Factory Five Racing '33 Hot Rod Assembly Manual Download Page 696

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695

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508-291-3443

Appendix F: Mustang Specifications

(All information is based on V8 Ford Mustangs from 1979 to 2004)

Mustangs by year

Year & Model

Engine

Torque

Rear Susp.

Transmissio
n

Wheels

235@460

280@400

93' Mustang Cobra

302, 5.0L

Solid Axle

T-5

17"x8"

93' Mustang Cobra

235@460

280@400

"R"

302, 5.0L

Solid Axle

T-5

17"x8"

94'-95' Mustang

240@480

285@400

Cobra

302, 5.0L

Solid Axle

T-5

17"x8"

95' Mustang Cobra

300@480

365@375

Tremec

"R"

351, 5.8L

Solid Axle

3550

17"x9"

96'-98' Mustang

305@580

300@480

Cobra

DOHC 4.6L

Solid Axle

T-45

17"x8"

99'-02' Mustang

320@500

317@475

Independen

Cobra

DOHC 4.6L

T-45

17"x8"

00’ Mustang Cobra

385@625

385@425

Independen

18"x9.5

"R"

331, 5.4L

T-56

265@500

305@400

01' Mustang Bullitt

SOHC 4.6L

Solid Axle

T-45

17"x8"

DOHC

03'-04' Mustang

4.6LSupercharge 390@600

390@350

Independen

Cobra

T-56

17"x8"

03’-04’ Mustang

305@580

320@420

Tremec

Mach I

DOHC 4.6L

Solid Axle

3650

17"x8"

Engines

Year/Engine

Horsepower

Torque
Rating

Induction

Comp
Ratio

1982 5.0L V8

157 @ 4200

240 @ 2400

2V carb

8.3:1

1983 5.0L V8

175 @ 4200

245 @ 2400

4V carb

8.3:1

1984 5.0L V8

175 @ 4200

245 @ 2400

4V carb

8.3:1

1984 5.0L V8

165 @ 3800

245 @ 2000

CFI

8.3:1

1985 5.0L V8

210 @ 4400

270 @ 3200

4V carb

8.4:1

1985 5.0L V8

180 @ 4200

260 @ 2600

CFI

8.4:1

1986 5.0L V8

200 @ 4000

285 @ 3000

SFI

9.2:1

1987-93 5.0L V8

225 @ 4000

300 @ 3000

SFI

9.0:1

1994-95 5.0L V8

225 @ 4000

300 @ 3000

SFI

9.0:1

Summary of Contents for '33 Hot Rod

Page 1: ...R E V I S I O N 2 T A U G U S T 2 0 1 7...

Page 2: ...2017 Factory Five Racing Inc 9 Tow Rd Wareham MA 02571 Phone 508 291 3443 Fax 508 291 3883 www factoryfive com...

Page 3: ...D AXLE REAR SUSPENSION 56 SOLID AXLE PREPARATION 56 REAR COIL OVER SHOCK ASSEMBLY 58 TRACTION LOK BRACKETS 60 4 LINK SUSPENSION 65 4 LINK REAR SUSPENSION TORQUE SPECS CHART 66 3 LINK 67 3 LINK REAR SU...

Page 4: ...SWITCH 198 IGNITION SWITCH WIRING 199 UNDER DASH LIGHTING 200 STEERING COLUMN WIRING 201 FAN WIRING 202 ALTERNATOR 202 TROUBLESHOOTING 203 BATTERY 203 HORNS 207 ENGINE TRANSMISSION AND DRIVESHAFT 212...

Page 5: ...NGE 353 BODY TEMPORARY 355 REAR WHEEL WELL MOUNT 357 BODY CUT OUTS 360 DOOR HINGE CUT OUTS 360 DOOR SILL BODY MOUNTS 364 PEDAL BOX MASTER CYLINDER ACCESS PANELS 365 FIREWALL 370 FUEL FILLER 374 TAILLI...

Page 6: ...LL 619 FIREWALL 621 REAR BODY 623 HOOD 624 TRUNK ALUMINUM 625 FUEL FILLER 627 CARPET 629 SHIFTER BOOT AND TRIM RING 633 E BRAKE HANDLE AND BOOT 634 TRUNK LATCH CABLE 637 TRUNK RELEASE HANDLE 640 TRUNK...

Page 7: ...REAR BRAKES 696 REAR AXLE 697 STARTER 697 DRIVESHAFT 697 MASS AIR SENSOR 697 OXYGEN SENSORS 697 EXHAUST HEADERS 698 APPENDIX G WHEEL TIRE SPECIFICATIONS 699 HOT RODS WITHOUT FENDERS 699 HOT RODS WITH...

Page 8: ...he idea of building your own car is NOT for everyone It is a serious endeavor that should be undertaken with care and consideration The desire to build your own custom car goes way back It is part of...

Page 9: ...ect you order a manual talk to car guys get all excited over glossy photos and perhaps order a kit from us With the whole pregnancy thing well for most folks that s even easier to get started When my...

Page 10: ...to test out how long an 8 8 rear diff can run on a track without gear oil answer about three laps before deciding to stop moving There will be highs and there will be lows but in the end there are fe...

Page 11: ...a project of this magnitude This kit is only a collection of parts designed for use primarily as a race car Factory Five Racing does not build completed or partially completed vehicles You are respons...

Page 12: ...he working load rating is correct for the weight Work in a well ventilated and well lighted area Use portable safety lights for under carriage work Never use an exposed bulb type light Be mindful of t...

Page 13: ...pre packaged rivets 1 8 short long 3 16 short long Complete Front Suspension Unequal length control arms with in board coil over shocks Koni high performance rod end shock absorbers Coil over kit inc...

Page 14: ...e following 28 spline driveshaft for T 5 AOD or Tremec 3550 s 31 spline driveshaft for Tremec TKO 500 600 T 45 3650 T 56 Gauges and Dash and Electrical Assembly Including indicator lights switches and...

Page 15: ...mounting hardware Master Cylinders Accelerator pedal accelerator cable return spring and ball stud retainer w fasteners Brake line adapters and T fittings Fasteners Over 1600 top quality zinc plated...

Page 16: ...up points and brakes Paint Most customers will farm out the body and paint work to a professional body shop Fuel pump External carbureted or fuel injected inline pump Battery We recommend the Odyssey...

Page 17: ...s Body storage area can be outside SAE and metric socket set a 52 piece set is a good choice Deep sockets for some common sizes are helpful SAE Combination wrench set 15 16 Metric combination wrench s...

Page 18: ...quivalent 4 tubes Coolant Engine oil Gear oil Transmission Fluid Brake fluid DOT 3 Chassis grease with grease gun and grease fitting coupler Oil filter Battery Spark plugs Black permanent marker Duct...

Page 19: ...before going on to the next box Kit Parts Prep There are a number of parts in the kit that are packed as bare metal This is done to allow you to paint powder coat or chrome the parts as you desire It...

Page 20: ...ea 33515 TRUNK STRIKER MOUNT 1 00 ea 33516 TRUNK LATCH MOUNT 1 00 ea 33026 HOT ROD STEERING COLUMN 1 00 ea 33510 GRILL MOUNT LEFT 1 00 ea 33511 GRILL MOUNT RIGHT 1 00 ea 33561 HOOD HINGE STRUT BRACKE...

Page 21: ...ve the body from the chassis One person on either side located where the door openings are if you have a third person position them at the rear of the car Removing the body should be done very careful...

Page 22: ...panels fit together i e which is on top To get straight and evenly spaced rivets trace the underside of the aluminum panel around the frame members with a black permanent marker Remove any screws hol...

Page 23: ...to the holes is correct to center the rivets on the tubes Use the rivets for all of the aluminum panels unless otherwise directed The following are the recommended sizes of the Industrial Fastener Ins...

Page 24: ...www factoryfive com 508 291 3443 Use Acetone to remove permanent marker as well as any ink that is on the aluminum Panhard Bar Mount 3 Link only Remove the Panhard bar mount from the rear of the fram...

Page 25: ...24 www factoryfive com 508 291 3443 Chapter 2 Chassis Build Up Front Suspension Lower ControlArm Assembly wrench chassis grease vise or plastic hammer ratchet socket Front lower control arm components...

Page 26: ...25 www factoryfive com 508 291 3443...

Page 27: ...26 www factoryfive com 508 291 3443 Dust boot placed over lower control arm ball joint Grease fitting in lower control arm ball joint...

Page 28: ...27 www factoryfive com 508 291 3443 Thread adjuster into lower control arm Screw the Clevis into the adjuster in the lower control arm...

Page 29: ...28 www factoryfive com 508 291 3443 Insert a rod eye into the front of the lower front control arm with the jam nut in place Apply grease to front lower collar sleeve...

Page 30: ...29 www factoryfive com 508 291 3443 Install sleeve in front lower collar Install collar onto adjuster clevis...

Page 31: ...30 www factoryfive com 508 291 3443 Rod end install on lower control arm Front leg of the front lower control arms completed...

Page 32: ...31 www factoryfive com 508 291 3443 Use the diagram above to roughly set the caster and camber alignment on the front suspension until a real alignment can be put on the car...

Page 33: ...ve com 508 291 3443 Upper Control Arm Assembly 5 16 wrench chassis grease vise or plastic hammer Front upper control arm assembly Install silicone dust boot packed in the kit on the front upper contro...

Page 34: ...33 www factoryfive com 508 291 3443 Insert the poly bushings into the front upper control arm Grease the sleeve for pivot points of the upper control arms...

Page 35: ...e grease fitting and fill with grease until the grease starts to seep out Coil OverShockAssembly Snap ring pliers wrench socket Ratchet Torque wrench Front shock set Front shock set Insulated clip har...

Page 36: ...cks If using the silver double adjustable shocks these must be mounted with the body of the shock down Unpack the front shocks coil over s and hardware Double check the jam nut under the rod end and b...

Page 37: ...91 3443 On the rear shocks only use snap ring pliers to move the snap ring to the second groove on the shock body The coil over hats have a snap ring which holds it in place Remove this snap ring to a...

Page 38: ...508 291 3443 Slide the rubber bumper about two inches down on the shaft Put the spring and hat on the shock and rotate the spring seat back up the sleeve so that the spring pushes the hat tight agains...

Page 39: ...e spring is seated correctly on the shock Run zip ties through the holes in the spring hat and around the spring to prevent the spring from becoming unseated Front Suspension Build Up Install the fron...

Page 40: ...all the shocks on the chassis with the body down Use the 0 32 spacers on either side of lower the spherical joint Install the other end of the shock to the upper control arm with the 0 21 shock spacer...

Page 41: ...com 508 291 3443 Install the lower control arm onto the frame The fixed part with the ball joint is towards the rear of the arm Front spindles 13 16 socket Torque wrench Needle Nose Pliers Rubber Mall...

Page 42: ...41 www factoryfive com 508 291 3443...

Page 43: ...s on the right If installing bike fenders attach the fender mount now The steering arms are attached to the spindles with the provided hardware The steering arm pickups are oriented towards the rear o...

Page 44: ...the front spindle on the front upper control arm with the supplied castle nut and cotter pin Torque to 90 ft lbs Install the spindle on the lower control arm ball joint stud Then install the 0 25 spa...

Page 45: ...les on the control arms next Torque this castle nut also to 110 ft lbs Make sure to install the cotter pin after you torque it Once the spindles are mounted firmly on the chassis tighten the steering...

Page 46: ...45 www factoryfive com 508 291 3443 Hubs and Brakes Install the front hub onto the spindle Install the hub nut onto the spindle Torque this nut to 235ft lbs...

Page 47: ...162 100 110 Front lower clevis to bushing sleeve 100 75 Front lower ball joint to spindle 106 163 80 120 Upper A arm to frame 135 162 100 110 Upper ball joint to Spindle 95 122 70 90 Spindle hub nut...

Page 48: ...47 www factoryfive com 508 291 3443 Install the caliper slider pins on the caliper using the supplied bolts and a 16mm wrench and 12mm socket Torque to 23 26 ft lbs...

Page 49: ...48 www factoryfive com 508 291 3443 Install the slider grease boots on the slider pins...

Page 50: ...steel clips that are designed to separate the pads from the caliper These clips allow the pads to slide on a smooth surface and not wear on the caliper The four clips that go on the ends of the hange...

Page 51: ...50 www factoryfive com 508 291 3443...

Page 52: ...king up through the center hole Insert the clip from the inside of the caliper through the large center hole with the larger tab on the side facing the pistons then press down on the outer part of the...

Page 53: ...52 www factoryfive com 508 291 3443 Slide the caliper hanger onto the caliper Push the rubber boots over the lip on the caliper bracket to seal the slider bolts correctly...

Page 54: ...of each brake pad to find the inside pads and the outside pads The difference is the location of the studs that are on the back of each pad The studs on the inside pads are out near the ends of the pa...

Page 55: ...54 www factoryfive com 508 291 3443 Install the brake pads in the Caliper...

Page 56: ...e hub Install the caliper on the spindle make sure that the fluid bleeder is at the top of the caliper Note that the caliper marked LH will actually mount on the pass right side so that the bleeder sc...

Page 57: ...FFR 14513 Make sure the pads are loaded into the caliper before installing it Solid Axle Rear Suspension Solid Axle Preparation sockets wrench drill bit drill floor jack jack stands Torque Wrench 8 8...

Page 58: ...ready done fill the axle with gear oil See Appendix for specifications and capacities If using a used rear axle remove the lower shock mounts and the anti vibration weight under the pinion Drill the l...

Page 59: ...nce of this part can cause serious injury or death If using the silver double adjustable shocks these must be mounted with the body of the shock down Unpack the rear shocks coil over s and hardware Do...

Page 60: ...semble the coil over shock Slide the rubber bumper about two inches down on the shaft Put the spring on the shock then install the spring hat on the shaft end of the shock and push the rubber bumper u...

Page 61: ...Install the snap ring on the spring hat so that it holds onto the shock end Make sure that the slot in the snap ring and the slot in the spring hat are not aligned Use zip ties to hold the spring to t...

Page 62: ...61 www factoryfive com 508 291 3443 Axle Bracket Driver s Side Axle Bracket Passenger Side...

Page 63: ...ww factoryfive com 508 291 3443 Position the Traction Lok brackets on the rear end with the bolts provided the two short bolts go on the sides Insert the long bolt through the rear of the bracket and...

Page 64: ...en the two short bolts Torque to Ford Specs 75 95 Nm 55 70 lbft Attach the lower control arms to the brackets on the axle using the bolt provided Torque to 101 111Nm 75 82 lb ft The lower bolt holes p...

Page 65: ...ith the body of the shock down FFR 12217 12218 33241 Make sure to use one of the 0 32 spacers on either side of the spherical joint Make sure to insert the bolt from the front placing the nut to the r...

Page 66: ...lace the rear axle assembly on a jack and move it into position Install the lower control arms onto the frame with the provided hardware making sure to install this bolt from the center of the car goi...

Page 67: ...smaller 0 125 shim FFR 13210 is placed at the rear Install the upper control arms onto the frame and the axle These are attached to the frame with provided hardware 4linkRearSuspensionTorqueSpecsChar...

Page 68: ...67 www factoryfive com 508 291 3443 Upper shock to frame 54 67 40 50 Lower shock to axle bracket 54 67 40 50 3 Link 3 link setup in chassis...

Page 69: ...link bracket onto the axle using the fine hardware FFR 12217 12218 The bottom attachment of the axle clamp bracket attaches to the hole on the flange section of the pumpkin This hole has some varianc...

Page 70: ...leg of the axle clamp bracket to the rear end housing FFR 11020 13964 13977 Insert the rod ends into the swedged tubes one is right hand thread and one is left hand thread The longer tube is the Panh...

Page 71: ...70 www factoryfive com 508 291 3443 Install the upper link onto the axle clamp bracket using the 5 8 x 3 00 bolt and locknut Place the rear axle assembly on a jack and move it into position...

Page 72: ...ke sure to install this bolt from the center of the car going outward to the side of the car FFR 13976 13706 13751 Install the shocks body down to the rear axle assembly FFR 12332 10834 The longer spa...

