Factory Five Roadster Build Part 2: The Build School

Getting right to it Saturday morning, our first bit of classroom instruction was to finish the brake lines. Charles and Todd showed us how to flare brake lines and make any bends necessary to install them.

While a tubing bender is a small investment, as Todd showed us, even a vise and a couple of sockets will get the job done.

Note the difference in a simple bend versus a complete loop. The loop offers more vibration protection, and when used at the fitting end allows for servicing a bad flare or stripped fitting without replacing the whole line.

The fuel system on the Roadster is designed around the donor usage of a late-model Mustang. Here, the class has installed the fuel tank with the internal fuel pump and connected the new FFR-supplied fuel lines. Again, the blue parts in the photo come from your donor or need to be purchased, as they are not included in the kit.

By mid-day the class was ready to install the engine and transmission, which were already assembled and waiting for each class, again to expedite some of the work. For safety reasons, only the instructors are allowed to install the engine and transmission themselves. Some students kept their eyes on the assembly as it was lowered into the chassis, while others took video, pictures, and notes. We took almost 200 pictures, a half hour of video, and three pages of notes over the course of the weekend.
Check out video of the engine install!
Windows Media | Quicktime

Editor Houlahan was glad he could give the class a laugh as he riveted some of the trunk aluminum in place. Notice he was working while everyone else watched. [I felt like part of a roadside repair crew!-Ed.]

Wiring is a big part of the FFR Roadster build. You'll have to trim and run the donor wiring harness and modify it to connect the body lighting, or if you use an aftermarket harness, you'll need to terminate many of the wiring ends on that harness as well. Custom gauges or any aftermarket items require extra wiring, too. Jim Jennings, another Mott instructor, was visiting for the day, and he jumped right in and showed the class several aftermarket wiring options and how to properly crimp connections, use shrink wrap, and to solder-all good things to know working around cars.

After the bench session on wiring, the class gathered around the school car and worked to wire the fuel injection harness and body wiring. We wanted to hear the engine come to life before wrapping up for the night.

With the wiring complete and a few gallons of gas on board, Charles hopped into the Roadster while it was still on jack stands, and gave the ignition key a twist. The battery wasn't up to par, and with a quick battery swap from the other school car, the high-mileage donor 5.0 fired on the second try. Even with stock exhaust (which is quieter than the optional Factory Five 4-into-4 headers), the bark from the side pipes got the class jazzed, and we all erupted into cheers and applause. Now on to the home stretch.
Check out video the engine starting for the first time!
Windows Media | Quicktime