First Modification from Kit – 1 Hour

After fitting the firewall it still appeared flimsy for the application and so after researching the thoughts of others I decided to manufacture my own firewall support bracket from the redundant foot box vertical front wall (FFR 10904), the bottom of this panel already has a 90 degree bend.

After installation is does improve the rigidity of the firewall especially in the area were the master brake fluid reservoirs will be mounted.

Patience and 320 Emery Sheets – 3 Hours

Have read many methods of fitting the front hubs to the spindles (heating the hub, freezing the spindle, brute force), I decided to be patient and use 1” strips of emery to reduce the spindle shaft diameter to provide a fit requiring hand pressure only.

I plan on keeping my car for many years, inevitably during that time the bearings may need replacing and as such I would like to be able to remove the hub without destroying the spindle.

Some would say there is a possibility to cause ovality when using emery to reduce the spindle shaft diameter leading to premature bearing failure, however working at 90 degree intervals and counting the sanding strokes provides consistency during the reduction process.

Getting into a Rhythm – 4 Hours

Starting to get into a rhythm when installing panels; fitted the firewall and front driver’s side foot box wall. The firewall as envisaged remains flimsy and so I plan to fabricate a panel to brace this around its midpoint.

Also reconstructed one upper control arm to make a true left and right mirror image, these were then mounted temporally to the chassis along with the steering rack.

The steering rack was mounted using the Breeze bump steer kit, this definitely provides the flexibility for eliminating this condition, time will tell once the front suspension is fully installed and aligned.

Limited Progress – 4 Hours

With so many items on backorder (hopefully these will be filled shortly), only limited progress can be made, basically this consists of fitting, drilling and temporally mounting of the aluminum panels.

Started today by working out the front caliper jigsaw puzzle, the first picture shows the various parts, fasteners, seals and pads included in the kit and the 2nd picture shows the completed assembly.


Also fitted both F-Panels experimenting with 2” and 3” rivet spacing (2” is the upper horizontal row, 3” is the lower row), I have decided moving forward I will use approximately 2” spacing.

As these panels are behind the wheel at the back of the wheel arch the riveting will hardly be noticed once fully assembled.

These panels, as with all engine compartment panels, will be powder coated black, although I am still undecided whether to use black rivets or natural aluminum.

First Day of Build – 6 Hours

Had a good first build day, it was encouraging to find the drivers side to passenger side 4” chassis frame geometry (front to back) was all within 1/8”, also the rear and front wheel arches were also within 1/8”, indicating the body was mounted squarely from the factory.

Spend most of the day removing the body mounting hardware and major components (doors, hood, trunk), with that completed the body was placed onto the body buck for the first time, and with a sigh of relief it fitted. Before the body was removed a sharpie was used to mark the panels with a cut line 3/8” from the body, this will require trimming prior to the panels being finally fitted

After photographing and marking the aluminum panels these were all removed with the exception of the firewall and F panels. After spending most of the day removing body work and panels the first part was officially installed, this being the A-Frame transmission mount (1/2 bolts set at 75ft/lb’s torque, 3/8 bolts set at 30ft/lb’s)

Santa Came Early

Well the big day arrived, Stewart Transport delivered the car this morning and we were completely off-loaded in less than an hour. Rest of the day was spent checking inventory of the 20 plus boxes, each one was like a Christmas present.

After a year of planning it seems a little cereal, keep looking for an excuse to go in the garage just to make sure it’s really there.


Pleased I raised the body buck those extra few inches, it clears the car perfectly with 6” to spare and so will probably raise the axle stands higher to give a more comfortable working height.

Body Buck Completed – 10 Hours

Finished off the Body Buck today, irrelevant of what any manual or on-line thread states it takes a good 10 hours to do by yourself.

Many thanks to Greg who helped me with “measure twice cut once” by measuring his own car height sitting on 12” jack stands at 42”, this buck clears 48”. It’s always good to learn from others.

Car should arrive in about 2 ½ weeks, ex-factory 12/12/09, just in time for Christmas.

Could not resist Factory Five Racing’s black Friday sale, purchased floor mats and sun visors both at half price.

First Parts Arrive

Today the first upgraded parts arrived. After reviewing a number of threads on the FFCobra forum, reviewing the manual and attending the build school, I had decided to purchase the LCA bushings and offset steering rack bushings from Breeze Automotive.