Page 73: ...anhard bar mount with the suspension at full droop Install the upper link onto the frame this bolt must be inserted form the inside of the frame going outward Make sure to use one of the 0 25 spacers...

Page 74: ...side traction lock bracket Three spacers are used in the front 2 0 375 FFR 33239 and 1 0 25 FFR 33240 The rear uses the thin 0 0625 shim FFR 13337 The Panhard bar is then installed on the Panhard fram...

Page 75: ...Upper link to axle 101 111 75 82 Upper link to frame 101 111 75 82 Lower control arm to axle 101 111 75 82 Lower control arm to frame 101 111 75 82 Upper shock to frame 54 67 40 50 Lower shock to axl...

Page 76: ...RS parts Super 8 8 center section L R spindles L R brake parts Mustang IRSSpecifications 2 3L Ecoboost 3 7L V6 5 0L Coyote Housing Steel Aluminum Steel Weight 93lb 78lb 93lb Gear Ratios 3 15 1 3 31 1...

Page 77: ...291 3443 Use a 5 8 drill bit to drill out the tapered hole at the top of the spindle Mark the spindle starting at the top just to the inside of the top inside hole down to the corner of the small bos...

Page 78: ...e spindle If using a Sawzall or similar use a wood blade a 14tpi blade or finer will just get gummed up with the aluminum Hubs Hammer vise ratchet 20 lugnut torque wrench Rear wheel studs Removal of t...

Page 79: ...vise to lightly hold the side of the wheel stud head then use a hammer to bang out the Mustang studs Repeat for all of the studs Insert one of the included wheel studs into the hub from the back and u...

Page 80: ...79 www factoryfive com 508 291 3443 Use a ratchet to draw the wheel stud into the hub and torque the stud to 135Nm 100lb ft Repeat for the other wheel studs...

Page 81: ...80 www factoryfive com 508 291 3443 If the Hub was removed use Loctite on the threads and reattach to the spindle Torque the bolts to 133Nm 98ft lb Center section 5 8 drill bit drill...

Page 82: ...81 www factoryfive com 508 291 3443 Use a 5 8 drill bit to chase the front mount holes on the center section Frame Rubber plastic mallet Differential mounting components...

Page 83: ...2 www factoryfive com 508 291 3443 Bushing locations Use a plastic mallet to install the polyurethane bushings marked 2048 and the longer 31 16 sleeves where the front of the center section will mount...

Page 84: ...m 508 291 3443 Use a plastic mallet to install the polyurethane bushings marked 2123 and the shorter 2 40 sleeves where the rear of the center section will mount Upper control arms Upper control arm c...

Page 85: ...Grease the control arms using chassis grease until the grease comes out of the flutes in the bushings next to the pivot sleeves Lower control arms Grease gun Grease the control arms using chassis grea...

Page 86: ...e adjustment arms as shown Installation Center section Rubber plastic mallet torque wrench 18mm 13 16 sockets 15 16 wrench Differential mounting components Roadster is shown but Hot Rod installation i...

Page 87: ...86 www factoryfive com 508 291 3443 Use rags to protect between the front center section mount on the frame...

Page 88: ...87 www factoryfive com 508 291 3443 With the help of a friend lift the center section nose up into the frame and over the front mount...

Page 89: ...er section out so it is horizontal then back it up so it is above the mount locations and lower it down so the bolts can be installed The smaller shorter bolts are used for the rear mounts The larger...

Page 90: ...on the front side of the rod end Use the 5 8 x 2 25 bolts to attach them to the frame Torque bolts to 135Nm 100 ft lb Lower control arms IRS lower control arm components 13 16 socket 15 16 wrench tor...

Page 91: ...rame with the thick tube at the front Use the longer M16 x 110mm 45 16 bolts Hold the arm horizontal and torque the bolts to 135Nm 100 ft lb CV Axle CV Axles spindles The inside CV joint is different...

Page 92: ...into the center section When fully installed there should be an 1 8 3mm gap between the inside of the CV joint and the center section If necessary compress the CV axle and with the CV axle nut on the...

Page 93: ...92 www factoryfive com 508 291 3443 Slide the left spindle onto the outer CV joint and start the nut on the end...

Page 94: ...com 508 291 3443 Spindle to Lower arm Connect the bottom of the spindle to the lower control arm using the M16 x 90mm bolts and locknuts Right side shown Wait to torque the bolts until after the other...

Page 95: ...e com 508 291 3443 Spindle to Upper arm Insert the angled mount adapter into the upper arm rod end Reuse the 5 8 washer that was on the old bolt and place it on the new 5 8 x 4 25 bolt along with a mi...

Page 96: ...91 3443 Attach the upper control arm to the spindle using the bolt with the misalignment spacer Use a 15 16 wrench 15 16 socket and ratchet to tighten the locknut Wait to torque the bolts until after...

Page 97: ...arm rod end make sure that the rod end is not touching the spindle and that it is aligned with the upper control arm Once the car has been aligned use a 15 8 wrench to loosen the upper control arm lar...

Page 98: ...Over Shock Assembly Snap ring pliers wrench socket Ratchet floor jack Shock set Insulated clip hardware The shocks are pre valved at the factory in compression and rebound for good street use The sho...

Page 99: ...nd bump stop to make sure that it is tight Screw the spring seat down on the sleeve so it is closer to the unthreaded end Slide the coil sleeve over the body of the damper beginning at the end which h...

Page 100: ...ww factoryfive com 508 291 3443 The coil over hats have a snap ring which holds it in place Remove this snap ring to assemble the coil over shock Slide the rubber bumper about two inches down on the s...

Page 101: ...rotate the spring seat back up the sleeve so that the spring pushes the hat tight against the end of the shock Install the snap ring on the spring hat so that it holds onto the shock end Make sure th...

Page 102: ...f the shock to the upper shock mount using the two equal length 0 32 kit spacers Make sure to insert the bolt from the front placing the nut to the rear of the car allows you to remove the shocks when...

Page 103: ...in front of the shock Torque the lower shock bolt to 54Nm 40 ft lb Remove the floor jack Driveshaft adapter There are two different Driveshaft adapters one for center sections from automatic cars whic...

Page 104: ...w factoryfive com 508 291 3443 Apply Loctite to the 6 M10 x 25mm socket head screws Attach the driveshaft adapter to the center section pinion flange and torque the bolts in a star pattern to 55Nm 41...

Page 105: ...SAE 75W 85 Synthetic Hypoid Gear Lubricant 3 15 3 30 pt 1 49 1 56 L Friction Modifier 3 0 3 5 oz 0 089 0 104 L Alignment specs Camber 0 5 to 0 75 Total Toe 1 8 Toe in Torque Specifications LB FT Nm C...

Page 106: ...www factoryfiveparts com instructions and install the brakes Connect the brake hose to the brake caliper Torque the banjo bolt to 39 Nm 29 ft lb Run the brake hose over to the frame while the suspens...

Page 107: ...106 www factoryfive com 508 291 3443 Wilwood e brake adapter Insert the cable end into the bent bracket then bolt the bracket to the e brake lever...

Page 108: ...d brake routing Run the left e brake cable over the top of the center section and left rear mount then down and over to the brake caliper Run the right cable over the center section and right rear mou...

Page 109: ...ow is a good time to paint all of the bare steel brackets The brake switch may look different than in the pictures The pedal box comes with two pedal switches one for the brake lights and the other ca...

Page 110: ...e of the mount bracket Clutch safety switch mount The clutch switch mount attaches the same way as the Brake switch mount Place the switch mount between the clutch pedal mount tabs on the side closest...

Page 111: ...the switch mount using a hex nut on each side of the mount bracket Optional Clutch Cable Quadrant For use with optional manual transmission components If you are using an automatic remove the clutch...

Page 112: ...111 www factoryfive com 508 291 3443 Use snap ring pliers to remove the clevis at the top of the clutch pedal...

Page 113: ...112 www factoryfive com 508 291 3443 Assemble the clutch quadrant to the Wilwood clutch pedal as shown above...

Page 114: ...use a file to remove the forging centerline so the 3 8 bolt can go through the clutch pedal hole Pedalbox Installation Attach the pedalbox to the underside of the frame brackets using the 5 16 x 1 bu...

Page 115: ...1 3443 Clutch quadrant stop If you building a manual transmission car you need install the clutch quadrant stop Install the aluminum spacers between the frame and the clutch quadrant stop bracket and...

Page 116: ...rovided with the Master cylinders they will get used with the door hinges The front master cylinder is the 0 75 master 0 625 is the rear master 6mm socket deep socket ratchet wrench Master cylinders W...

Page 117: ...116 www factoryfive com 508 291 3443 Screw the 90 brake line adapter into the end of the master cylinder making sure that the opening points up when tight...

Page 118: ...der mounts and turn the threaded shaft into the threaded mount on the brake pedal As a starting point thread the shaft in until you can see it is flush on the other side of the mount The brake pedal m...

Page 119: ...hten the locknuts using a wrench holding the master cylinder to the pedal box then repeat for the other master cylinder Put the plastic angled inlet adapter with hose clamp on the master cylinders Use...

Page 120: ...he other To set up the balance bar thread the master cylinder pushrods through their respective clevises to obtain the desired position Threading one pushrod into its respective clevis means threading...

Page 121: ...ter cylinder pushrods remain true in relationship to the cylinder during entire pedal travel pushrods should not be pushing master cylinder pistons at an angle In its non depressed position the pedal...

Page 122: ...8 291 3443 Clamp the front passenger footbox in place Clamp the driver side footbox front panels has steering shaft hole in it in place Firewall Marker drill silicone clamps Secondary body fasteners p...

Page 123: ...three pieces where they come in contact with the frame Remove the three panels Determine how you want to install your firewall 3 16 rivets 20 button heads or any other type of fastener We recommend th...

Page 124: ...le hole 1 375 hole saw drill 3 16 drill bit silicone Manual Transmission components For use with optional manual transmission components If you are building a manual transmission car lay the following...

Page 125: ...124 www factoryfive com 508 291 3443 Drill the center mark with a 3 16 drill bit Drill the firewall for the clutch cable...

Page 126: ...voirs one for each master cylinder The other way is only use one reservoir and put a Y in the line to go to the two reservoirs There are also two ways to mount the reservoirs in the engine bay or over...

Page 127: ...126 www factoryfive com 508 291 3443 Screw in the hose barb Loosely screw the mounting bracket onto the reservoir...

Page 128: ...reservoir can either be mounted in the engine bay on the firewall or on the inside of the firewall depending on personal preference Mounted inside the reservoir would be accessed through the hole in...

Page 129: ...ons on the frame Make sure that the top of the mounting flange is below the top of the frame tube or the cap will hit the body Remove the reservoir and use a 5 16 nut driver to drill screw the self ta...

Page 130: ...291 3443 Attach the steering shaft flange bearing to the front surface of the firewall using the 5 16 Button head and locking nut Place a piece of masking tape on the firewall and mark the location of...

Page 131: ...Steering Rack 15mm 16mm 5 8 socket Ratchet 16mm 17mm 5 8 wrench Torque wrench Steering Rack Assembly The steering rack is installed onto the chassis with the input shaft facing down and to the driver...

Page 132: ...ww factoryfive com 508 291 3443 On the left side of the rack use the M10 fasteners Push the bolts through but do not fasten with the locknuts yet On the right side the rack is mounted using a steel br...

Page 133: ...t bottom to the frame but do not tighten the nuts attach the top bracket Check the fitment of the rack on the rack mount make sure that the large nut on the rack is not hitting the plate If it does us...

Page 134: ...ounting lock nuts Make sure the jam nut is on the inner tie rod then spin the outer tie rod onto the inner tie rod Insert the Tie Rod into the spindle with the stud pointing down For now align the fro...

Page 135: ...is used for the rear brakes Run the brake lines starting at the master cylinders The master cylinder is used for front and the 5 8 master cylinder is used for the rear brakes Connect a 60 section of...

Page 136: ...the brake line towards the outside of the car along the outside of the 1 5 frame rail Route both of the brake lines through to the engine side of the firewall by passing it between the frame and the 4...

Page 137: ...136 www factoryfive com 508 291 3443 At the bottom of the footbox split the lines and angle one towards the front of the car and one towards the rear...

Page 138: ...electric steer motor or the flange bearing for the steering linkage install a female female brake line union Coming off one side of the brake line union attach a 20 section of brake line Route this br...

Page 139: ...3 female T junction Install an 8 section of brake line and route it towards the driver side wheel Install the brake line mount on the round tube under the upper control arm This mount is installed wit...

Page 140: ...is line to the passenger side of the car Install the brake line mount on the round tube under the upper control arm This mount is installed with 2 3 16 rivets Fasten the braided brake line onto the fr...

Page 141: ...140 www factoryfive com 508 291 3443 Rear Brake line Route the initial 60 section of brake line along the outer 1 5 frame rail attaching it as you go with the insulated line clips...

Page 142: ...ece install a female female union and attach a second 60 section of brake line At the end of the passenger compartment route the brake line up the back side of the vertical 1 5 tube Stay to the inside...

Page 143: ...pper control arm mount tube The body will be very close to the outside of the 1 5 tube so do not go to the outside If you are using your own rear brake assembly attach the rear brake line mounts now O...

Page 144: ...143 www factoryfive com 508 291 3443 Insert the adapter into the brake line mount Attach the 2 female 1 male brake line adapter to the flexible brake line adapter...

Page 145: ...om 508 291 3443 Rotate to clock the brake line adapter as shown in the picture and push on the brake line clip Use a set of pliers to make sure the clip is fully seated around the groove in the flexib...

Page 146: ...ve com 508 291 3443 Hand tighten the rear brake line to the end of the brake line mount assembly and position the mount on the frame Place a crush washer on either side of the banjo fitting on the fle...

Page 147: ...the flexible brake line to the brake line frame mount by hand so that you can make sure that the brake line is not tight If necessary move the brake line mount to a new location so that the flexible l...

Page 148: ...the axle is at ride height Move the mount if necessary Place some masking tape on the frame tube and mark the hole locations for the mount Move the mount out of the way and drill one of the 3 16 moun...

Page 149: ...ke line from the side of the brake line mount up to the 1 5 tube at the back of the frame making sure to leave room around the bolts for the 3 link frame mount if you are running it Route the line tow...

Page 150: ...n the brake line down the frame on the passenger side to a location similar to the driver side again leaving room around the 3 link mount bolts if running it Attach the flexible brake line adapter to...

Page 151: ...ake caliper Attach the flexible brake line to the hard brake line and check the reach of the flexible brake line Put some masking tape on the frame where the mount is located Mark one of the mount hol...

Page 152: ...and attach a rivet Steering Column wrench socket ratchet flathead screwdriver Steering column steering column components The standard column material is brushed steel so you may want to coat paint or...

Page 153: ...2 www factoryfive com 508 291 3443 Fasten each of these points onto the chassis with the provided hardware FFR 13965 11058 Install the turn signal stalk onto the steering column with the provided scre...

Page 154: ...n Steering shaft 5 32 hex key wrench Steering shaft components When installing the steering linkages loosely install the entire system then tighten the bolts and s e t screws once it is complete With...

Page 155: ...154 www factoryfive com 508 291 3443...

Page 156: ...to DD joint on to the steering column output shaft using a 5 32 Hex key and wrench The smaller end goes on the steering column Install the 117 16 upper steering shaft in the other side of this joint...

Page 157: ...the bearing On this joint use the short set screw provided and no jam nut next to the firewall Use Loctite on this set screw when tightening for the final time Push the steering joint 9 16 26 spline...

Page 158: ...the frame bracket using the 5 16 button head fasteners Install the flange bearing is installed on the front face of the frame mount with the locking collar forward Do not tighten the locknuts until t...

Page 159: ...aring and attach it to the steering rack joint Again make sure the end of the shaft is flush with the inner part of the joint Attach the 151 16 middle DD steering joint to the end of the front steerin...

Page 160: ...3 Insert the middle steering shaft into the lower joint first then insert it into the firewall joint Tighten all of the set screws jam nuts and flange bearing fasteners Don t forget to locktite the sm...

