Archive for the ‘Factory Five’ Tag

Type 65 Coupe Update: Exhaust Side Pipes and More Fuel System Stuff   Leave a comment

I got bored with figuring out the fuel line routing and filtering, and it was a nice warm day today, so I decided to paint the Coupe exhaust system pipes and silencers. Even though they were stored in a corner of my dining room, and were covered with oil, there was a lot of rust forming on the surface of the pipes. My kit is now a little over a year old, and I wanted to prevent further rusting.

Here is the box of pipes and associated mounting hardware from The Factory. . .

Type 65 Coupe Exhaust, Uncoated, from Factory Five Racing, after one year

Type 65 Coupe Exhaust, Uncoated, from Factory Five Racing, after one year

There is an option to get the pipes ceramic coated, I probably should have ordered the exhaust with the coating. I noticed the brochure on the Factory Five Racing website has the exhaust listed as ceramic coated at no charge. I wonder why I missed that part?

I used silver Rustoleum BBQ paint (Ultra) to finish the exhaust. But first, I prepped the pipes with wire brushes, to remove the rust and roughen up the surface, and then wiped them with acetone to degrease so the paint will stick better.

I used a wire brush on a drill motor to get the rust off and roughen the surface.

I used a wire brush on a drill motor to get the rust off and roughen the surface.

Type 65 Coupe side exhaust pipes painted with silver BBQ paint - I think it looks OK.

Type 65 Coupe side exhaust pipes painted with silver BBQ paint – I think it looks OK.

The BBQ paint is a bit soft, I think this is because it needs to expand and contract when heated and cooled. But it will be easy and cheap to touch up.

I am not sure what the final exhaust side pipe color will be, so I sprayed three coats of the silver on just to prevent further rusting. I may change the color to black, since I want the main body to be white.

I did manage to mount the pre-filter for the fuel system. My 302 is fuel injected with an MSD Atomic EFI system, and came with most of the parts, including the fuel filters, hose, and external fuel pump. The first filter mounts where the Factory Five fuel filter is located, near the quad shock mount on the right side of the chassis. The MSD-supplied filter is smaller than the one supplied in the kit, so I had to figure out how to mount it. I am using a pair of electrical conduit clips to mount the first filter, as shown.

Electrical conduit clips are used to mount the first fuel filter to the chassis

Electrical conduit clips are used to mount the first fuel filter to the chassis

The fuel pump will mount to the bottom of the Factory Five Metal battery box. If you have IRS and want to use the same box, you must modify the battery box slightly, as mentioned in an earlier post. In addition, you will have to figure out how to make the battery box removable, since it will block the differential filler plug.

I will be mounting the battery box with nuts and bolts, and mount it so that it can tilt upwards for access to the rear end filler plug. More details and pictures will follow when I get to that chore. Here’s a sneak peek at where the external fuel pump will be mounted.

Type 65 Coupe with IRS - battery box and external fuel pump mounting location

Type 65 Coupe with IRS – battery box and external fuel pump mounting location

Type 65 Coupe Update: Fuel System Begins   Leave a comment

I should have done more homework on this part of the build process, since Factory Five Racing tells us they do not include the fuel system. This makes sense since it will depend on the engine. I have a 302 with an MSD Atomic EFI system, and it came with the (external) fuel pump and filters.

So now I have to figure out how to get from the fuel tank output tube to the first fuel filter, then to the pump and then to the EFI unit. I decided to install a return fuel line, based on the information in the MSD instructions, I hope this extra effort will be worth it.

I will make access holes and hatches for the fuel pump and filter, as well the rear suspension components and tali lights – this should make maintenance and repair easier.

Here are some pictures of the work done today.

Type 65 Coupe fuel pump possible location. This is the external pump that came with the MSD Atomic EFI kit. The first fuel filter will mount to the battery box.

Type 65 Coupe fuel pump possible location. This is the external pump that came with the MSD Atomic EFI kit. The first fuel filter will mount to the battery box.

Using CAD - cardboard aided design, the fuel pump mounting plate is taking shape.

Using CAD – cardboard aided design, the fuel pump mounting plate is taking shape.

Here is the fuel pump in its possible location.

Here is the fuel pump in its possible location.

The cardboard template is transferred to aluminum. The mounting plate is almost a quarter-inch thick, so it will be nice and sturdy. This piece will be drilled and painted later.

The cardboard template is transferred to aluminum. The mounting plate is almost a quarter-inch thick, so it will be nice and sturdy. This piece will be drilled and painted later.

