * 351W - Ford …

Thermostat

2010-01-17T08:45:11-06:00

[Thermostat housing] Thermostat housing and fasteners are supplied in the Breeze EzePak. The thermostat itself is packaged with the Ford Racing 302 engine and is usually in a plastic bag placed on the lifter valley. Note the small crescent indentation on the engine side of the thermostat housing. This holds the a brass pivot pin on the thermostat and insures a proper fit. Orient the thermostat so that it fits snugly into the housing.

Russ Thompson Turn Signal

2010-08-15T13:22:56-06:00

Overview [Thompson signal system] The FFR dash layout contemplates a single green indicator light that flashes for both left and right turns, triggered by a ON-OFF-ON toggle switch. A second toggle switch activates high beam lights. This arrangement, while operational, increases cockpit workload and is suboptimal from a ergonomic viewpoint.

AC Cobra Timeline

2010-02-02T07:29:56-06:00

[AC Cobra timeline]

Tool Inventory

2010-01-17T08:45:11-06:00

Tools and Supplies

2010-05-21T14:55:26-06:00

Vendor legend Vendor icon followed by SKU number (in italics) and rounded dollar cost excluding tax and shipping; see also vendor links :-1 Harbor Freight :-2 McMaster-Carr :-3 Northern Tool :-4 other online vendor :-5 local vendor (e.g., Home Depot, Lowe's, AutoZone, Ace hardware)

Torque Specifications

2010-05-21T14:54:58-06:00

Background Torque is the measure of the force applied to produce rotational motion and is determined by multiplying the applied force by the distance from the pivot point to the point where the force is applied (that is: Torque = Force x Moment Arm). In the English system, torque is measured in foot-pounds, abbreviated as as ft-lb, or inch-pounds. In the Metric system, torque is measured in Newton-meters, abbreviated as MM. Useful conversions are:

Transmission

2010-01-17T08:45:09-06:00

[Staging the transmission] Attaching the transmission to the bellhousing is straightforward, but delicate work. The transmission must be perfected aligned with the release bearing, clutch disc, and pilot bearing at the center of the flywheel. The transmission shaft correspondingly has three portions: a thin end that fits into the pilot bearing, a spline that fits into the clutch disc, and wider part that snugly passes through the release bearing.

Trunk Lid

2010-01-17T08:45:09-06:00

[Trunk lock and light] NOTE: In order to drive the Roadster in gel coat legally, a valid license plate must be affixed to the trunk lid mount (see Registration and Title section). Attach the trunk lip lock and license plate light mount. Temporarily attach the trunk lid using the FFR brackets; these will be substituted later for the Breeze trunk hinges.

Trunk Finish Details

2010-01-17T08:45:09-06:00

While the original AC Cobras were delivered with a bare metal trunk, a finished trunk is more appropriate for our street-oriented version and accommodates wiring, tools, and vehicle protection needs without detracting from its period-correct appearance.

Trunk Hinge

2010-01-17T08:45:08-06:00

[FFR trunk hinge] The Complete Kit includes a simple exterior hinge that mounts through the body shell and attaches to the trunk with two bolts. While functional, the FFR trunk hinge may cause rubbing between the top leading edge of the trunk and the body, and the single bolt mount to the body shell may wobble when opening and closing. Over time, this hinge design can mar the paint finish.

Finished Trunk Overview

2010-01-17T08:45:08-06:00

[Trunk overview] There are different methods of finishing the trunk area. The finish described here uses five carpet pieces, labeled A through E, to cover the entire trunk floor and wall panels: * A - top rear trunk wall above cross strut * B - bottom rear trunk wall below cross strut * C - driver side wall * D - passenger side wall * E - trunk floor

Trunk Area Panel Assembly

2010-01-17T08:45:07-06:00

Eight panels, all mounted when Complete Kit was delivered, and passenger roll bar mount: * FFR 10560: front trunk floor * FFR 10561: rear trunk floor * FFR 13637: LH front trunk wall * FFR 13635: RH front trunk wall * FFR 14027: RH roll bar mount * FFR 13636: RH/LH rear trunk walls * FFR 10870: RH/LH rear trunk wall side covers

Transmission Tunnel Finish

2010-01-17T08:45:07-06:00

The carpet piece for the transmission tunnel, FFR 13918, is cut as a single piece (see carpet templates). This build splits the FFR template into three separate pieces: one for the top and for each side of the tunnel. Removable top [Tunnel carpet] The decision is incorporate a removable transmission cover alters the FFR carpet template pattern since the tunnel top carpet piece can no longer be part of the tunnel sides. In addition, the fresh air vents require appropriate holes in the side car…

Transmission Tunnel Overview

2010-01-17T08:45:07-06:00

[Transmission tunnel] The transmission tunnel carries, as the name implies, the transmission through the cockpit to the driveshaft. The tunnel also provides space for the emergency brake, related cables, the rear harness, the speedometer sending unit, and the neutral safety switch wiring.