Page 161: ...at is being used The bearing mount has holes to fit the 4 6L and 302 Ford engines with a stock style double sump pan If a different pan or engine is used it is better to install the engine without the...

Page 162: ...161 www factoryfive com 508 291 3443 Attach a joint to the front of the electric steering unit Insert the small DD shaft into the joint on the front of the electric steering unit...

Page 163: ...162 www factoryfive com 508 291 3443 Insert the DD shaft into the steering rack joint Attach the rack joint onto the steering rack so the screw is on the flat side...

Page 164: ...3 Mount the electric steer unit on the frame mount below the engine mount It is mounted on the front face of this bracket with the hardware provided with the unit If necessary for frame clearance remo...

Page 165: ...164 www factoryfive com 508 291 3443 Tighten the locking screws and nuts for the front shaft...

Page 166: ...olt from the remaining splined joint with a 6mm hex key and insert the 151 16 middle steering shaft into the joint Make the end of the shaft flush with the inside face of the joint and use a marker in...

Page 167: ...actoryfive com 508 291 3443 Grind a relief in the steering shaft for the bolt that is used in the steering joints Insert and attach the steering shaft into the splined joint and loosely insert the loc...

Page 168: ...lined u joint to the back of the electric steering unit loosely with the locking bolt Hold the middle shaft up to the joint that is mounted on the firewall and mark where the shaft needs to be cut so...

Page 169: ...om 508 291 3443 Remove the shaft and cut the end of the shaft with a hack saw or similar and grind the end of the shaft so that it will slide into the joint a little easier Insert the shaft into the j...

Page 170: ...169 www factoryfive com 508 291 3443 Remove the splined joint from the electric steering unit and push it onto the shaft Push the splined joint onto the electric steering unit...

Page 171: ...m 508 291 3443 Tighten all of the set screws jam nuts and flange bearing fasteners Don t forget to locktite the small set screw on the firewall joint Control Module mounting Insert the harness plugs i...

Page 172: ...ule either in the engine bay where the wires will reach or behind the dash if you extend the wires so that the module does not get excessive water contact These pictures show a fabricated bracket moun...

Page 173: ...172 www factoryfive com 508 291 3443 Use the diagram above for hole drilling Wiring Return to this section and do the wiring after the chassis harness is installed...

Page 174: ...173 www factoryfive com 508 291 3443 Run the power wires from the control module up into the pedalbox area where the brake lines come out...

Page 175: ...yfive com 508 291 3443 Run the wires up the side of the 1 50 square tube Wire the large red wire to constant 12 volts The 30 amp slow blow fuse needs to be installed in line with this wire to prevent...

Page 176: ...nal purpose make sure to note the new function on the fuse panel and also make sure the correct fuse size is used Optional Wire an LED for use as a dash warning light for the electric steering The ora...

Page 177: ...steering wheel hub to the steering column with the nut which came on the steering column Mount the steering wheel to the hub using the fasteners which came with the steering hub The steering wheel cen...

Page 178: ...177 www factoryfive com 508 291 3443 Wiring Harness and Battery Cable Main wiring harness A larger latest revision is packed with the harness...

Page 179: ...ion If you have any technical questions concerning this installation please call and ask for our tech department Route the harness away from sharp edges exhaust pipes and moving parts Have all needed...

Page 180: ...e block to the aluminum mount plate using the screws and locknuts You will have to remove the flashers from the panel to do this Position the fuse block and the mounting plate to the right of the peda...

Page 181: ...mounting location Drill into the 1 5 square tube firewall mounting surface tube and the tube lower one which triangulates the pedal box mounting location Install the panel with rivets Attach the groun...

Page 182: ...Locate the electronic flashers in the kit pack These must be used instead of the standard flashers because of the LED rear lights The flashers are located on the fuse block for the flasher and turn si...

Page 183: ...182 www factoryfive com 508 291 3443 For now use zip ties to begin draping the harness into the car The main wiring harness will exit the cockpit towards the right side of the transmission tunnel...

Page 184: ...183 www factoryfive com 508 291 3443 Rear Harness Battery cable Locate the rear wire harness and the battery cable...

Page 185: ...all route the cable and harness to the rear of the car by running it over the transmission mount and under the top 1 square tube holding it in place loosely with zip ties temporarily At the back of th...

Page 186: ...d will get attached to the battery after installation and the rear harness continues up next to the battery mount location and over the 1 50 tube Drape the harness over the rear axle straight back to...

Page 187: ...e fuel pump will get located on the right middle side of the frame while the fuel level is on the left side of the frame An in tank pump is close to the fuel level sender so it is not necessary to sep...

Page 188: ...ke line running across the car Moving forward towards the firewall pull the harness and battery cable tight and attach them to the frame every 12 or as needed using the insulated clips FrontHarness Ra...

Page 189: ...Loosely run the front harness to the front of the car The best place to bring this harness into the engine bay is to the left of center directly under the firewall piece of aluminum passing through t...

Page 190: ...factoryfive com 508 291 3443 Run the harness forward to the engine mount then run it along the inside of the 1 50 square tube next to the brake line Forward of the X bring the harness up above the 3 1...

Page 191: ...e left headlight harness to the 1 50 round tube going to the upper control arm Pull the blue fan wire and the ground back out of the harness so that it can get located front and center Run the right s...

Page 192: ...1 3443 Locate center the fan wires If necessary use scrap wire of the correct gauge to extend the ground wire Re tape where the fan wires come out of the harness Drill a 3 16 hole in the center of the...

Page 193: ...192 www factoryfive com 508 291 3443 Insert a long 3 16 rivet into a small insulated line clip Rivet the line clip to the back of the lower control arm mount plate...

Page 194: ...193 www factoryfive com 508 291 3443 Use a zip tie to hold the front harness to the line clip Run the right headlight harness up the right 1 50 round tube...

Page 195: ...194 www factoryfive com 508 291 3443 Leave the right headlight harness around the grill mount until the headlight is wired later StarterSolenoidWiring Locate the starter solenoid wires...

Page 196: ...smaller S terminal connect the LT BLU NS SW START if you are running an EFI car you will have additional wires connected to this terminal as seen in the picture Brake Switch Locate the brake switch p...

Page 197: ...of the spades on the brake pedal switch ClutchSafetyswitch A clutch safety switch is used to prevent starting the car while in gear It requires pushing the clutch pedal in while starting the car Anot...

Page 198: ...acing main kit pack FuelInertiaSwitch Drill nut driver Use the fuel inertia cut off switch attached to the main harness near the fuse panel as a guide and mount the inertia fuel cut off switch to the...

Page 199: ...Headlight switch Locate the headlight switch plug and install it onto the headlight switch Install the female spade connector which is connected to the black wire ground onto the male spade connector...

Page 200: ...gnition switch wires and make the following connections to the ignition switch itself Ignition wiring After you connect the wires to the correct terminals tape over the backside of the casing with ele...

Page 201: ...200 www factoryfive com 508 291 3443 Under dash lighting Install the under dash lights on the frame as desired according to the wiring harness instructions...

Page 202: ...assis harness plug Locate the dash harness section of the chassis harness Cut the horn wire back and tape the end so that it will not ground out and make the horn go off once they are connected Cut th...

Page 203: ...e alternator wires and gauge sender wires for use with the coil Fuel Injected Engine Leave the coil and crank wires in the footbox and connect them to the power wires for the EFI harness according to...

Page 204: ...f the Alternator stops working the light will stay on Troubleshooting Some of the areas that can cause problems are Inertia Switch This switch can cause a no start problem Make sure that the button is...

Page 205: ...the rear bulkhead of the cockpit We recommend the Odyssey PC925 dry cell or similar The battery is held in place with the center mount cross bar hold down and the J bolts Mock up these items on the b...

Page 206: ...e the battery and drill the holes for the J bolts to pass through Drill a hole in the side of the battery mount plate for the ground cable to attach Grind the paint or powder coat so that the ground c...

Page 207: ...ten the center mount cross bar hold down to the battery Attach the chassis side of the ground strap onto the chassis with the supplied 5 16 button head fasteners Depending on the battery choice you ma...

Page 208: ...the battery until all of the wiring on the vehicle is finished Horns 14mm wrench wire cutters wire crimpers 5 32 hex key Hot Rod Electrical system components There are a couple of possible locations...

Page 209: ...ng instructions The wires are long enough to reach either location Attach one horn to the included bracket using one of the 14mm lock washers and nuts included Note the orientation of the wire connect...

Page 210: ...209 www factoryfive com 508 291 3443 Mounting brackets on the horns Holding the horns the connectors should be spaced so that the wires will not hit each other...

Page 211: ...nd of the chassis harness horn ground wire and strip the end of the chassis harness ground wire Twist the chassis harness ground wire and small wire ground together and insert them into one of the fem...

Page 212: ...ires Twist the chassis harness green wire and small wire ground together and insert them into one of the female connectors included with the horns then crimp the connector on Attach the chassis harnes...

Page 213: ...iveshaft If installing a small block Chevy LS or Ford Coyote Engine go to www factoryfiveparts com instructions for installation instructions Appendix J has the various driveshaft lengths that we stoc...

Page 214: ...213 www factoryfive com 508 291 3443 289 302 351 engine mounts 4 6L Coyote engine mounts If you are using a 4 6L engine you may have to modify the oil filter bracket assembly You can also...

Page 215: ...e one which works perfectly from a 2003 4 6L Explorer part number 1L2Z 6881 AA and F6AZ 6840 BA for the gasket Some engine choices also need a short style oil filter We recommend the Purolator L17019...

Page 216: ...Cut any extra length off the bolts to preventdamaging the firewall Install the engine mount mounts onto the frame with the 20 hardware FFR 33454 25619 It is helpful to only bolt the top of the mount...

Page 217: ...ion engine mounts to the engine before installing the engine If the chassis is powdercoated you may want to protect the engine bay down tubes Once the engine is in place pivot the engine mount bracket...

Page 218: ...Lift on the rear of the transmission and slide this bracket into place It is fastened to the chassis with the carriage bolt washer and nut Depending on the transmission choice you may have to use the...

Page 219: ...ng the front of the driveshaft onto the output shaft of the transmission Fasten the axle to the rear end with the 12 point bolts supplied with the driveshaft Torque these bolts to 90 ftlb Fill the eng...

Page 220: ...that holds the starter cable just before it leaves the block or to the lower engine bay tubing Make sure that the cable is clear of the hot exhaust header and the steering shaft or the cable may fail...

Page 221: ...ive com 508 291 3443 Engine Ground Sand paper or grinder bit socket ratchet 3 16 hex key drill 5 16 drill bit Electrical system completion components Undo one of the engine mount bolts on the right si...

Page 222: ...221 www factoryfive com 508 291 3443 Pass the engine mount bolt through the ground strap Attach the ground strap to the engine...

Page 223: ...222 www factoryfive com 508 291 3443 Find a location on the frame to mount the ground strap The back side of the right engine mount is a good place Drill a 5 16 hole at the mount area...

Page 224: ...223 www factoryfive com 508 291 3443 Remove any powdercoat or paint around the hole for a good ground Attach the ground strap using the 5 16 button head screw and locknut provided...

Page 225: ...224 www factoryfive com 508 291 3443 Front Grill Radiator and Fan Ruler marker 25 64 drill bits 5 32 hex key riv nut tool grinder...

Page 226: ...ll Radiator The radiator has a built in Transmission cooler that can be used if so desired Lay the grill on its front and use a marker to mark the location of the holes on the radiator mount tabs on t...

Page 227: ...226 www factoryfive com 508 291 3443 Place the radiator on the grill so that the radiator tabs are centered on the grill mounts Transfer the marks from the grill to the radiator...

Page 228: ...227 www factoryfive com 508 291 3443 Use a ruler to mark the locations of the holes on the radiator mount tabs Remove the radiator from the grill and drill mounting holes in the radiator mount tabs...

Page 229: ...443 Lay the radiator back on the grill and check the hole alignment by putting the button head screws in as many holes as possible If necessary with the radiator and screws in the grill use the drill...

Page 230: ...Remove the radiator from the grill Open up the holes in the grill using a 25 64 drill bit Install Riv nuts in the grill holes If you are installing an A C unit in the car mount the Condenser to the ra...

Page 231: ...e radiator to the grill using the 20 x screws provided FanThermostat switch Teflon tape 11 16 wrench Cooling components front grill If you are not running the thermostat switch this hole can be plugge...

Page 232: ...231 www factoryfive com 508 291 3443 Insert the electric fan thermostat switch in the bottom center threaded bung on the radiator Carefully tighten the thermostat switch...

Page 233: ...key wrench Cooling components front grill Attach the fan mounts to the electric fan using the 10 32 fasteners provided Insert the screws from the bottom side so that the nut is on top of the fan This...

Page 234: ...3443 Rotate the fan assembly so that the fan wires are on the bottom and the mount bars go across the radiator then push the fan assembly onto the back of the Radiator by putting one side in then the...

Page 235: ...toryfive com 508 291 3443 Push on the fan mount sides against the Radiator tabs or hold the fan mount side against the tab with a pair of pliers Drill though the radiator tab and fan mount with a 13 6...

Page 236: ...ng the screws and lock nuts provided Pass the screw from the outside in for a clean look Grill Assembly 5 32 Hex key 7 16 wrench floor jack Front Grill cooling components secondary body fasteners If r...

Page 237: ...ctoryfive com 508 291 3443 Use a floor jack to hold the bottom of the grill while getting the assembly into position Hold the grill up to the grill frame mounts so that the mounts are on the inside of...

Page 238: ...using the flat head socket screws and locknuts in the secondary body fasteners Leave the locknuts loose to allow adjustment when the hood and engine side covers are put on later Wiring Wire cutters wi...

Page 239: ...factoryfive com 508 291 3443 Cut the fan wire so that it can connect to the plug Install a spade connector onto this wire and connect it to the fan wires Make sure to connect it to the blue wire of t...

Page 240: ...ermostat sender which you just installed in the radiator With this setup the fan will operate by interrupting the ground to operate the fan Make sure your grill radiator is grounded If you are having...

Page 241: ...ower Radiator Hose Open one of the radiator hose adapter kits and remove the adapters inside the larger hose and the hose clamps from the outside of the hose Cut off the end of the larger hose Push th...

Page 242: ...g one of the hose clamps and a 7mm socket and ratchet It gives a clean look if you position the hose clamp so that the screw is accessible but is not seen From the underside of the frame pass the corr...

Page 243: ...he rubber hose adapter on the water pump inlet You will have to put a sharp bend in the end of the tube Do not hose clamp it On the underside of the frame route the corrugated hose straight to the low...

Page 244: ...243 www factoryfive com 508 291 3443 Remove and cut the corrugated tube with a hack saw or band saw Re install the corrugated tube and hose clamp it to the water pump using a 7mm socket and ratchet...

Page 245: ...3 Open one of the radiator hose adapter kits and remove the adapters inside the larger hose and the hose clamps from the outside of the hose Push the hose onto the lower radiator outlet and hose clamp...

Page 246: ...ive com 508 291 3443 Upper Radiator Hose Open one of the radiator hose adapter kits and remove the adapters inside the larger hose and the hose clamps from the outside of the hose Push the hose onto t...

Page 247: ...one of the hose clamps and a 7mm socket and ratchet It gives a clean look if you position the hose clamp so that the screw is accessible but is not seen Bend and route the hose over to the radiator i...

Page 248: ...rrugated tube with a hack saw or band saw Open one of the radiator hose adapter kits remove the adapters and the hose clamps from the large hose Push the thinner hose adapter onto the radiator inlet P...

Page 249: ...adiator using a hose clamp 7mm socket and ratchet It gives a clean look if you position the hose clamp so that the screw is accessible but is not seen Re install the corrugated tube and hose clamp it...

Page 250: ...stem Overflow Tank Cooling components The overflow tank can either get mounted to the radiator as shown in the diagram before the radiator installation or directly to the firewall Attach the overflow...

Page 251: ...five com 508 291 3443 Fuel Filter Unpack the fuel filter and mounting hardware Open the hose clamp and slide it through the slots in the mount and start to tighten it back up into a hoop just bigger t...