By the way – the fuel tank is still not in its final location – the right side mounting bolts are not long enough. I may just get a length of all-thread and make my own bolt for that side. The left side seems to be OK. Next on the “To Do” list is fill and bleed the brake system.

Type 65 Coupe Update: Battery Box Installation   2 comments

I painted and installed the slightly modified battery box from FFMetal this past weekend. Just to be different, I decided to paint the box white on the inside and black on the outside.

As you recall from my previous Coupe update, the battery box fits very tightly into the chassis – and I figured out a way to install the battery box without scratching up the paint – the trick is to install and build the box piece-by-piece into the chassis space. In other words, do not assemble the battery box and then mount it into the chassis – instead, build the box into the chassis.

NOTE: By building the battery box into the chassis, adjusting one side of the box inward (as described in my previous battery box notes) may not be necessary. Try a dry-fit before you drill the side of the box to change the dimension slightly.

This is actually easy to do, but difficult to explain. Here are some pictures of the freshly-painted battery box installation:

FFMetal battery box for the Type 65 Coupe - the individual parts are inserted into the frame one piece at a time, Cleco-ed into place, and then riveted.

FFMetal battery box for the Type 65 Coupe – the individual parts are inserted into the frame one piece at a time, Cleco-ed into place, and then riveted. (Left side view.)

A close-up of the small cut needed on the left side of the battery box. This cut-out does not interfere with the battery - but the battery clamp bar may have to be moved, depending on where terminals, vents or filler caps are on the battery.

A close-up of the small cut needed on the left side of the battery box. This cut-out does not interfere with the battery – but the battery clamp bar may have to be moved, depending on where terminals, vents or filler caps are on the battery.

Another view of the two-tone battery box. I like the white interior, it makes it look nice and clean. Of course, a lid will cover everything later. . .

Another view of the two-tone battery box. I like the white interior, it makes it look nice and clean. Of course, a lid will cover everything later. . .

Another view. . .

Another view. . .

The battery box with the supplied cover in place. Since I moved one side inwards, one cover screw does not line up properly. This does not bother me too much - I will install a small piano hinge at the upper side of the battery box, and the bottom two screws will hold the cover in place.

The battery box with the supplied cover in place. Since I moved one side inwards, one cover screw does not line up properly. This does not bother me too much – I will install a small piano hinge at the upper side of the battery box, and the bottom two screws will hold the cover in place.

When the trunk floor panels are installed, I will make a cut-out to access the battery compartment. The instruction sheet shows how to make the cut-out in the floor panel, but I will make the cut-out with an easier technique that woodworkers use: A router and pattern bit. I will show how this is done when I get to that stage.

I may make a small finger-hole on the cover so it will be easier to open. Insulation and carpet will cover the entire trunk area later.

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.

Type 65 Coupe Update: Disc Brake Plumbing   Leave a comment

It’s been a long time since I posted an update on the Factory Five Racing Coupe. Here is an update in pictures and captions . . .

Back to the Coupe Project: Brakes and Goodies from Russ!   Leave a comment

Where does the brake reservoir go?

Where does the brake reservoir go?

Before I drill any holes, I need to verify where the brake rez can should go. This polished stainless steel can looks great, and it is small. It must be easily accessible for filling and must also be higher (at level with) the brake master cylinders.

Location of the brake rez here or there?

Location of the brake rez here or there?

A few weeks ago I received a box of accessories from Russ Thompson, expert maker of Coupe add-on items. Here are some pictures. . .

Factory Five Racing Cruise-In 2013   2 comments

HUNTINGTON BEACH, Calif. — April 27, 2013 — Huntington Beach Pier Plaza and Main Street were filled with car enthusiasts and their hand-built sport cars  from 9 am to 4 pm today. This was the sixth annual Factory Five Racing Huntington Beach Cruise-In which included over 100 Factory Five Racing cars, each one custom hand-built. Other custom and street cars were also on display, and included a vintage Chevrolet Corvette, and Ford GT.

Factory Five Racing is located in Wareham, MA and currently offers five component car kits, the Mk4 Roadster, the Type 65 Coupe, a classic ’33 Hot Rod, the GTM Supercar and the newest model called Project 818. Pricing varies depending on the kit configuration and accessories and options. In addition to the kit, builders supply their own engine, transmission, wheels and tires and finish and paint.

Dave Smith, president of Factory Five Racing, is a hands-on guy, and is involved in every aspect of his company… and is the friendliest person you’ll ever meet. He loves talking about his – and our – cars, and Dave says every time he meets people at these gatherings, he learns something new from each builder.

More information is available on the Factory Five Racing website, www.factoryfive.com

My mission at this year’s event: To gather more information on the E-brake cable routing, look at paint color combinations and get some more ideas for dashboard layouts.