The 4130 steel bushings solve the binding problem with FFR Tubular Front Lower Control Arms. The longer length prevents the frame tabs from pinching the poly bushings, and the reduced diameter permits grease to migrate between the bushing OD and the poly bushing ID. The ends are knurled so they can be firmly gripped by the frame tabs.

Solid offset bushings to lower and center the rack in the Mk3.1 Factory Five Roadster chassis. The offset is .35" which will lower the rack 1/4" and offset it 1/4" to the passenger side from the factory designed mounting points. This location centers rack travel in the chassis and further reduces bump steer. The one piece bushings insert from rear to clamp rack to the rear face of the front mounting ear. This makes the rack an integral frame member and adds to the stiffness of the front of the frame. The position is about 1/4" further forward than when installing the rack with two piece poly bushings. Material is as-machined 6061 aluminum.

Checked with the guys at Factory Five today and Stewart Transport everything is still on track to leave the factory 12/12/09.

Unexpected surprise

Got an unexpected surprise today, Jerry (AKA Airspeed1 on the FFCobra forum) call this afternoon and invited me over to see his car.

Jerry and his brother both built their cars together, (Blue car in the foreground is Jerry’s) and offered a wealth of information ranging from the fun of getting the car titled, to local body shops for paint and finishing.

The real thrill was Jerry took me out for a drive and I haven’t stopped smiling since!

Many thanks Jerry, the excitement grows as I wait for my kit to arrive.

Body Buck Thoughts

After looking at the on-lines plans for the body buck (http://www.ffcobra.com/FAQ/bodybuck02.html) I decided to implement a quick re-design after measuring the highest point on the frame at Build School when the car was mounted on 13” jack stands. For others following this thread, I have decided to build a clearance of 48” under the front and rear body supports.

In addition because of the number of boxes I am expecting when the kit arrives, I also included a full shelf to my design.

The following material was all purchased from Lowes:
4 sheets of 7/16” x 4’ x 8’ OSB Sheet
10 length of 2” x 4” x 8’ studding
1Lb Box of 1 5/8” Course Drywall Screws
1Lb Box of 2 1/2” Course Drywall Screws
3/4" x 6’ x 3/8” Foam Pipe Insulation
Titebond Original Wood Glue 8oz

The 4 x 5” Castor wheels were purchased from Harbor Freight. My plan is still to complete the body buck over Thanks Giving.

Build School Summary

I like many others were skeptical about the benefit of this course, as an engineer and someone who had read the manual, been active on FFForum for many months I felt confident in building my car, WRONG!






This is the most valuable experience anyone can get who intendeds to build a FFR roadster, whether from a donor or full kit package. Don’t cut corners, go to build school, this will save you time, money and your sanity further into your build, plus you get to meet a great bunch of like minded people, many of whom I am sure will become lifelong friends.

Day 3 of Build School

Three days, 15 guys, 2 great instructors, and a Factory Five Roadster, the experience was priceless.

Day 3 started with a discussion on finishing the body and paint, followed by the installation of the lights and other body fittings. Next we assembled and installed the dash, parking brake, remaining sheet metal, seatbelts, and bulb seal. The body was then mounted back on the frame as we began the home stretch of this build.

Starting with the windshield, this and the doors were installed together with a discussion on mounting the hood. Although this was the end of our build the remaining inner wheel well sheet metal parts were offer up as was the shark gills for discussion on fitting.

With the wheels popped back on, steering wheel and gear lever fitted she was ready to be let loose. Jim, our instructor, as you can see from the video had more faith in our workmanship then we had.

She Runs! Day 2 objective completed

Another day of great progress, all break lines installed and the brakes bled, more sheet metal, steering column installed, as was the engine and transmission. Radiator and coolant hoses added, more sheet metal, full electrical harness, battery box and you guessed it - more sheet metal. Engine fired successfully after a little fault finding. The really cool part of today was three local roadster owners tuned up for lunch.

Day 2 of Build School

After an enjoyable group dinner and a good night’s sleep Day 2 expectations are that the car will be at the go kart stage with running engine by the end of today.

(Picture is a 302 EFI with T5 Transmittion)

Great first day

Great first day at build school with a good group of guys and experienced instructors. This is a priceless insight into everything the manual does not tell you.

Today we completed front and rear suspension, rear axle, fuel tank, pedal box, F panels and passenger foot box.

We also went through shock settings, fuel filter location, brake reservoir positioning and finally front and rear suspension alignment. Not a bad achievement for one day.

Day 1 of Build School

I guess this is how everyone feels, its day one of build school and I have not been able to sleep for thinking about the adventure which is about to begin.