Page 252: ...e filter in place on the mount with the filter flange oriented as shown The fuel filter is installed near the battery behind the passenger seat If necessary slide the tank back a bit then drill and at...

Page 253: ...key drill bit drill rivet tool silicone gun Install the front aluminum floor that goes under the front of the fuel tank Place the fuel tank onto the frame The angled face of the tanks sits right behi...

Page 254: ...ge arms to the frame Do this by installing the bronze bushings in the trunk hinge arms The trunk hinge is attached to the frame with the 1 shoulder bolt The arm attaches to the frame on the bracket wh...

Page 255: ...ont face of the tank comes into contact with the 1 down tubes Make sure the rear face of the tank is behind the horizontal tube located above the tank the trunk aluminum has to attach to this tube dur...

Page 256: ...91 3443 Using a marker mark the location on the frame where the 4 mounting locations Remove the tank and drill the 4 mount locations on the frame tabs with a drill bit Place the tank back into the fra...

Page 257: ...256 www factoryfive com 508 291 3443 Fuel TankVent 5 16 sockets ratchet 2 1 wrenches Teflon tape razor knife Wrap the vent with Teflon tape Screw the vent into the plastic bushing and tighten...

Page 258: ...257 www factoryfive com 508 291 3443 Insert the rubber grommet into the small hole in the top of the tank Push the vent into the grommet...

Page 259: ...258 www factoryfive com 508 291 3443 Attach a 25 section of 5 16 fuel line and fuel line clamp onto the vent and rotate the vent so that it points forward...

Page 260: ...to the tube near the battery and attach it to the tube using a zip tie Fuel Pick up prep If the car will have a high horsepower fuel injected engine there are a few tweeks we recommend get done to the...

Page 261: ...d discard the rubber piece on the end of the return line this can affect the fuel pressure at the engine Starting with a drill bit drill out the end of the send line then change to a 9 32 or 19 64 dri...

Page 262: ...yfive com 508 291 3443 Starting with a drill bit drill out the end of the return line then change to a 9 32 or 19 64 drill bit the pressed end is a little restrictive Fuel Pick up Hammer large flat he...

Page 263: ...262 www factoryfive com 508 291 3443 Place the rubber ring in the groove in where the sender will go in the top part of the tank near the vent...

Page 264: ...om 508 291 3443 Insert the pick up into the tank as shown rotating it as it bends so that it will end up in the basket in the tank and the small tabs on the underside of the top plate go in the slots...

Page 265: ...at head screwdriver to lock the lock ring in place making sure that all three tabs catch the ring Make sure that the lock ring is held by all three locking tabs on the tank or the sender will leak Fue...

Page 266: ...265 www factoryfive com 508 291 3443 Place the rubber ring in the groove in where the sender will go on the lower part near the trunk hinge arm...

Page 267: ...Fuel level sender into the tank the float will point towards the middle of the tank once the small locating tabs are in the slots Use a hammer and flat head screwdriver to lock the lock ring in place...

Page 268: ...cking tabs on the tank or the sender will leak Fuel Filler neck 5 16 socket ratchet razor knife The fuel fill tube has to be modified to fit into the car perfectly Trim material off both sides of the...

Page 269: ...el cap on the end of the fuel fill tube and attach it to the fill tube with a hose clamp It is also a good idea to wire tie this to the frame to hold it in place for now Fuel Lines Tube bender 3 16 dr...

Page 270: ...he is used for the return if needed The fuel lines will run from the tank down the 1 50 square tube then along the right side of the frame on the inside of the 1 50 tube to the firewall and up Run the...

Page 271: ...ould like the fuel lines to end up in the engine bay along with where you are going to install your fuel pressure regulator if using a separate regulator Usually this is on the right side of the firew...

Page 272: ...271 www factoryfive com 508 291 3443 Install the rubber fuel hose from the hard line to the engine Make sure to clamp the line onto the barbs with the correct size hose clamps...

Page 273: ...om 508 291 3443 Fuel line The larger fuel line is the feed for the engine Install the 5 16 fuel line barb at the end of one of the 60 5 16 lines Push one of the quick connect fittings onto the out sid...

Page 274: ...he 5 16 fuel line 2 from the fuel filter far enough away that you can disconnect the fitting from the filter Note the location of the vertical 1 50 square tube and bend the line so it will go down the...

Page 275: ...274 www factoryfive com 508 291 3443 Run the fuel line down the back of the 1 50 tube and then bend and snake it over the tube and under the top 1 50 tube...

Page 276: ...d drill 3 16 rivet holes then place the rivet in the hole to hold it in place but do not pull the rivets with the rivet tool yet Measure and cut a 3 section of the rubber 5 16 fuel hose to connect the...

Page 277: ...itioned correctly position the end of the line 2 away from the barb inline with the pick up and bend it so it will go down the front side of the tank Run the line down to the backside of the 1 50 hori...

Page 278: ...Run the line next to the 5 16 line down the 1 50 tube to the side 1 50 tube Use small insulated line clips on the line or put the line in the larger line clip then pull the rivets holding the line cli...

Page 279: ...atten them with a pair of pliers to conform to the shape of the lines being next to each other Remove the plastic barb from the tank return and the barb off the fuel line Attach a 3 piece of the rubbe...

Page 280: ...279 www factoryfive com 508 291 3443 Attach the fuel line to the tank and the hard fuel line Front Fuel Lines Use the and 5 16 unions to connect another piece of 60 fuel line...

Page 281: ...08 291 3443 Run the fuel lines to the front of the footbox and up to the fuel pressure regulator Attach the lines to the correct ports of the fuel pressure regulator or to the lines on the engine depe...

Page 282: ...the tank using the fasteners Place the washers on the tank side of each of these mounting locations Exhaust The exhaust has been designed and built with ball flanges to allow for the most adjustment...

Page 283: ...stock exhaust is designed to exit through the body in front of the rear wheels using the aluminum with the cutout The end of the pipe can be cut to the angle desired The optional rear exit exhaust run...

Page 284: ...283 www factoryfive com 508 291 3443 Shorty pipes and mufflers If doing the rear exit exhaust use this section for the muffler and forward exhaust pipes only...

Page 285: ...284 www factoryfive com 508 291 3443...

Page 286: ...coming off of the engine Do not fully tighten this ball and socket joint yet Pass the front exhaust assembly through the frame from the front so that the flange is at the front and will match up with...

Page 287: ...e flanges Loosely install the exhaust clamp and mount onto the muffler The inlet to the muffler is in the center and outlet is offset to the outside of the car The nuts on the exhaust clamps are orien...

Page 288: ...pe to the muffler The mount tabs for the exhaust mounts have the ability to slide on the rubber bushing Position the mount tabs so that they overhang the frame rails Mark the location of the frame on...

Page 289: ...com 508 291 3443 Remove the exhaust mounts and clamp them into a vise Using a hammer bend the tab over to a 90 angle Re install the exhaust brackets on the frame and mark the locations for the mount...

Page 290: ...1 3443 Also mark the location of the brackets that protrude past the surface of the frame where the aluminum floor sits Old exhaust clamp mounts shown Grind the corners of the brackets which protrude...

Page 291: ...ww factoryfive com 508 291 3443 Remove the exhaust mounts and drill the frame where you just marked with a 3 8 drill bit Re install the brackets and attach them to the frame with the 3 8 hardware prov...

Page 292: ...st components tighten all of the fasteners holding the exhaust in place Check all of the connections including the ball and socket joint for sealing and clearance If the shorty pipe is angled so that...

Page 293: ...ive com 508 291 3443 Check to make sure none of the bracket of hardware is above the top surface of the frame rails If need be grind anything that is sticking past this leading edge where the aluminum...

Page 294: ...exit exhaust 9 16 socket Ratchet Drill 5 16 drill bit 3 16 hex key 2 clamps Marker hack saw or razor knife This exhaust is designed to mount the exhaust tips below the tail lights so the top of the ti...

Page 295: ...294 www factoryfive com 508 291 3443...

Page 296: ...fflers as directed in the manual Insert the front tube ball end through the frame from the muffler side Bolt one of the ball flanges together around the front pipe ball Attach the front tubes of the r...

Page 297: ...yfive com 508 291 3443 Slide one of the clamps onto the rear tube up near the top of the bend Cut the rubber hanger just below the second hole otherwise it will hit the trunk floor using either a razo...

Page 298: ...297 www factoryfive com 508 291 3443 Slip one of the hangers under the clamp and hand tighten the clamp so that it can be easily adjusted later Attach the rear tubes to the front tubes...

Page 299: ...298 www factoryfive com 508 291 3443 If running an IRS locate the rear top part of tube on the inside of the upper control arm mount next to the center section...

Page 300: ...t already on The following pictures are shown on a chassis for better pictures and understanding of location Clamp the hangers so that the lowest hole is on the back side of the tube shown in the pict...

Page 301: ...300 www factoryfive com 508 291 3443 Stock Cut tip...

Page 302: ...or the back of the body Use the tube bend over the axle as a lever to rotate the front tube to level the tips out Raise or lower the rubber hanger as needed or push the rear tube onto the front tube m...

Page 303: ...291 3443 On the front side of the tube mark the side locations of the rubber Remove the clamp and rubber hanger Drill the 1 tube in the middle of the tube in the middle between the rubber side marks...

Page 304: ...508 291 3443 Open the 3 16 hole up with a 5 16 bit Rotate the rubber hanger and attach it to the tube using the included 5 16 bolt and washers Double check the tips Tighten the rubber hanger clamp nu...

Page 305: ...291 3443 Cut any rubber that sticks up past the top of the frame tubes Chapter 3 Interior Assembly Interior Aluminum Drill drill bit rivet tool silicone silicone gun Packaged aluminum Mounted aluminu...

Page 306: ...wall piece of aluminum When installing these aluminum panels use the 1 8 rivets located in the rivet pack of the kit and the same process s used on the firewall The battery and fuel filter access pan...

Page 307: ...306 www factoryfive com 508 291 3443 Install the left and right floors by inserting the front first Push the rear of the floors down so they sit on the rear wall lip...

Page 308: ...307 www factoryfive com 508 291 3443 Install the patch panel on the passenger side floor The drive side hole will be used for the trunk release Install the drive shaft cover piece of aluminum...

Page 309: ...308 www factoryfive com 508 291 3443 E Brake handle Assembly 5 32 3 16 hex keys 7 16 wrenches channel lock pliers WD 40 E brake handle assembly brake line components...

Page 310: ...309 www factoryfive com 508 291 3443...

Page 311: ...310 www factoryfive com 508 291 3443 Unpack the emergency brake handle components Push a nylon bushing into one side of the fixed gear...

Page 312: ...ive com 508 291 3443 Push the other bushing into the other side of the fixed gear From the right side of one of the Handle to ratchet mounts insert the shoulder bolt through the ratchet mount and then...

Page 313: ...de of the fixed gear Using a 3 16 hex key and wrench tighten the shoulder bolt lock nut so that the ratchet to handle mount plates are against the bushings but they can still move up and down Make sur...

Page 314: ...08 291 3443 Slide the lower handle between the ratchet to handle mount plates and bolt the three pieces together using the two 5 16 x 1 button head screws Put the ratchet tooth on the long anchor bolt...

Page 315: ...ctoryfive com 508 291 3443 Rotate the fixed gear out of the way and pass the anchor bolt up through the lower handle Rotate the ratchet tooth between the handle to ratchet mount plates and align the m...

Page 316: ...e the 1 nylon spacer onto the end of the anchor bolt There are two nylon spacers included They provide preload on the spring so there is more force holding the ratchet tooth to the fixed gear and maki...

Page 317: ...316 www factoryfive com 508 291 3443 Spray a little WD 40 on the lower handle threads and screw the upper handle onto the lower handle Insert the spring into the upper handle over the anchor bolt...

Page 318: ...317 www factoryfive com 508 291 3443 Screw the button onto the end of the anchor bolt Screw the male and female rod ends together...

Page 319: ...43 Use a wrench to spread the ears of the ratchet to handle mounts so that the rod end can just slide between them Slide the male rod end between the ratchet to handle mount plates and attach it using...

Page 320: ...t a 5 16 carriage bolt into one of the bent mount brackets so the square shoulder is in the square hole Attach the mount brackets to the fixed gear using a wrench Leave the locknut slightly loose so p...

Page 321: ...320 www factoryfive com 508 291 3443 Check the fit of the emergency brake cable end in the brake cable clevis If necessary use a drill bit and drill or a Dremel tool to open up the slot slightly...

Page 322: ...com 508 291 3443 Facing the cable slots towards each other attach one of the cable clevises to each side of the female rod end using the x 1 50 socket head bolt and locknut Just start the nut for now...

Page 323: ...unnel into the cockpit Look at the bellhousing to tunnel clearance It is advisable to have at least clearance between the bellhousing and the tunnel to allow the engine to torque under acceleration wi...

Page 324: ...com 508 291 3443 Cut the center of the transmission tunnel so that it sits down on the transmission tunnel flange Shifterhole Measure forward from the rear side of the driveshaft loop to the center of...

Page 325: ...324 www factoryfive com 508 291 3443 On the transmission tunnel cover top measure forward from the rear edge and mark the cover where the center of the shifter is located...

Page 326: ...325 www factoryfive com 508 291 3443 Center the shifter boot ring over the point marked so that the mounting holes are front back and on the sides...

Page 327: ...he cover then move the ring back to the narrow part of the tunnel make sure it is oriented correctly and push it down to the tunnel to shape the ring more It will spring back a bit to the correct shap...

Page 328: ...front of the footboxes and t h e 1 5 square bulkhead cross member Depending on the thickness of the fiberglass you may have to sand the inside of the rear of the tunnel to allow it to sit flat on top...

Page 329: ...er on the frame Mark the hole location for the emergency brake handle Remove and trim the transmission tunnel cover for the throttle pedal and emergency brake handle E brake Handle Mounting holes sock...

Page 330: ...hrough the frame e brake handle mount from the inside edge of the slot using a 5 16 drill bit Inside the cockpit use the rivets as a guide to draw a line on the transmission tunnel This is the locatio...

Page 331: ...rough the rear handle mount and into the hole drilled through the aluminum With the handle down position the handle so that your hand can go around the grip and not hit the transmission tunnel while k...

Page 332: ...www factoryfive com 508 291 3443 Mark the front hole location along the line drawn on the floor Look under the frame to make sure you will not hit anything wires brake lines exhaust in this general a...

Page 333: ...ocation with a 5 16 drill bit Cables Your E brake cables should be from the same car as your rear brakes For 87 92 Mustang and FFR cables route them through the bracket next to the transmission tunnel...

Page 334: ...the Panhard mount if using a 3 link Make sure your routing is out of the way of any moving parts and the cable has slack to move with the axle Two possible ways are shown below either in front of the...

Page 335: ...ch the brake cable to the brake caliper Adjustment If using Wilwood brakes attach the two spacer brackets included with the brakes between the clevises and rod end Remove the cable clevises from the r...

Page 336: ...djust the rod end so that the bolt goes through the rod end and both clevises and the cable is tight Put the locknut back on the bolt hand tight Slowly pull up on the handle to set the brake pads and...

Page 337: ...336 www factoryfive com 508 291 3443 Release the brake and if necessary remove the clevis bolt and readjust the rod end so that the cable is tight...

Page 338: ...hits the aluminum floor trim the floor slightly to clear Remove the handle from the cockpit Accelerator Pedal Positioning 5 16 wrenches 5 32 hex key Accelerator pedal components secondary body fastene...

Page 339: ...ainst the 1 50 square tube Move the pedal if necessary so that when the ball stud retainer is horizontal it is above the tube and re mark the aluminum for the pedal mount Mark the firewall where the b...

Page 340: ...k the flange on the side of the tunnel if it hits the accelerator pedal mount Check the full range of the accelerator pedal travel to ensure that there are no interferences with the pedal or travel Se...

Page 341: ...ece in place to determine the seat location Position the seats in the chassis and adjust them to where you would like Without moving the seat pull up on the rear of the base of the seat it has Velcro...