I had always planned on a white body/black or blue stripe Coupe, but after seeing these other paint jobs, I may change my mind. LED headlamps, cool-looking switch name plates, BRE side mirrors for the Coupe, honeycomb (hexagonal hole) screen for the side vents and other ideas are shown in these photos.

Thanks to everyone displaying and explaining and answering my questions about their cars today, and it was great to meet the Southern California – and other area – builders in person at this event.

Here are some random images from today . . .

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Above – Dave Smith, Factory Five Racing president, telling another great car story. . .  Karen Salvaggio, Thunder Valley Racing Owner (and driver of the Type 65 Coupe number 28), signing my “signature plate” that will be mounted on my Type 65 Coupe dashboard – this will fill that big blank spot nicely. Take a look at Karen’s website and her blog posts for more informaton on her team and the cars they race. www.thundervalleyracing.com  and http://thefactoryfiveforum.com/entry.php?346-Coupe-Challenge-Building-a-Legend

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Anyone know what this hole is for on the Roadster exhaust?

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This Saturday 4/27 – Factory Five Racing HB Cruise-In!   Leave a comment

6TH ANNUAL FACTORY FIVE HUNTINGTON BEACH CRUISE-IN click here

Here’s a short video of last year’s Moment of Thunder – click here

Some images from last year. . . .

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Type 65 Coupe Update: More Foot Box Work . . .   3 comments

. . . and a BBQ Dessert Experiment

Work on the passenger and driver side foot boxes continues on the Factory Five Racing Type 65 Coupe.

I painted the engine side of the panels with silver BBQ paint, and left the interior side un-painted, since all panels will be covered with Cool-It heat and sound barrier. Panels that face the exterior of the car – like the foot box floors and the trunk area, will be painted with RustOleum truck bed liner. It is a textured black finish that will also help reduce sound and noise. Here are some images. ..

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On the left is a detail of one of the cookie sheet heat shields, fastened to the firewall with 8-32 riv-nuts. The spacing is about one-quarter-inch. On the right is a view of the top of the heat shield, showing the nicely rolled edge.

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Passenger side foot box appears on the left of the photo above. The photo on the right shows a closer look at the passenger foot box.

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Photos above: Passenger foot box, before and after installing the Cool-It mats.

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Above left: The top seam on the passenger foot box – this will be either trimmed or a strip of aluminum will be used to cover the mis-match. On the right, I added srtips of aluminum angle to the outer wall of the driver side foor box. This should make the outer wall easier to install.

The next series of photos show how the interior panels go into place. The un-finished aluminum is difficult to photograph, I wish the manual would include an exploded view of the panels and how they fit into place. This is a complex jigsaw puzzle, and many of the parts must be flexed, trimmed and pulled into place. Clecos really help. This is one area where the manual offers good advice – the sections fit best when you follow the order outlined in the manual. Although many of the panels are marked with a part number, they do not indicate the orientation of the panel.

The foot box floors were very difficult to fit into place, so I sliced them into sections. If you look carefully you can see the saw kerfs (seams) on the floor panels. I chose the cuts carefully, in order to make sure I would have something solid to rivet to. In the areas without any supporting chassis tubes, I will install strips of aluminum bar stock.

The panels will be permanently attached later with silicone adhesive and rivets – at this stage, the panels are being “dry-fitted” with clecos to make sure everything is properly in place.

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Somewhere during this building session, I made some time to pack my hot giardiniera into jars, and made a few deliveries. . .

I also managed to do some BBQ experiments. This time I baked some apple turn-overs in the Big Green Egg. They turned out OK, but could be better. They are like just-right bites of apple pie. Here are some pictures. . .

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Type 65 Coupe Update – IRS Brakes   Leave a comment

I forgot to add notes and images from the IRS (standard width) brake installation. Here are some images, plus a link to a YouTube video…

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As you can see in the picture above left, an open end wrench can go onto the caliper mounting bolt. This was a button head Allen screw in the past. The emergency brake cable seems very tight and has a sharp bend, but this seems to work OK.

 

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The vintage Halibrand replica wheels fit nicely over the axle-hub-brake assembly, but I don’t have tires yet.

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The rear wheels are 17-inches by 10.5-inches, and the tires will be 275 / 40ZR17, probably BF Goodrich g-Force Sport Comp 2, but not sure yet.

A Silent Movie: Rear Brake Installation

Oh – almost forgot. Here is a silent movie about the rear brake installation:

http://www.youtube.com/watch?v=bVcX8-Nnqfo