Transmission Tunnel Cover

2010-01-17T08:45:06-06:00

[Fill plates] The aluminum tunnel cover panel, which has been previously powder coated, must be modified for the precise locations of the Lokar handbrake and transmission shifter (see also Lokar handbrake installation). The original panel has a cutout for the shifter. However, the shifter position will likely need an adjustment, and an oval fill plate with a round hole is provided for this purpose.

Upper Control Arm (UCA)

2010-01-17T08:45:06-06:00

[UCA assembly] The FFR upper control arm (UCA) ships as a single piece without the ball joint installed (the lower control arm ball joint is pre-installed). To begin the installation, orient UCA as shown in the photo with pivot bolts facing up. Screw the ball joint into UCA ball joint mount until it is hand tight with the grease fitting facing up (the ball joint grease fitting faces down in the photo).

Vehicle Identification

2010-01-17T08:45:06-06:00

The purchase of a FFR Roadster, either in the basic or complete kit version, generates a Manufacturer’s Certificate of Origin (MCO), also known as a Manufacturer’s Statement of Origin (MSO). This is the primary legal document used for subsequent title and registration.

Vendors

2010-01-17T08:45:05-06:00

Listing of vendors used in this build:

Fresh Air Vents

2010-01-17T08:45:05-06:00

Cockpit heat, especially in the footbox area, can be a problem due to the close proximity of exhaust headers and engine. Fresh air vents, placed on the side of the transmission tunnel, bring cool air from under the chassis into the cockpit. At speeds above 10 mph or so, ambient air flows freely, unheated by the engine.

Wash and Wax

2010-05-28T06:50:58-06:00

After the paint has completed cured, usually about six months, the Roadster should be carefully washed and waxed. The Turtle Wax ICE system is recommended because it is relatively simple, although other popular premium products also work well (see especially Zaino test below). The complete ICE system can be ordered online for $30 (do not pay for rapid delivery; shipments are made much quicker than “4 to 6 week” notice on the website).

WeatherPack Connectors

2010-01-17T08:45:04-06:00

Harsh environment electrical connections, like those present in automotive applications, require watertight capabilities. In the FFR Roadster build, the ability to quickly connect/disconnect wiring between the metal chassis and fiberglass body greatly facilitates any maintenance where the body must be removed. For this reason, specialized connectors, like WeatherPack, are recommended. WeatherPack is a component system available from a number of different vendors, including White Products, Pega…

Wind Wings

2010-01-17T08:45:04-06:00

[Wind wings][Wind wing hardware] The Mk3.1 Complete Kit includes FFR wind wings, a plexiglass extension of the windshield that helps minimize wind noise in the cockpit at higher cruising speeds. The wind wings can be pre-fit during the gel coat stage, or deferred until the painted body is complete and mounted.

Windshield

2010-01-17T08:45:03-06:00

[Windshield screws] The side mounting braces that are shipped as part of the windshield assembly are too long to fit into the provided slots in the chassis. To prepare the windshield for installation, cut 2” off the end of both braces. Attach the metal mounting braces with provided small screws into the side of the windshield frame. Take extra care not to over-tighten, since this can crack the windshield glass.

Wipers

2010-01-17T08:45:03-06:00

See also Wiper Motor, Lucas Wipers, Dash Overview, Dash Construction, Wiring Overview, Fuse Box Wiring and Dash Wiring sections. The Mk3.1 Complete Kit includes dual speed Lucas wipers controlled by a toggle switch inserted into the dash panel. The following diagram shows the wiper sub-system.

Wiper Motor

2010-01-17T08:45:03-06:00

The Mk3.1 wiper system is driven by an electric motor mounted on the passenger side, attached to a grooved cable that, in turn, rotates wiper blades back and forth. [Wiper motor] While the mechanical system is simple, the installation is awkward because exact placement of some components requires the body to be on, and this makes access under the hood difficult.

Wire Specifications

2010-01-18T07:56:53-06:00

[AWG amp vs distance] The automotive electrical system cannot operate, obviously, without proper wire connections between components. Wire gauge indicates diameter size that directly corresponds to the amount of electric current the wire can safely carry, as well as its electrical resistance; resistance increases with wire diameter.

Wiring Connections

2010-01-17T08:45:02-06:00

The Roadster wiring uses different connectors to make secure, vibration-resistant and environmentally robust circuits. Exterior lights use the WeatherPack connection system. Electrical ground connections must be carefully installed to insure continuous circuits. Dash wiring uses terminal blocks to connect various relays and gauges.

Wiring Overview

2010-01-17T08:45:02-06:00

Optimization of the FFR harness and integration with EFI electronics requires a number of modifications as shown in the diagram below (green lines indicate the FFR/Ron Francis harness, and red indicates the Mass-Flo EFI harness). See WeatherPack Connectors.