Page 342: ...with the frame rails by looking at the floor rivets Drill 4 holes through the metal framework of the seat and through the frame Do not mount the seats yet as you still need to install the aluminum car...

Page 343: ...pedal to the aluminum footbox using two 20 x flange head screws in the secondary body fasteners We like to install these fasteners from the engine side of the firewall for a cleaner look Attach the mo...

Page 344: ...sign is set up for a 96 04 4 6L Mustang engine with an OEM pedal but using the supplied ball studs and retainers it can be adapted for all applications 87 93 5 0L Fuel Injected Applications Run the ac...

Page 345: ...e on the rear edge of the rubber wipe then push the rubber wipe back onto the threads There is a ball stud and retainer in the accelerator cable components to attach to the throttle body on 87 93 appl...

Page 346: ...idle screw underneath the throttle body to see if the throttle arm is hitting it If it is not either loosen the ball stud retainer set screw and readjust the cable or readjust the accelerator pedal un...

Page 347: ...ake Carbureted applications If necessary attach the supplied ball stud to the carburetor in the appropriate location Refer to the carburetor instructions for placement Attach the ball stud retainer to...

Page 348: ...cable mount on the engine using and 7 16 wrenches Put a dab of silicone on the rear edge of the rubber wipe then push the rubber wipe back onto the threads InteriorFitment Clip off the ball fitting on...

Page 349: ...ball stud retainer using a 5 64 hex key Check the full range of the accelerator pedal travel to ensure that there are no interferences with the pedal or travel After driving the car for the first tim...

Page 350: ...e the most amount of space for the seat Wheels See the Appendix for wheel tire specs Install and torque your wheels Make sure they rotate freely and do not interfere with the brake calipers lines or a...

Page 351: ...ission Fill the transmission with fluid and install the shifter assembly Leave the shift handle and knob off for now Engine Fill the engine with Oil and coolant Both these fluids should be rechecked a...

Page 352: ...before you seal it all up If you do this bolt the seat harnesses in and use them You will be very surprised at how quickly the car responds to small inputs and it is amplified by being extra light wi...

Page 353: ...3 The brake pedal balance bar and brake pedal bearing looks like this Chapter 4 Body Work Trunk upper aluminum Drill hex driver clamps ruler tin snips Mounted aluminum secondary body fasteners Set the...

Page 354: ...e aluminum sits flat against frame tubes Door Hinge 9 16 socket ratchet ruler 5 16 Hex key Door hinge assembly Mount the door hinge standoff to the frame with the small ears at the top using the short...

Page 355: ...www factoryfive com 508 291 3443 Adjust the standoff so that it is 5 16 higher than the top of the frame mount area Tighten the locknuts Install 3 8 socket head bolts on the hinge standoff as hinge st...

Page 356: ...t 2 Jack stands extra person clamps 3 16 hex key floor jack Body Secondary body fasteners assembly Check the location of the jack stands on the frame The body will come down so that it is flush with t...

Page 357: ...ody one person on either side is the easiest way to lift the body Pull the sides of the body outward ever so slightly to get the front of the body around the frame and front control arms Make sure to...

Page 358: ...357 www factoryfive com 508 291 3443 Clamp the dash area to the firewall Rear wheel well mount Place a jack stand under the back of the body...

Page 359: ...291 3443 Use a tape measure between the front and rear of the cockpit and set the distance to 45 50 by raising or lowering the body Drill through the rear wheel well body frame mounts and through the...

Page 360: ...359 www factoryfive com 508 291 3443 Push the U nut onto the frame mount Slide one of the 5 16 washers onto the button head bolts Run the 5 16 bolt through the body...

Page 361: ...08 291 3443 Place the spacer on the bolt and screw the button head bolt into the U nut using a 3 16 hex key Remove the Jack stands from under the trunk Body Cut outs Door Hinge cut outs Ruler marker c...

Page 362: ...down slightly and clamp the door sills to the frame The bottom hinge mount may touch the body Lay a ruler or something straight that is thick to account for the bushing flange thicknesses on top of th...

Page 363: ...362 www factoryfive com 508 291 3443 Use a marker to draw a line along the backside of the body Place one of the door hinge arms on top of the ruler and mark the body on top of the arm...

Page 364: ...uler and lay it on top of the hinge arm so that the arm is parallel to the frame and the ruler is along the edge of the arm and the hinge pin hole is straight forward from the standoff hole Mark the e...

Page 365: ...s drill bit drill nut driver ruler marker Kit aluminum screws Use a marker and ruler to mark the under door body mounts 1 down from the door sill spaced every 3 Use three kit aluminum screws to mount...

Page 366: ...ining marks in the body only using an drill bit Pedal box Master Cylinder Access panels Tin snips marker ruler Packaged aluminum The passenger side access panel is helpful when installing the windshie...

Page 367: ...ww factoryfive com 508 291 3443 Place the aluminum access hole cover on the driver side of the hood recess of the body Use the masking tape with the Master cylinder location as a guide to locate the p...

Page 368: ...actoryfive com 508 291 3443 If necessary mark the edge of the aluminum to trim so that the aluminum does not hit the back of the hood area and has a nice even gap Trim the aluminum panel as needed and...

Page 369: ...368 www factoryfive com 508 291 3443 Mark around the outside of the panel Remove the panel Use a ruler to make marks in from the inside edge of the lines made...

Page 370: ...369 www factoryfive com 508 291 3443 Use the panel to make offset lines that are inside the panel outline Remove the body from the frame...

Page 371: ...er line for the access panels Firewall Marker square masking tape drill 3 16 or drill bit Rivet tool or 5 32 hex key and 7 16 wrench Secondary body fasteners Decide how the firewall will attach to the...

Page 372: ...371 www factoryfive com 508 291 3443 Riveting Space and mark the rivet locations around the edge of the firewall using the rivet spacing too...

Page 373: ...com 508 291 3443 Drill and install a couple of rivets through the so that the body can get mounted again in the same position Bolting A good place to put a couple of bolts is within reach of the acce...

Page 374: ...om 508 291 3443 Put masking tape on the firewall and use a marker and square to mark the locations desired The pictures show aligning the hole with the edge of the access cover aluminum Drill mounting...

Page 375: ...374 www factoryfive com 508 291 3443 Attach the bolts to the firewall and body Fuel filler Drill hole saw marker 3 16 drill bit ruler Fuel filler assembly...

Page 376: ...375 www factoryfive com 508 291 3443 Use a ruler to measure the OD of the cut out needed for the fuel filler cap Check the size by placing the correct hole saw over the cap...

Page 377: ...376 www factoryfive com 508 291 3443 Use the template to find the center of the fuel filler area Drill the center hole with the correct size hole saw...

Page 378: ...377 www factoryfive com 508 291 3443 Test fit the filler cap and mark the mounting screw hole locations Drill the mounting holes using a 3 16 drill bit...

Page 379: ...378 www factoryfive com 508 291 3443 Final check the filler cap and hole locations in the body Taillights Lock tite 3 16 drill bit hole saw marker drill masking tape pencil Tail light components...

Page 380: ...379 www factoryfive com 508 291 3443 Put a drop of lock tite on one end of the threads for the bezel studs...

Page 381: ...380 www factoryfive com 508 291 3443 Thread the studs into the bezels Place the LED light in the bezel from the backside...

Page 382: ...381 www factoryfive com 508 291 3443 Put a piece of masking tape over the large hole in the center of the mounting gasket Turn the gasket over and put another piece of masking tape over the hole again...

Page 383: ...bly then use a pencil to highlight where the three wires come out of the LED circuit board Remove the gasket from the light assembly and poke a small hole through the tape where the center wire comes...

Page 384: ...old the gasket on the tail light location on the body the single bezel mount hole goes at the top and mark the three mount hole locations and the wire hole location Drill the three mounting holes for...

Page 385: ...com 508 291 3443 Drill the light wire hole using a hole saw Gauges 7 16 drill bits drill marker 2 3 hole saws file Gauge set packaged aluminum The gauge template is the FFR proposed center dash gauge...

Page 386: ...385 www factoryfive com 508 291 3443 The template can also get used as a gauge trim plate if desired The large holes will need filing the gauges are an odd size...

Page 387: ...386 www factoryfive com 508 291 3443 Other gauge layouts have been used by customers Keep in mind though that the master cylinders and pedal box tubes are very close to the dash...

Page 388: ...mp the aluminum to the dash and drill through the holes for the ignition horn headlight and gauges Test fit the gauges in the holes File if necessary Test fit the ignition switch If necessary remove m...

Page 389: ...388 www factoryfive com 508 291 3443 Door hingeslots Body temporary 2 Remount the body on the frame Attach the rear wheel well mount bolts and spacers...

Page 390: ...389 www factoryfive com 508 291 3443 Attach the clamps between the dash and firewall Door Door hinge fitment Door hinge assembly...

Page 391: ...390 www factoryfive com 508 291 3443 Press the bronze bushings into the top and bottom of the hinge arms and pin sleeves on the hinge standoffs...

Page 392: ...391 www factoryfive com 508 291 3443 Attach the hinge arms to the hinge arm standoff but leave the nut hand tight...

Page 393: ...e sure there is clearance between the arm and the body cut out on the top and bottom Move the arm through its range of motion making sure that the top arm can contact the bolt stop and also point stra...

Page 394: ...their own desired panel gaps Hold the door in position and note the areas that need to be trimmed to allow the door to fit in the opening and allow the half moon trim accent of the door to align with...

Page 395: ...394 www factoryfive com 508 291 3443 Use the marker to mark the door hinge body cut out locations on the door Remove the door...

Page 396: ...If you plan to use a Hard top with the power windows now is the best time to prepare the door frames for the window track mounts so that the frames will not need removing later The pictures shown sho...

Page 397: ...396 www factoryfive com 508 291 3443...

Page 398: ...ouble check the holes Note that the bracket will not mount parallel to the frame but at an angle which is the reason behind the different measurements to the side of the tube Make sure to offset the l...

Page 399: ...bit to drill through the tube at the hole locations marked Attach the bracket to the window track motor assembly using the washer head screws provided Use one of the shorter screws on the right motor...

Page 400: ...399 www factoryfive com 508 291 3443 Attach the upper mount to the lower track mount...

Page 401: ...bracket to the door frame using a couple of the 20 x 1 50 bolts provided Rotate the track mount so that it sits flat on the angled door frame tube and with the end of the bracket flush with the edge o...

Page 402: ...ck assembly and drill the window track mount hole DoorHinge frame Doorassembly 3 16 hex key wrenches sockets ratchet saw marker drill 3 16 5 16 drill bits hole saw masking tape Bubble level clamps Doo...

Page 403: ...ve com 508 291 3443 Attach the hinge arms to the hinge arm standoffs as shown The hinge arms go on top of the mounts with the bronze bushings pushed into both sides of the arm and both sides of the hi...

Page 404: ...hten the locknut so the arm can still rotate but there is no slop Center and attach the door latch mount to the door frame using the 5 16 carriage bolts and locknuts Leave the locknuts just loose enou...

Page 405: ...www factoryfive com 508 291 3443 Place door frame and door frame rear plate in door Place the door frame rear plate in the door so that the straight part sticks down and is towards the outside of the...

Page 406: ...405 www factoryfive com 508 291 3443 Slide the door onto hinge arms Make sure the door hinge rear plate is touching the back of the door...

Page 407: ...s to the door frame using the carriage bolts and a socket so that the frame can still move around on the arms Check the fitment on the door and tape in place Check the alignment of the half round acce...

Page 408: ...m 508 291 3443 Use washers or paint sticks or something similar to hold the door gap at the back of the door If the door is high it may be sitting on the hinge arms Trim the door hinge arm opening wit...

Page 409: ...408 www factoryfive com 508 291 3443 Place a bubble level on the door frame and make the door frame level Clamp the front of the door to the door latch mount keeping the door frame level...

Page 410: ...ter of the car as possible The top arm is especially important since this is the arm that hits the stop The further in the arm is the more the door can open before it hits the stop Cut the door hinge...

Page 411: ...five com 508 291 3443 Push the latch mount forward so that it touches the door Tighten the carriage bolts with a wrench or socket Use an drill bit and drill through door through the top hole in the do...

Page 412: ...the alignment of the door then put a couple of the aluminum screws through the door frame rear plate Spread them apart if possible so the door can not rotate Mark the location on the door of the lowe...

Page 413: ...ts are tight against the inside of the door mark the locations of the heads Unbolt and remove the door door frame from the body and door hinge Remove the door frame from the door and cut the areas mar...

Page 414: ...latch template on the front of the door using the top hole next to the slot on the template and matching it up with the hole drilled in the door If necessary move the template towards the outside of...

Page 415: ...d the end of the spring post to give additional clearance Drill through the template and the front of door at the crosshair locations with a 3 16 drill bit first to make sure the holes will be in the...

Page 416: ...415 www factoryfive com 508 291 3443 Drill an hole through door at the sticker location Remove the material between the two holes using a hacksaw blade or jig saw...

Page 417: ...five com 508 291 3443 You should now have three door latch mount holes the slot for lever and a small hole where t h e striker would go Without the door frame hold the door up to the body align and ta...

Page 418: ...ctoryfive com 508 291 3443 Using an drill bit drill through the striker hole in the door and through the body Remove the door Latch striker mount Drill the striker locating hole in the body out using...

Page 419: ...wrench leaving the locknut loose so the striker can move in the slot Mount the striker mount to the frame on the outside of the bracket using the 5 16 carriage bolts provided and a socket and ratchet...

Page 420: ...er in the hole remove the striker mount and grind the built in washer Tighten the striker mount using a socket Tighten the striker on the mount using a socket and wrench Door Latches Ruler marker sock...

Page 421: ...hole is needed on the door latches On the door latch draw a line from the horizontal mount hole across to the center of the rotating pin Mark the lever 9 16 from the center of the horizontal hole Lub...

Page 422: ...rlier using the flange head bolts from the inside of the door out and a 3 8 socket and Ratchet If using external door handles at the door latch area use a drill bit to drill a hole through the door an...

Page 423: ...422 www factoryfive com 508 291 3443 Use a pair of tin snips to make the sides of the hole look nice Interior Door latch release Ratchet socket Pliers 33 door handle components...

Page 424: ...e locknut onto the lever Test the lever and remove any door material if necessary so that the latch works correctly Striker cover Drill drill bit rivet tool silicone silicone gun Packaged aluminum Sec...

Page 425: ...291 3443 With the door hinge and latch adjusted position the striker cover Silicone and rivet the panel in place Fuel tank side cover Drill drill bit rivet tool silicone silicone gun Packaged aluminu...

Page 426: ...rivet the panel in place Cockpit rear cover 1 hole saw drill marker tin snips hack or air saw body assembly rear cockpit cover secondary body fasteners upholstered interior parts The cockpit rear cov...

Page 427: ...ar cover The top cover should sit down nicely along the bend in the rear cover If it does not note the height that needs to be trimmed remove the top cover mark the rear cover remove and trim the exce...

Page 428: ...7 www factoryfive com 508 291 3443 Remove the upholstered top cover and mark 0 50 up from the bend Cut off the top area marked Push bulb on the side weatherstrip onto the rear edge of the side aluminu...

Page 429: ...28 www factoryfive com 508 291 3443 Cut the weatherstrip 1 long and remove 1 of the hard clip leaving the bulb Set the rear cockpit cover in place on the frame Mark the rear cover above the door hinge...

Page 430: ...of the cover so that it sits down in the body recess at the rear of the door Remove the rear cover from the cockpit and trim the areas marked Reinstall the cockpit rear cover Mark the rear cockpit al...

Page 431: ...443 The rear cover can either be installed with riv nuts 3 16 rivets or black trim screws The rear cockpit cover can be sent out for paint with the body or sent to get covered or see the installation...

Page 432: ...431 www factoryfive com 508 291 3443 With rollbar Install the rear cockpit cover temporarily with clamps black trim screws or masking tape...

Page 433: ...e com 508 291 3443 From inside the trunk hold a marker inside the rollbar mount tube and bring it up to the rear cockpit panel and mark the underside of the panel for the rollbar hole Remove the rear...

