Archive for the ‘cockpit aluminum’ Tag

Type 65 Coupe Update: Cockpit Aluminum, Battery Box and Fuel Lines   Leave a comment

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After several weeks, it is good to get back to work on the Factory Five Racing Type 65 Coupe. I finally completed drilling the rivet holes for all cockpit aluminum panels, and added a battery cut-off switch as you can see above.

Here is a hint for builders – there is a fairly large gap in the bottom right corner of the driver’s side floor and the “A” shaped piece that meets the transmission tunnel. I looked at several Coupes and Roadsters and they all have this space. However, by pushing on the A-shaped piece from behind (under the chassis and in the engine bay) – this gap can be closed up nicely. See below. . .

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But what about this area, at the rear of the driver’s side door – indicated by a piece of blue masking tape – see that gap? Does something cover this space up or do I need to fabricate a replacement panel? Both sides look the same.

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As mentioned in a previous post, I finally decided to mount the external fuel pump under the Factory Five Metal battery box. This is a protected location and is a low point on the chassis.

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One problem will be access to the fill and drain holes for the Ford Racing differential. I had to drill out the rivets previously installed and tapped some 1/4-20 holes – this will enable the removal of the battery box when draining and filling the rear end fluid. Not the ideal situation, but I do not see too many alternatives to this arrangement.

My Ford 302 V8 has an MSD Atomic electronic fuel injection system, and I am running both feed and return fuel lines. Here is a picture of the tank end. . .

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The fuel line runs from the first filter (right side of the chassis) to the fuel pump, and goes around to the driver side. Then it goes under the rear end to the passenger side of the chassis, where it goes to a second fuel filter mounted under the passenger seat, and finally to the engine.

The same path will be used for the return system. Pretty much standard layout.

Next Build Session

Depending on the weather, I will remove all interior panels and paint the under side with automotive under body paint. It is a rubberized black paint which should deaden some road noise, insulate heat and protect the panels from road debris.

Another item on the next to do list is the wiring harness. Here is a look at the main portion. . .

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Type 65 Coupe Update: More Cockpit Aluminum Chores   Leave a comment

On Saturday morning, I remembered that I stopped working on the sheet aluminum. So I decided I should get that Cleco-ed in place so I can get the panels ready for prep and paint. Then I can move on to the fuel tank, and then – finally – install the engine.

Post-Holiday Type 65 Coupe Updates and Visitors to the Garage   2 comments

I am working on several things on the car at the same time. Whenever I get stuck or run into a problem, I move to a different part of the car to build. At some point, things will meet up and progress in a more orderly fashion, but at this stage, nothing is complete.

This Factory Five Racing Coupe project is consuming my life. Even when I am sleeping, I have dreams about the car, the building process or driving the car.

But lately I have been having nightmares about the car….

Front Suspension Re-Do

I managed to install a part on the front suspension upside down and backwards. Of course, like a lot of automotive things, in order to get to that part, a lot of other parts must be removed first. Some parts required a tremendous amount of torque to install. These are parts that should never “fall off” like anything in the front suspension and wheel mounts.

So, one of the chores I had to do was to remove the front wheel bearings and hubs. I tried to remove the mechanical lock nut with my ratchet, but it would not budge. This is a good thing, since this one nut fastens the wheel to the car. Installing these parts required several very hard whacks with my plastic hammer and several Rated R and X words and phrases. I could not help but wonder how those parts would come off if I ever needed to repair or replace them.

Reading the forums made me lose a lot of sleep, since it seems that a lot of fellow builders have had trouble with this part, too. I bought an AC-operated impact wrench and some very large (36mm) impact sockets to remove the hub nuts. As a back-up, I also bought a large 1/2-inch drive breaker bar and a piece of pipe to increase the torque if needed.

I called my friend Larry over for some assistance.

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Surprisingly, the breaker bar made the hub nut come right off. Even more surprising is the condition of the spindle where the wheel and bearing mounts – it still looks brand-new and without any distortions or scratches.

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After purchasing the impact wrench, Larry sent me an e-mail advising me to not use an impact wrench on the front hubs, because this may damage the wheel bearings. I took this advice, and returned the impact wrench. Good thing I did not open the box. . .

Interior (Cockpit) Aluminum Panels

After the problem with building the IFS, I decided to “dry-fit” all parts from now on. This way I can verify everything is correct – or fix things that are wrong – before tightening the parts into place.

I decided to do some more work on the interior sheet aluminum. Compared to some of the other tasks, fitting the aluminum is easy. I made some diagonal cuts along the floor to make the parts fit easier, and to prevent scratching the nearby interior panels. By cutting the single large pieces into multiple smaller pieces, they will drop into place, rather than bend and scrape into place – preserving the painted surfaces.

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The seams and bend directions are hard to see in these pictures, the aluminum sheets do not provide enough contrast. I may use masking tape to show where the parts go and where the seams meet next time. As I said, this is the first attempt to fit the cockpit aluminum. Based on old Factory Five Racing forum posts, it looks like my aluminum panels have been improved somewhat. The only poorly fitting space is this big gap on the driver side, right at the corner of the transmission tunnel.

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I may either trim the mounting tab behind one of the panels, or just install some sort of patch over the top. Overall, though, this Generation 2 Coupe seems to have better-fitting interior panels, so far.

Dashboard

Here is an example of something gone wrong —

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Notice the odd-shaped hole for the steering column? The mounting location for the steering shaft is not straight and parallel along the ladder structure in the driver side footbox and clutch quadrant. As I examined all the parts in this area, I believe the factory did this because of an interference issue with the brake pedal. If the steering column shaft were to run parallel to the ladder structure, it would block the brake pedal actuator. Moving the mount – but not compensating for this on the dashboard panel – makes this problem look worse than it may be.

I used a nibbling tool, a round file and a sanding drum to enlarge the hole for the steering shaft.

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A popular modification to the dashboard is to cut along the bend, making the one long piece dashboard into two long pieces. This enables access to the inside of the dash from the top as well as the front, and will make installing and maintaining dash components such as gauges, air conditioner and plumbing much easier. I will make this cut at the next build session.

I just have to figure out a way to disguise the big and ugly hole in the dashboard. . .

The Racing Seats

I placed the Kirkey high-back racing seats to see how it fits, and although the steering wheel is a bit toward the passenger side, I think it will be all right.

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Clutch Quadrant and Pedal Box

Many Coupe builders owe a lot to a guy named Chris, who has documented his Type 65 Coupe build experience with lots of pictures. (I added a link to his flickr photostream in the Automotive Links section.) The Factory Five Racing assembly manual left an entire section out for us Complete Kit builders. There are no instructions for the Wilwood pedal box and clutch quadrant assembly. Thanks Chris for sharing your images!

Anyway – here are some pictures of my Wilwood pedal box and clutch quadrant. I do not have too many fitment issues here, except for the mounting points to the 3/4-inch tubes – I will have to wedge the mounts at the firewall in order to securely mount the pedal box to the ladder structure. I painted my footbox mounting plate with silver Rust-Oleum BBQ paint. I wanted to do a test to see how the color came out and how durable the finish is. I like the color, it is much better than the raw steel and hopefully will prevent any rust from forming inside the car.

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A Roadster Driver Visits

Rick, a neighbor and Roadster owner, stopped by for a visit. Here are some pictures of his very nice car. Rick did the paint job by himself in his garage – I am very impressed with the way the finish came out – take a look!

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