Page 434: ...el and check the fit of the rollbar by sliding it down into the mounts If necessary use a file to open the holes where necessary Drill the lower mounting holes through the cover and into the 1 50 tube...

Page 435: ...508 291 3443 Tape the small and large bumpers included with the kit to set the height of the trunk so that it is flush with the body If necessary cut the large bumpers to the correct height if the sm...

Page 436: ...ww factoryfive com 508 291 3443 Use shims or washers to set the gap so that it is even around the sides and top of the t r u n k Remove the trunk Trim the flange around the trunk opening so that it is...

Page 437: ...inges 5 32 3 16 hex keys 7 16 wrench marker socket ratchet shop light 3 16 25 64 drill bits d r i l l masking tape rivnut tool Trunk hinge assembly If not already in place attach the hinge arms to the...

Page 438: ...437 www factoryfive com 508 291 3443 Loosely attach the trunk hinge mounts to the inside of the hinge arms so that they can just move...

Page 439: ...k in place with the shims so that it can not move With a shop light and marker go up into the trunk from under the car Hold the hinge mounts on the trunk so that the carriage bolts are centered in the...

Page 440: ...439 www factoryfive com 508 291 3443 Mark around the hinge mount and in the mounting slots Remove the trunk Mark the center of the slots...

Page 441: ...them up with a 25 64 bit for rivnuts Install a 20 rivnut in each of the holes drilled Re shim the trunk in the body opening and tape in place From inside the trunk fasten the trunk hinge mount bracket...

Page 442: ...he hinge arm up to the trunk and tighten the hinge arm carriage bolts Tighten up the mount bracket to trunk screws From outside the trunk try opening the trunk If it catches on the front edge of the t...

Page 443: ...um screws The body is easier to remove and install with some of the trunk aluminum off the frame so do not rivet the lower floor on now Install the trunk side aluminum It may hit the bottom of the bod...

Page 444: ...e a ruler or straight edge to align the front bent flange on the side wall aluminum with the tube frame tube that goes across the trunk Clamp the trunk wall aluminum to the frame then screw it to the...

Page 445: ...444 www factoryfive com 508 291 3443 If necessary trim the aluminum around frame welds so that the aluminum sits flat against frame tubes Repeat for the other side...

Page 446: ...445 www factoryfive com 508 291 3443 Screw the upper floor to the frame Remove the side panels Install the lower trunk floor...

Page 447: ...446 www factoryfive com 508 291 3443 Install the trunk sides If they are tight on the rear lower body flange use a marker as a guide and trim off the area needed with tin snips...

Page 448: ...447 www factoryfive com 508 291 3443 TrunkPropRod The trunk prop rod is mounted on the right side of the car on the vertical wall of the trunk Mark the 3 mount holes for the prop rod mount...

Page 449: ...448 www factoryfive com 508 291 3443 Attach the mount to the frame with a couple of the 6 self tapping screws for now Attach the prop rod assembly to the prop rod mount...

Page 450: ...n the prop rod can be positioned anywhere you would like but it seems to work the best in the triangular section on the trunk liner Trunk Latch 5 32 hex key flat head screwdriver 5 16 wrench ruler hex...

Page 451: ...450 www factoryfive com 508 291 3443...

Page 452: ...ww factoryfive com 508 291 3443 At the handle end of the cable push the barrel end of the cable into the handle so that the wire can go into the slot and swing forward Push the cable sheath into the h...

Page 453: ...452 www factoryfive com 508 291 3443 Insert the trunk latch cable into the latch spacer bracket Insert the wire stop into the latch...

Page 454: ...508 291 3443 Insert the wire end through the wire stop Attach the trunk latch and latch spacer to the trunk latch bracket as shown in the drawing at the beginning of this assembly Leave it loose for n...

Page 455: ...454 www factoryfive com 508 291 3443 Use needle nose pliers to pull the cable tight then screw the wire stop screw down Use a 5 16 wrench and screw driver to tighten the screw more...

Page 456: ...455 www factoryfive com 508 291 3443 Mark the center line on the trunk opening Line up the center of the latch up with the centerline you just drew...

Page 457: ...factoryfive com 508 291 3443 Drill and mount the latch mount bracket to the body with 3 16 rivets and the nylon spacers if necessary The rivets go through the body lip then the spacers and into the b...

Page 458: ...factoryfive com 508 291 3443 The bottom of the bracket is mounted to the trunk floor and attached with rivets from the bottom of the body Pass the release handle and cable through the hole in the trun...

Page 459: ...508 291 3443 Striker Clamp marker ruler drill 25 64 drill bit rivnut tool square 5 32 3 16 hex keys wrench Trunk latch assembly secondary body fasteners Close the trunk and mark the center of the latc...

Page 460: ...w factoryfive com 508 291 3443 Close the trunk and measure the distance from the body lip to the trunk edge Open the trunk and measure the distance from the body lip to the bottom of the actual latch...

Page 461: ...triker mount Hold the striker up to the trunk and use a square to measure and locate the striker so that the head of the shoulder bolt just clears the bottom of the latch finger and the striker is ali...

Page 462: ...ker to the trunk Mark the center of the mount slots on the trunk Remove the striker assembly Drill holes through the trunk liner and the 1 8 aluminum inside of the trunk then open the holes up with a...

Page 463: ...oulder bolt Remove the rear latch Remove the trunk lower floor aluminum Hood Engine side covers nose cone Hood Orbital sander 80 grit sand paper masking tape jig saw or air saw marker Hood engine side...

Page 464: ...463 www factoryfive com 508 291 3443 Put a few of the small bumpers across the cowl on the car and tape to the body Put a few of the large bumpers across the top of the grill...

Page 465: ...the hood in place for initial fitment so that the front is down in the grill recess Trim the hood around the grill a little at a time if necessary so it just fits Trim the rear edge of the hood so tha...

Page 466: ...Adjust the angle of the grill and height of the grill so that there is no gap between the straight edge and the hood The half moon trim accent on the hood should be aligned with the trim on the body a...

Page 467: ...ere is clearance between the front lower control arm mount bolt and the radiator Nose Cone Orbital sander 80 grit sand paper masking tape jig saw or air saw marker ruler clamps drill b i t drill 5 32...

Page 468: ...291 3443 If not cut mark the top of the nose cone 1 75 back so that the grill will fit in the nose cone Cut the nose cone Trim the front vertical flange off the nose cone so that the nose cone has no...

Page 469: ...w factoryfive com 508 291 3443 Clamp the nose cone to the front of the body section so that the bottoms are flush and the outside trim pieces align Clamp the front of the nose cone to the front of the...

Page 470: ...ge Look at the side of the nose cone and top of the body section that the nose cone attaches to This area should be flat If necessary raise lower or angle the grill so that the area is flat This may a...

Page 471: ...steel on the frame which the lower control arm is attached to At the front of the nose cone fasten it to the bottom of the grill with a 3 16 rivet or screw and at the 4 and 8 o clock positions if nec...

Page 472: ...471 www factoryfive com 508 291 3443 If necessary push the boot back slightly to prevent rubbing Turn the rack again to check to see if the boots move when all the way in...

Page 473: ...472 www factoryfive com 508 291 3443 More Hood Mark around the grill on the hood so that there is an even 3 16 gap Trim and sand the front of the hood...

Page 474: ...Side covers Ruler marker saw Orbital sander 80 grit sand paper masking tape jig saw or air saw marker razor knife large kit box ruler 5 32 hex key 7 16 wrench drill drill bit Engine side covers Trim...

Page 475: ...toryfive com 508 291 3443 Trim the bottom front of the side cover so that the cover goes around the grill Trim the bottom of the side cover so that it is the same width as the top body lip that the co...

Page 476: ...www factoryfive com 508 291 3443 Use a couple of washers or cut some small rubber bumpers so that they are about high and place them at the front and back of the body lip that the side cover will sit...

Page 477: ...e of the flaps off one of the larger boxes and hold it up to the side of the grill And put a small mark on both the grill and cardboard where it starts Push the cardboard against the grill edge so tha...

Page 478: ...477 www factoryfive com 508 291 3443 Use a razor knife to cut along the line Tape the engine side covers to the body and the outside of the grill...

Page 479: ...478 www factoryfive com 508 291 3443 Mark the side cover where the grill starts at the top and bottom Align the rear cardboard template on the side cover...

Page 480: ...uld be done separately for each side of the grill the fitment on each side i s different Trim the side cover a little at a time so that there is a gap at the back of the cover against the body and at...

Page 481: ...oryfive com 508 291 3443 Mark and trim the bottom edge of the hood so that there is a 3 16 gap between the hood and top of the side cover Drill a 3 16 hole through the engine side panel mount flange a...

Page 482: ...nd the body Remove the side cover and enlarge the holes in the side cover to For the rear body mount holes drill the body hole out to 25 64 and install a rivnut For the front hole either tap the grill...

Page 483: ...482 www factoryfive com 508 291 3443 Temporarily attach the panel to the grill with 20 flange head fasteners...

Page 484: ...ttom of the panel and through the body in two or three locations with a drill bit Remove the side panel and enlarge the body flange holes and install rivnuts in the body Headlights are bolted through...

Page 485: ...d the spacer so headlight removal is not necessary Hood cable release Drill 3 32 3 16 11 32 drill bits drill rivet tool air saw or jig saw Philips screwdriver marker scissors Hood hinge components ins...

Page 486: ...485 www factoryfive com 508 291 3443 Open the hole up to 11 32 Push the gray end of the release cable into the cockpit...

Page 487: ...486 www factoryfive com 508 291 3443 Route the cable down the inside of the 1 50 round tube towards the front of the frame Run the cable under the 1 round tube...

Page 488: ...487 www factoryfive com 508 291 3443 Run the cable under the coil over 1 cross tubes Continue the cable forward and up the side of the radiator...

Page 489: ...edge of door jam by drawing around the flange Make sure to leave clearance for the door when the door is shut Use this template to mark the inside area to cut and to drill the 3 32 mounting screw hol...

Page 490: ...the cable to the handle the same way as was done for the trunk handle At the handle end of the cable push the barrel end of the cable into the handle so that the wire can go into the slot and swing fo...

Page 491: ...0 www factoryfive com 508 291 3443 Mount the handle using the 8 sheet metal screws Mount the cable to the frame using small insulated line clips and self tapping screws or 3 16 rivets near the firewal...

Page 492: ...com 508 291 3443 Put another insulated clip under the rear 1 tube Hood Latch 5 32 hex key 7 16 wrench grinder measuring tape marker square Hood hinge components The hood latch is similar to the trunk...

Page 493: ...492 www factoryfive com 508 291 3443...

Page 494: ...493 www factoryfive com 508 291 3443 Insert the hood latch cable into the latch spacer bracket Insert the wire stop into the latch...

Page 495: ...wire stop screw down Use a 5 16 wrench and screw driver to tighten the screw more Check that the pull handle releases the latch by adjusting the cable stop before mounting the latch assembly Mount the...

Page 496: ...495 www factoryfive com 508 291 3443...

Page 497: ...496 www factoryfive com 508 291 3443 Press bronze bushings into the hood mount brackets Mount the Grill mount to upper radiator mount Leave the screws snug for later adjustment Passenger side shown...

Page 498: ...7 www factoryfive com 508 291 3443 Hinge pin assembly From the outside left shoulder bolt washer bushing link bushing link washer nut Mount the gas strut link using a shoulder bolt Passenger side show...

Page 499: ...08 291 3443 Attach the hood mount to the gas strut link using another shoulder bolt Driver side shown With the hinges mounted on each side and hood in place rotate the hinge up so that the hood mount...

Page 500: ...499 www factoryfive com 508 291 3443 Mark the slots on the hood for rivnut holes Remove the hood and drill the center of the marks for rivnuts...

Page 501: ...500 www factoryfive com 508 291 3443 Install 20 rivnuts in the hood Striker Mount the striker to the bracket...

Page 502: ...501 www factoryfive com 508 291 3443 Push the striker down into the latch Place the hood on the car and attach the hood mount to the hood finger tight to allow for adjustment...

Page 503: ...ing with the Radiator mounts first then the hood mounts With the striker engaged in the latch place latch bracket up to hood and mark the hood Make sure the striker will clear the Grill when opening I...

Page 504: ...503 www factoryfive com 508 291 3443 Remove both upper hinge pins and remove the hood Drill the hood striker bracket holes and install 20 riv nuts in the hood...

Page 505: ...504 www factoryfive com 508 291 3443 Mount the hood striker bracket to the hood loosely to allow for adjustment...

Page 506: ...all pin mounts With hood upside down and level mark the holes for the firewall pin brackets Place the bracket so that pin slot arrow is vertical and there is enough clearance to slide the bracket outb...

Page 507: ...506 www factoryfive com 508 291 3443 Drill and install 20 riv nuts Mount the brackets to the hood centering the slots on the screws...

Page 508: ...rikeradjustment Place hood back on car and reattach the hinge pins Check that the latch properly engages and disengages At the front of the hood With proper engagement of striker in the latch and Gril...

Page 509: ...508 www factoryfive com 508 291 3443 Carefully open the hood to make sure the striker clears the front of Grill To adjust the hood height relative to grill adjust striker placement on the bracket...

Page 510: ...509 www factoryfive com 508 291 3443 Firewall pin receiver Put some masking tape on the firewall...

Page 511: ...in place mark center of pin slot on the firewall The bracket is about an inch away from the firewall Prop open the hood and make sure that behind the firewall inside the cockpit is clear before drilli...

Page 512: ...511 www factoryfive com 508 291 3443 Use a hole saw for the pin receiver Place a plastic cap on the smaller end of the firewall pin receiver Receiver is shown with the cap and nut...

Page 513: ...291 3443 Mount the pin receiver to firewall from inside out and tighten the nut using thread lock Mount the pin with a washer to the hood mounted bracket finger tight and just loosen the bracket scre...

Page 514: ...d completely Tighten the pin and bracket mounts Open and close the hood to ensure proper alignment If the hood feels like it catches slightly when you close it check the pins they might be catching i...

Page 515: ...factoryfive com 508 291 3443 will not catch If needed space the pin mount bracket so that it will go far enough into the receiver Install the ball studs and gas springs on the Grill mounts driver sid...

Page 516: ...515 www factoryfive com 508 291 3443 Lift the front of the hood and mount the gas springs to the gas strut linkage Close and release hood to check for proper operation and striker grill clearance...

Page 517: ...he body at the back of the hood If necessary unbolt the lower gas strut mount position the hood how you would like noting the lower gas strut mount position then drill and remount the gas strut mount...

Page 518: ...517 www factoryfive com 508 291 3443 Mock up the Prop Rod to find the desired placement Mark the holes on the underside of the hood for the ball stud bracket on the raised surface at rear of hood...

Page 519: ...518 www factoryfive com 508 291 3443 Drill and install 3 16 rivets Snap the Prop Rod onto the ball stud Snap the Prop Rod clip to the rod and mark the hood for desired placement...

Page 520: ...tap mounting screw into fiberglass Windshield Install Masking tape marker drill drill bit tape measure 3mm hex key 10mm wrench Loctite Windshield These instructions correctly locate the Windshield to...

Page 521: ...www factoryfive com 508 291 3443 Use a tape measure at the front top corners of the door to locate and mark the middle of the front windshield area 520...

Page 522: ...www factoryfive com 508 291 3443 521...

Page 523: ...stud of the windshield Use the gasket to mark the front of where the windshield will sit Remove the mounting studs on the base of the windshield with a 3mm hex key Have a friend assist you and mock u...

Page 524: ...angle is reached and the windshield sits flat on the gasket body This windshield had a small ridge in the area shown that had to be removed Once you are happy with its location trace the outline of t...

Page 525: ...which are the mounting points for the windshield The windshield stud holes go all the way through the frame Insert the stud by hand until you feel i t touch the rubber gasket then stop Do not over ti...

Page 526: ...ly on the car the angle of the windshield needs to be correct Make sure the top corner of the windshield to the top rear of the door opening If necessary slot the holes slightly for the windshield Usi...

Page 527: ...526 www factoryfive com 508 291 3443 Optional Hardtop Drill marker masking tape measuring tape square 1 75 hole saw 25 64 drill bit wrench rivnut tool Hardtop package...

Page 528: ...pside down on the roof attach the half moon weatherstripping to the underside of the back of the hardtop along both the inside and rear edges Attach the half moon weatherstripping to the underside of...

Page 529: ...3443 Measure the width of the rear window on the Hard top and mark the center of the window around 15 50 Use a square to mark the bottom of the Hard top from the window center mark made so that the m...

Page 530: ...529 www factoryfive com 508 291 3443 From the inside of the top rear flange mark 1 in from the inside edge on the center mark made Measure over 14 from the center and mark the flange...

Page 531: ...te side If the soft top will get used the mount locations behind the doors should be made using t h e measurements for the body mount in the Appendix and not the measurement given below On the sides b...

Page 532: ...531 www factoryfive com 508 291 3443 Measure from the inside edge and mark 1 at all of the locations marked DO NOT drill in the center of the flange Drill holes at the locations marked...

Page 533: ...532 www factoryfive com 508 291 3443 On the inside of the rear section of the Hard Top measure down and mark 11 16 from each of the marks Use a 1 75 hole saw to drill a hole at each of the marks...

Page 534: ...m 508 291 3443 If the body is painted use painters tape around the rear 2 of the body around the cockpit and two 2 strips across the front of the cockpit starting at the front edge of the door as show...

Page 535: ...com 508 291 3443 With help place the Hard Top on the body Align the front and rear edge of the door cut out with the molded trim line on the Hard top and make sure that the front windshield area sits...

Page 536: ...535 www factoryfive com 508 291 3443 Mark around the inside and outside of the front of the Hardtop on the masking tape...

Page 537: ...n the rear of the top use a marker in the hole saw holes to mark the body through the drilled holes Remove the Hardtop and use a tape measure at the front top corners of the door to locate and mark th...

Page 538: ...rd top and the roadster with a soft top it is necessary to check the windshield mounting measurements with those required for the soft top windshield location and the soft top bow mounts Check the App...

Page 539: ...64 Repeat for the other side On the front windshield area drill the three locations marked in the middle of where the windshield will sit using a drill bit On the rear of the Hardtop area drill the m...

Page 540: ...he rear area of the body Place the Hard Top back on the body and attach it at the locations just behind the door using the bolts provided and a 3 8 wrench Double check that the molded trim line on the...

Page 541: ...use a marker through the holes drilled to mark the underside of the Hard Top windshield area Remove the Hard Top again put it upside down on the floor and drill 25 64 holes in the bottom of the Hard T...

Page 542: ...holes in the body so that they will line up with the Hard Top holes DO NOT offset the holes in the hardtop Insert and attach rivnuts in the 25 64 holes just drilled If installing the rollbar under th...

Page 543: ...291 3443 Remount the Hard Top for the final time and fasten the top to the body using the bolts from the underside of the dash in the windshield area Fasten the top to the body using the bolts from th...

Page 544: ...543 www factoryfive com 508 291 3443 Push the plastic plugs in to the bolt access areas on the rear of the Hard Top...

Page 545: ...the back of the window opening as close to the door as possible hanging below the Hard Top push the weatherstripping onto the flange around the door opening to the front of the door again hanging bel...

Page 546: ...he switches do not fit on the flange with the mounting bracket the switches can be mounted individually and sideways to the flange The window glass holder will have to be installed and uninstalled a f...

Page 547: ...546 www factoryfive com 508 291 3443 Repeat this at the front of the door Using a ruler straight edge or the bottom of the side window draw a line connecting the two marks made...

Page 548: ...547 www factoryfive com 508 291 3443 Measure in from the line drawn and draw another line down the length of the door Using the side window as a guide mark the ends of the glass on the door...

Page 549: ...of the glass and one of the pre cut window wipe rubber pieces Cut the outer lines marked using a jigsaw or air saw Check to make sure that the glass will fit in the length of the hole If necessary cut...

Page 550: ...ips to trim the ends so that they can push all the way on If you can not push it all the way on check the thickness of the top of the fiberglass door It can be no thicker than 3 16 for the felted rubb...

Page 551: ...re up and mark 19 from the bottom then hot wire the window motor by attaching a ground and positive to the wires on the plug pigtail to lower the rectangular plate so that it is below the mark made Cu...

Page 552: ...com 508 291 3443 Insert the window track through the door opening with the motor towards the hinge end of the door Attach the motor mount bracket to the door frame leaving the bolts slightly loose to...

Page 553: ...291 3443 Attach the window track mount to the window track and to the door frame Leave the bolt a little loose so that the track can pivot on the bolt if needed and so the bottom can move in and out P...

Page 554: ...m of the dash so the switches are not visible and can be reached by the driver if necessary Wire has been included for this mounting location If the switches do not fit on the flange with the mounting...

Page 555: ...com 508 291 3443 Use the diagram above to connect the power window switches to the chassis harness The electric choke or Fuel injection harness wires for the power Make sure to run the included 25A f...

Page 556: ...onnectors to attach the included wires to the window motor pigtails Attach the included wires to the switch using the un insulated connectors and push them into the correct holes in the plug so that t...

Page 557: ...included aluminum U channel mark the center of the channel at one end using a ruler in two locations at the end and about 4 from one end The center should be between 5 16 and 3 8 Draw a line connecti...

Page 558: ...43 64 Drill 13 holes at the and 4 50 points marked Attach the U channel to the window guide bracket using a 7 16 wrench and 3 32 Hex key Leave the bolts just loose enough so that the channel can slide...

Page 559: ...3443 push the rubber felt lined weatherstrip into the U channel Insert the U channel assembly into the front of the door and put the 5 16 carriage bolt from the top through the window guide bracket a...

Page 560: ...le goes under the U channel and stays between you and the U channel not between the U channel and the door skin Tighten the carriage bolt lock nut with using a socket and ratchet Attach the window gla...

Page 561: ...of the window goes towards the back of the car Also note that the logo and information on the passenger side window is backwards when viewed from outside the car This is normal practice even on OEM Ve...

Page 562: ...561 www factoryfive com 508 291 3443 Close the door then raise the window up using the switch...

Page 563: ...ck and forth in the glass holder so that the gaps on each end are the same Carefully open the door without moving the glass and mark the glass at the back of the holder Remove the window carefully Thi...

Page 564: ...ctoryfive com 508 291 3443 Fold the 36 piece of window channel rubber in half and cut it in half One piece will be used for each door Remove the glass from the door Remove the window glass holder from...

Page 565: ...on the window using the glass marks made as a guide Make sure that you have the glass holder the correct way around on the glass so it will mount correctly Use a plastic dead blow hammer to push the g...

Page 566: ...glass holder with the glass back in the door Close the door and raise the window up to where you would like it to stop Be careful doing this Once this position is found open the door and mark the wind...

Page 567: ...566 www factoryfive com 508 291 3443 Lower the window so that the top of the glass is just below the top of the door Mark the window track where the top of the plastic guide is...

Page 568: ...do this is by removing the track with the lower bracket on it Remove the top window track bracket and bolts then slide the assembly as far to the back of the door as possible then bring the track up a...

Page 569: ...32 locknuts on top of the plastic guide on the window track then use a 5 32 drill bit the same size as the nylon locknut opening and using the lock nut as a locator drill through one side of the windo...

Page 570: ...69 www factoryfive com 508 291 3443 Move the track bracket down and attach the 10 32 x 5 8 stop bolt using a 1 8 Hex key and 3 8 wrench Align the track bracket with the lower stop mark made previously...

Page 571: ...done with the top stop hole place one of the 10 32 locknuts under the bottom of the plastic guide on the window track and use a 5 32 drill bit to drill through one side of the window track Remove the...

Page 572: ...1 www factoryfive com 508 291 3443 Move the track bracket up and attach the 10 32 x 5 8 stop bolt using a 1 8 Hex key and 3 8 wrench Reinstall the window track in the door with the bolts slightly loos...

Page 573: ...or checking the clearance of the glass at the front and back near the top then raise the window up and have a friend push the glass against the weatherstrip From inside the car look tighten the window...

Page 574: ...3 Lower the glass all the way Carefully push the felted rubber seals onto the top of the door Check the window up and down with the door open and closed The idea is to have the felted seals to just to...

Page 575: ...sh the glass in a different direction than what you want If necessary trim more off one side or the other to eliminate any excess pressure on the window Exterior DoorHandle The Passenger right side is...

Page 576: ...575 www factoryfive com 508 291 3443 Mark 3 from front of door...

Page 577: ...576 www factoryfive com 508 291 3443 Use a 7 8 hole saw on the outer door skin at the point marked...

Page 578: ...ww factoryfive com 508 291 3443 For easier access to the outer door handle parts it is recommended to have a hole in the angled part of the inner door liner which goes against the dash with the door c...

Page 579: ...508 291 3443 To locate this hole once the outer skin is cut go through the inner door skin with the pilot bit of the hole saw only On the inner skin where the locating hole is use a 1 75 hole saw thro...

Page 580: ...579 www factoryfive com 508 291 3443 Place door handle in the outer door skin hole and mark the mounting holes Drill 13 64 holes at the points marked...

Page 581: ...five com 508 291 3443 On the handle control lever measure and mark 5 8 and 1 25 from the center of the square hole With the lever in a vise or drill press drill a hole in the center of the lever at th...

Page 582: ...581 www factoryfive com 508 291 3443 Mark the door handle shaft 1 125 from the shoulder Cut the door handle at the mark made...

Page 583: ...582 www factoryfive com 508 291 3443 Use Lithium or chassis grease to lubricate the exterior door handle Insert the cable end into exterior door handle backing plate...

Page 584: ...yfive com 508 291 3443 Pass the door handle through the mount gasket door and Backing plate Attach the Handle to the door using the 10 32 x 1 Philip head screws using a Philips head screwdriver and 3...

Page 585: ...08 291 3443 Use a vise or vise grip pliers to squeeze one of the cable clevis parts so that the legs touch just above the hole that goes through it Mark the top leg of the right hand wound spring show...

Page 586: ...585 www factoryfive com 508 291 3443 Mark the bottom leg of the spring 2 25 from the spring coil Use a heavy duty set of electrician pliers or a hack saw to cut the spring at the points marked...

Page 587: ...586 www factoryfive com 508 291 3443 Picture of cut and uncut spring Push the spring over the handle shaft so that the short 1 end points towards the front of the car...

Page 588: ...ive com 508 291 3443 Rotate the spring so the short end is up and put the pressed clevis on the 1 end of the spring Attach the pressed clevis to the front handle screw using another 10 32 locknut and...

Page 589: ...ange head screws and lock nuts along with a 3 32 hex key and 7 16 wrench in the hole closer to the square hole Make sure that the clevis is attached with the large circular hole side as shown in the p...

Page 590: ...tighten the screw so that the screw goes through the nylon on the locknut about one thread Remove the set screw from the end Making sure that the exterior handle is positioned correctly push the contr...

Page 591: ...291 3443 Rotate the handle so that you can insert and tighten the set screw in the top of the handle Rotate the handle the other direction so that the clevis is closer to the cable and insert the bar...

Page 592: ...591 www factoryfive com 508 291 3443 Move the long end of the spring so that it is on the other side of the lower screw head...

Page 593: ...r in place this is what the exterior door handle assembly looks like Put a jam nut from the kit door handle fastener pack onto the threaded cable end Insert the other end of the door handle cable into...

Page 594: ...593 www factoryfive com 508 291 3443 Put a door handle clevis on the door latch so that it is on both sides of the latch...

Page 595: ...hole saw drill marker measuring tape Rollbar fasteners rollbar rear cockpit cover The rollbar has been designed so that it will fit both inside the hardtop and can be used with the car a s a Roadster...

Page 596: ...he Hardtop so that there is no rubbing or contact with the top Measure from the bottom of the rollbar to the top of the 1 50 square tube Remove the hard top Remove the rollbar Measure and mark 1 down...

Page 597: ...k the side of the rollbar mounts Remove the rear cockpit cover Install the rollbar to the height desired Clamp the rollbar so that it can not slide down into the mount tube Drill all the way through b...

Page 598: ...3 The quick release pins can be used as is but a large 1 50 hole must be drilled in the rear cockpit cover for the ring or squeeze the pin ring in a vise and a smaller 1 hole can be made The hole is b...

Page 599: ...508 291 3443 Drill the rear cockpit cover with the hole saw size appropriate for the way the quick release pins will be run Install the rear cockpit cover and test fit the release pin If necessary op...

Page 600: ...a high rollbar two different holes must be drilled in the rollbar frame mounts Slide the roll bar down into the frame mounts Set a seat in the driver side of the car Set the rollbar to the desired hei...

Page 601: ...k the side of the rollbar mounts Remove the rear cockpit cover Install the rollbar to the height desired Clamp the rollbar so that it can not slide down into the mount tube Drill all the way through b...

Page 602: ...3 The quick release pins can be used as is but a large 1 50 hole must be drilled in the rear cockpit cover for the ring or squeeze the pin ring in a vise and a smaller 1 hole can be made The hole is b...

Page 603: ...508 291 3443 Drill the rear cockpit cover with the hole saw size appropriate for the way the quick release pins will be run Install the rear cockpit cover and test fit the release pin If necessary op...

Page 604: ...rk is the finish on all the edges and openings All of the following edges are visible on the finished car and need to be evened out and have a small radius sanded in for a good looking finish Doors Ho...

Page 605: ...604 www factoryfive com 508 291 3443 Body Painting Remove all trim doors windshield etc before beginning body work The primer gel coat sands easily and is a forgiving material to work with...

Page 606: ...ept to a minimum Allow the bodywork or repairs performed to sit for several days outside in the sun or at elevated temperatures to allow the repair materials to cure before final paint While the body...

Page 607: ...w factoryfive com 508 291 3443 Install the flexible serrated grommeting around the area where the fuel tank full tube passes through Dash gauges Pliers wire cutters wire crimpers Gauge assembly dash h...

Page 608: ...ht or ignition switches yet as these are easier to just leave attached to t h e chassis harness and install them after the body is mounted If the dash area where the ignition or headlight switches wil...

Page 609: ...auges so that they are fully seated and will not pop out If not already done in the dash harness cut the rear turn signal light wires off the back of the connectors that are for the dash turn signal s...

Page 610: ...s in series using the small jumper wires included Attach the gauge ground wire to one of the small gauges and connect the remaining small gauges in series using the small jumper wires included Attach...

Page 611: ...610 www factoryfive com 508 291 3443 Drill the body to mount these in place Install the LED indicators into the body...

Page 612: ...611 www factoryfive com 508 291 3443 A Cdefrosterducts If installing A C now is a good time to install the defroster vents...

Page 613: ...612 www factoryfive com 508 291 3443 Tail lights Cut the original plugs off both taillights Remove the nuts and lock washers from the bezel studs...

Page 614: ...613 www factoryfive com 508 291 3443 Put the light in the bezel Put the gasket on the back of the light...

Page 615: ...614 www factoryfive com 508 291 3443 Insert the light wires through the body hole and insert the studs through the mounting holes Fasten the light to the body using the lock washers and nuts...

Page 616: ...it to allow the plug to pass though to the outside of the trunk The color coding for the lights is White Ground Black Running light Red Stop Turn signal Attach the included connectors to the tail ligh...

Page 617: ...Install the wires into the plug White from the light goes to black on the harness red on the light goes to yellow or white on the harness and black on the light goes to tan on the harness Close the p...

Page 618: ...Weatherstripping Install a strip of the expanding weatherstrip FFR 13712 on the upper tank 1 x 1 frame rail at which is located at the front of the trunk opening Run the moon weatherstrip around the...

Page 619: ...618 www factoryfive com 508 291 3443 Finish the moon weatherstrip just below the top sill Push the aluminum weatherstrip onto the trunk sides...

Page 620: ...o tape the panel openings with masking tape to prevent scratches It is now time to mount the body for the final time We like to blacken out the area of the body which is on the sides of the engine bay...

Page 621: ...ure that the exhaust tip is not installed as it protrudes though the body You can leave the door hinge standoffs on the frame just be very careful with the body when pulling it out to go over them one...

Page 622: ...621 www factoryfive com 508 291 3443 Install the rear wheel well 5 16 x 1 5 mounting screws using the spacer between the wheel well and the frame Firewall Clamp the dash area to the firewall...

Page 623: ...622 www factoryfive com 508 291 3443 Attach the aluminum firewall and footboxes to the body using either 3 16 rivets or screws...

Page 624: ...nd rivet the sides of the body to the frame using the screws used before paint as a guide for locating Rear body Drill mount holes in the sides of the body under the doors into the 1 5 square tube Mou...

Page 625: ...nal time attach the Firewall fill pieces to the body flange using silicone and hold it in place with masking tape until it has dried Hood Measure 19 from the center of the car then measure out 3 5 Sti...

Page 626: ...rge bumpers included with the kit to set the height of the panel so that they are flush with the body If necessary cut the large bumpers to the correct height if the small ones are too small Trunk Alu...

Page 627: ...626 www factoryfive com 508 291 3443 Push the bulb weatherstrip with the bulb on the side around the trunk opening starting at the bottom center Install the lower trunk floor...

Page 628: ...wer trunk where it meets the body attach the trunk floor to the body with 3 16 rivets Apply a liberal amount of silicon between this panel and the body Fuel filler 8mm deep socket ratchet 2 5mm hex ke...

Page 629: ...tatic electric build up in the filler which is important when f i l l i n gthe tank Locate one of the steel tubes behind the side aluminum by finding a row of rivets Either drill out one of the rivets...

Page 630: ...Attach the filler neck to the fuel cap Carpet Razor knife spray adhesive we recommend using 3M Super 77 or Super 90 spray adhesive Carpet Test fit the carpet before gluing Clean the surface of aluminu...

Page 631: ...630 www factoryfive com 508 291 3443...

Page 632: ...the shifter depending on the transmission used Glue the center of the carpet first Then work your way around to the base of the tunnel in a few steps gluing a few inches at a time Install the rear co...

Page 633: ...arpet Install the floors last Cut holes where the seats will attach to make install easier later Carpet the trunk Start with the center section of the trunk You will also have to slice a little sectio...

Page 634: ...here the hinges pass through the front vertical wall is to simply slice the carpet with a razor knife Then push the carpet back to allow the hinges to pass through them Shifter boot and trim ring Phil...

Page 635: ...43 Once the carpet is installed install the shifter handle boot and trim ring We suggest you bend and form the trim ring to the contour of the tunnel E brake Handle and boot Attach the handle to the f...

Page 636: ...factoryfive com 508 291 3443 Push the emergency brake boot over the handle Look at the boot and floor and decide where to bend the wire in the boot so that it will sit flat Drill and mount one screw a...

Page 637: ...ve com 508 291 3443 Hold the cover in place and drill a 3 32 hole through the cover near the ring that is captured in the boot and the cockpit aluminum Attach the boot to the cockpit aluminum using th...

Page 638: ...five com 508 291 3443 Repeat the drill and screw procedure around the boot so that the boot will seal against the floor Trunk Latch cable 3 16 drill bit drill rivet tool Insulated clip hardware trunk...

Page 639: ...he trunk latch cable The instructions and kit provides a latch and cable to get mounted in the cockpit An alternative would be to cut the cable and leave it directly under the trunk Drill an 11 32 hol...

Page 640: ...Spray some WD40 on the cable and slide the grommet so that it is about two feet from the other end of the cable The following pictures show the body off the frame this is done for easier viewing Run t...

Page 641: ...the 1 5 square tube to where the handle will attach Trunk release handle Philips head screwdriver drill bit drill razor knife If not installing a trunk release handle skip this section Using a razor...

Page 642: ...release cable through the hole and attach it to the handle Push the handle into the opening Use the handle as a guide to drill mounting holes through the aluminum Attach the handle to the aluminum us...

Page 643: ...3 Attach the release cable to the frame using the small insulated line clips and 3 16 rivets Trunk Latch 3 16 drill bit drill rivet tool Insulated clip hardware trunk latch assembly Attach the release...

Page 644: ...factoryfive com 508 291 3443 Remount the trunk latch assembly in the trunk using 3 16 rivets Prop Rod Reattach the trunk prop rod mount to the trunk aluminum using either 3 16 rivets or the aluminum...

Page 645: ...www factoryfive com 508 291 3443 Remount the prop rod clip to the trunk aluminum You can space the clip out from the carpet using a small rubber bumper behind the clip to give more clearance if desir...

Page 646: ...will also cut the license plate wires Push the tail light wires through the grommet into the trunk so they will reach the light Strip the ends of the tail light wires and the harness wires Tail light...

Page 647: ...ect harness wires Wire the tail lights to the harness using either butt connectors or solder Cut the wire loom outside the trunk so that the loom ends at the grommet Put the wire loom on the wires in...

Page 648: ...f the license plate bracket Under the car use a measuring tape to locate the center of the trunk and mark the bottom of the trunk aluminum near where the body ends Center the bracket on the trunk alig...

Page 649: ...ivet first then drill and attach the second rivet Drill a 11 32 hole for the license plate wires behind the license plate bracket Install a grommet in the hole In the trunk run the license plate wires...

Page 650: ...649 www factoryfive com 508 291 3443 Pull the wires through the grommet so that the wires are tight in the trunk Cut the harness wires so they are about 6 long...

Page 651: ...08 291 3443 After the license plate is installed connect the white wires together and the black wires together Connect the white wires to the brown wire and black wires to black wire Test the lights a...

Page 652: ...silicone on the wires grommet where they go through the trunk to seal the hole and hold the wires Silicone the grommets wires for the tail lights at this time as well Final Dash Wiring and Assembly Ma...

Page 653: ...3443 Install the headlight switch in the dash from the backside of the dash thread the mounting nut into the housing itself to secure it in place Place the knob over the switch shaft and then tighten...

Page 654: ...from the backside Secure it in place with the threaded ring from the front It maybe helpful to sand the backside of the body if the front threaded ring is not engaging far enough onto the ignition sw...

Page 655: ...dboard 7 64 17 64 5 8 drill bits drill tin snips Philips head screwdriver masking tape Upholstered interior parts door handle components Place the inner door panel on top of the door so that it sits o...

Page 656: ...the lever so that it is at the other extreme of its travel and mark the back of the panel again Use the trim piece included as a template and center the two locations marked in the ends of the templat...

Page 657: ...oryfive com 508 291 3443 Mark around the inside of the trim piece Use a drill bit followed by a 5 8 drill bit to drill the two circle locations Do not go too big or the trim piece screws will not moun...

Page 658: ...the inner door panel on a sheet of paper or cardboard and trace around the outside Attach the trees to the back of the door panels Cut out the panel to make a template then lay it over the door panel...

Page 659: ...d the panel up to the door and make sure the trees line up with the holes If necessary re drill or slot Position the template on the door and attach it with masking tape Drill through the template and...

Page 660: ...es using a 17 64 drill bit Push the panel into the holes in the door Put the trim piece over the release lever and make sure that the lever is centered at one end then pull the lever making sure that...

Page 661: ...08 291 3443 Use the trim piece as a template and drill 7 64 holes through the trim part Screw the trim piece onto the door liner Check the door release lever to make sure that it works correctly Repea...

Page 662: ...291 3443 Center Armrest Marker 17 64 drill bits drill masking tape Upholstered interior parts Insert the trees into the aluminum on the back of the armrest Put some tape in the general areas where the...

Page 663: ...662 www factoryfive com 508 291 3443 Use a marker to mark the location of the trees...

Page 664: ...e tunnel aluminum Cockpit rear cover Super 77 spray adhesive razor knife measuring tape sand paper masking tape Carpet box Vinyl roll fiberglass rear cockpit cover The rear cockpit cover can be sent o...

Page 665: ...664 www factoryfive com 508 291 3443 The above picture shows a rear cockpit cover that has been sent out for covering The sewn lines that are in the seat and the top trim cover were added to the vinyl...

Page 666: ...ryfive com 508 291 3443 The picture above shows the rear cockpit cover painted to match the body This is a picture showing the kit vinyl installed which is detailed below Note the cut under the right...

Page 667: ...of the rear cover so that the glue will bite Center the vinyl on the rear cockpit cover left to right as well as up and down and tape the center The vinyl is very elastic but the inside corners are st...

Page 668: ...just past the rollbar holes This will get trimmed after gluing This will give you 3 pieces The idea will be to do something similar to the sewn version above Flip the middle large vinyl piece over in...

Page 669: ...de piece on the rear vinyl and smooth the vinyl over the side of the fiberglass part Use a masking tape to get a straight in the corner going through the rollbar hole Cut through both vinyl pieces wit...

Page 670: ...pieces and roll them through the hole and stick them to the back side Fold the vinyl over the edges of the fiberglass and stick it to the back side of the fiberglass Install the rear cockpit panel in...

Page 671: ...ctoryfive com 508 291 3443 Final Seat Installation Reattach the seat in the holes drilled before using the fasteners provided Rear cockpit trim panel Upholstered interior parts Only used when no top i...

Page 672: ...oth Attach this piece so you can remove it by using Velcro silicon or anything of your choice Final Hardtop installation Headliner 3M General Trim Adhesive razor knife masking tape towels or something...

Page 673: ...er area off so that no glue gets on the outside of the area Place the headliner upside down on newspapers or kit packing paper Spray 3M general adhesive onto the headliner and hardtop as directed on t...

Page 674: ...ach the hardtop using the fasteners used during the first fitting Headlights Wire cutters soldering iron wire strippers ruler electrical tape drill bit drill tin snips file Headlight assembly extra ha...

Page 675: ...674 www factoryfive com 508 291 3443 Push the rubber grommet onto the back of the bulb Remove the indicator light harness from the headlight...

Page 676: ...factoryfive com 508 291 3443 Remove the headlight mounting nut lock washer and base Remove the threaded mounting bolt with the wires in Two wires need to get added to the wires going through the mount...

Page 677: ...676 www factoryfive com 508 291 3443 Move the mounting bolt to the end of the wires...

Page 678: ...com 508 291 3443 Use two wires that were not use and were removed from the harness that do not have thick insulation but are still 16ga wires or the white and red indicator wires Push the wires throug...

Page 679: ...678 www factoryfive com 508 291 3443 Cut the indicator light wires to 6 long Strip the black ground wire for the headlight about 3 behind the headlight plug...

Page 680: ...e Headlight connections Chassis harness Headlight Ground Black Black High Beam Brown Red Low Beam Red Green Park Tan Red Left Turn Dark Green White Right Turn Light Blue White Solder the other indicat...

Page 681: ...factoryfive com 508 291 3443 On the headlight bucket where the mount bolt passes through if the slot stops halfway like the bucket shown mark 0 25 behind the slot Drill holes in the corners of the are...

Page 682: ...681 www factoryfive com 508 291 3443 Use tip snips to cut the area marked Test fit the mounting bolt in the elongated slot and make sure there is easy movement...

Page 683: ...291 3443 If necessary file the sides of the slot for easy bolt movement This slot elongation allows correct headlight alignment since the engine cover sides are angled i n towards the grill Place the...

Page 684: ...m ring Remember that the light is mounted vertically and that the orientation for the driver passenger side is unique Pass the wires though the hood side panels and into the engine bay Make sure the h...

Page 685: ...sten the headlight in place with the nut supplied with the headlights If you would like to be able to switch between running side covers or not it is possible to use single spade connectors on the wir...

Page 686: ...he wires from the lights to the connectors included with the wiring harness Connect the common wires such as the grounds together from both lights Use the above pictures as a guide to assemble the wea...

Page 687: ...tulate you on finishing your Hot Rod Recheck the ride height of the frame Weight has been added since initially done Check the Appendix for alignment ride height and headlight alignment specs and proc...

Page 688: ...dix A Alignment and Ride Height Alignment Specifications Total Toe In inches Camber deg Caster deg Manual steering Power steering 1 16 1 16 0 5 0 5 0 75 3 4 6 7 Ride Height Front 4 5 Rear 5 Measured f...

Page 689: ...t require special aiming equipment and ensures proper aim Find a flat level surface next to a vertical white wall where the car can be parked a garage door is an ideal location at home Pull the car st...

Page 690: ...rk at the distance of Measurement B from the vehicle centerline vertical line Figure 2 Headlight alignment Turn the headlights on and adjust the vertical aim of the headlights so that the top horizont...

Page 691: ...Steering free lock to lock Front Suspension Front wheel bearings tight Upper and lower ball joints tight with cotter pins Upper control arm bolts tight Upper control arm jam nuts and clevis nuts tight...

Page 692: ...ed Air pressure set Lug nuts torqued Transmission Clutch height free play adjusted No leaks Universal joints no bind or wear Output shaft snug no bind Drive shaft bolts tight Transmission mount bolts...

Page 693: ...t you know that you are not alone Although we know our kit is the most straight forward assembly around there may be a time when you need to speak to us We will be there for you to make sure you are s...

Page 694: ...693 www factoryfive com 508 291 3443...

Page 695: ...omplete when seeking registration of your vehicle Provided with your Factory Five Racing kit is a Manufacturer s Certificate of Origin This document records the origin of the kit and is not a vehicle...

Page 696: ...n Cobra DOHC 4 6L 0 0 t T 45 17 x8 00 Mustang Cobra 385 625 385 425 Independen 18 x9 5 R 331 5 4L 0 0 t T 56 265 500 305 400 01 Mustang Bullitt SOHC 4 6L 0 0 Solid Axle T 45 17 x8 DOHC 03 04 Mustang 4...

Page 697: ...3 38 360 120 2003 04 T 56 2 97 2 07 1 43 1 00 0 800 0 62 3 28 450 129 Rearaxleratio Manual Optional Automatic 2004 3 55 2 49 2003 3 55 3 27 1996 2002 3 27 3 27 1995 3 08 3 27 1994 3 08 3 27 1987 1993...

Page 698: ...sed in the 2003 2004 Cobra Mustang and the 2000Cobra R Mustang has a 27 spline yoke Mass Air Sensor Mass air sensors are devices used to measure air flow into the engine for the vehicles computer Thes...

Page 699: ...en sensors it is suggested to purchase a by pass kit to eliminate two of the sensors This can also be done with modifications to the wiring harness Exhaust headers 1986 to 1993 Mustang headers have 1...

Page 700: ...t other sizes may also fit Information is separated into groups of wheels tires used on Hot Rods without fenders and those with fenders and it is also important to note that this information is based...

Page 701: ...ar 20x12 335 30 20 5 75 backspace Notes Purchased from Billet Specialties ordered with Mustang Cobra brake clearance IForged Seneka wheels Front 18x9 5 275 35 18 6 backspace Rear 19x11 305 30 19 6 bac...

Page 702: ...ns will allow the wheels and tires to fit under the optional Fenders Front maximum wheel width and Backspacing 9 00 with 5 50 Backspace Front maximum tire width 255mm Rear maximum wheel width and Back...

Page 703: ...702 www factoryfive com 508 291 3443 Appendix H Soft Top Diagrams...

Page 704: ...703 www factoryfive com 508 291 3443...

Page 705: ...704 www factoryfive com 508 291 3443...

Page 706: ...705 www factoryfive com 508 291 3443...

Page 707: ...706 www factoryfive com 508 291 3443 Appendix I Driveshaft lengths...

Page 708: ...707 www factoryfive com 508 291 3443...

Page 709: ...rque specifications standard Thread SAE English Zinc Plated Ft Lb 20 8 28 10 5 16 18 17 5 16 24 19 16 30 24 34 7 16 14 48 7 16 24 54 13 75 20 83 9 16 12 100 9 16 18 100 11 100 14 100 General Bolt torq...

Page 710: ...10W 30 5 0 qts 4 6L Coyote 5W 30 5W 50 8 0 qts w FFR pan 8 0 qts Transmission Oil Type T 5 T 45 3650 TKO T 56 Mercon Dexron III Trans Fluid 2 8 qts 3 25 qts 4 0 qts 2 64 qts 4 0 qts Recommended fluid...

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Factory Five Racing '33 Hot Rod, Assembly Manual

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