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Factory Five Racing '33 Hot Rod Assembly Manual

Summary of '33 Hot Rod

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    R e v i s i o n 2 t , a u g u s t 2 0 1 7.

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    2017 factory five racing inc. 9 tow rd wareham, ma 02571 phone 508.291.3443 • fax 508.291.3883 www.Factoryfive.Com.

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    Ii www.Factoryfive.Com 508-291-3443 table of contents general information ..................................................................................................................................... 7 f oreword ...................................................................................

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    Iii www.Factoryfive.Com 508-291-3443 o ne r eservoir ..................................................................................................................................................................................... 128 t wo r eservoirs ...............................................

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    Iv www.Factoryfive.Com 508-291-3443 s hifter hole ........................................................................................................................................................................................ 323 e- brake h andle ...............................................

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    V www.Factoryfive.Com 508-291-3443 s ide covers ........................................................................................................................................................................................... 473 h ood cable release ...........................................

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    Vi www.Factoryfive.Com 508-291-3443 appendix f: mustang specifications .................................................................................................. 695 m ustangs by year ...............................................................................................................

  • Page 8: General Information

    7 www.Factoryfive.Com 508-291-3443 i general information foreword f you are reading this, you are embarking on a mission to build your own car, or at least considering doing so. I wanted to share with you some of my experiences and lessons learned while working with literally thousands of people who...

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    8 www.Factoryfive.Com 508-291-3443 very definition of always trying to go faster. The late carroll smith wrote something i really loved that speaks to this point. “there is no magic! The one basic truth of successful racecar preparation bears repeating. There is no magic. There is only logic, common...

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    9 www.Factoryfive.Com 508-291-3443 all the way thru the process, as you build your car, the seasoned guys at factory five in tech support will help you. The larger community of factory five customers will also be there for you, as the one thing that really sets us above the crowd of other companies ...

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    10 www.Factoryfive.Com 508-291-3443 safety notice while there are many things to love and be proud of in our country today there are a few things that we wish were different. With regret and a small amount of resentment we include the following warning and statement of non-liability at the advice of...

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    11 www.Factoryfive.Com 508-291-3443 safety tips read the manual. It is at least a good guide and place to start. Don’t take short cuts. Before starting work, make sure you have the proper tools, the required parts, and sufficient space for the job. If you damage any parts, it will probably be becaus...

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    12 www.Factoryfive.Com 508-291-3443 what you get the factory five ‘33 hot rod kit gives you everything you need to build your car in one big package. The only things you’ll need are the engine/trans/rear end, wheels/tires, fuel pump and a paint job. When we say everything, we mean it. We include eve...

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    13 www.Factoryfive.Com 508-291-3443 fuel system/parts: this assembly is designed to work with carburetor or fuel injection systems. External inline fuel pump required. Fuel tank w/mounting hardware, vent, gaskets, pick-up and fuel level sending unit fuel filler neck and fasteners pre-flared fuel lin...

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    14 www.Factoryfive.Com 508-291-3443 license plate lights and bracket with fasteners exterior side mirror ceramic ffr badges headlamp assemblies, including chrome buckets, halogen headlamps, with integral turn signal, and fasteners red led tail-lights (dot approved). Pedal box and components: the ‘33...

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    15 www.Factoryfive.Com 508-291-3443 ford 8.8” rear end or a 9” modified to accept mustang suspension pick-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 t...

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    16 www.Factoryfive.Com 508-291-3443 optional part instructions part instructions for all factory five parts and options can be found online at: www.Factoryfiveparts.Com/instructions/ tools and supplies list the following lists detail the tools and supplies that are needed to build your kit. The “hel...

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    17 www.Factoryfive.Com 508-291-3443 helpful cordless drill (w/clutch helpful, 14-18 volt units are best) #6 hex driver attachment for cordless drill adapter for cordless to use ¼” socket driver flare nut wrenches (⅜” & 7 / 16 ”) flat file and round file ratchet wrenches required supplies engine degr...

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    18 www.Factoryfive.Com 508-291-3443 chapter 1 – kit disassembly unpacking your hot rod kit  please note that your boxes are numbered, when you read your packing list you will see that next to each assembly there is a number circled. This is the box number that the assembly was packaged into.  afte...

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    19 www.Factoryfive.Com 508-291-3443 33123 door stricker plate, right 1.00 ea 33121 door hinge standoff assembly 2.00 ea 33498 left side door frame 1.00 ea 33499 right side door frame 1.00 ea 33113 trunk hinge mount 2.00 ea 33112 trunk hinge arm 2.00 ea 33515 trunk striker mount 1.00 ea 33516 trunk l...

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    20 www.Factoryfive.Com 508-291-3443 remove the doors and trunk and store them for later. Two people can remove 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 ...

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    21 www.Factoryfive.Com 508-291-3443 before removing the aluminum from the chassis, mark each panel and take pictures of how the 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 perman...

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    22 www.Factoryfive.Com 508-291-3443 rivet spacing tool packaged aluminum  in most cases we use a 3” rivet spacing when mounting aluminum panels to the chassis and a 2” spacing when mounting panel to panel. The rivet spacing tool has this hole spacing marked. The distance from the edge of the tool t...

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    23 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 frame..

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    24 www.Factoryfive.Com 508-291-3443 chapter 2 - chassis build up front suspension lower control arm assembly ⅜”, ¾” wrench, chassis grease, vise or plastic hammer, ratchet, ¾” socket front lower control arm components.

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    25 www.Factoryfive.Com 508-291-3443.

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    26 www.Factoryfive.Com 508-291-3443 dust boot placed over lower control arm ball joint. Grease fitting in lower control arm ball joint..

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    27 www.Factoryfive.Com 508-291-3443 thread adjuster into lower control arm screw the clevis into the adjuster in the lower control arm..

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    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..

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    29 www.Factoryfive.Com 508-291-3443 install sleeve in front lower collar. Install collar onto adjuster clevis..

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    30 www.Factoryfive.Com 508-291-3443 rod end install on lower control arm front leg of the front lower control arms (completed).

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    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..

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    32 www.Factoryfive.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 control arm ball joint..

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    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.

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    34 www.Factoryfive.Com 508-291-3443 insert the greased sleeve into the bushings in the upper control arm install the grease fittings into the pivot points on the upper control arm. Attach a grease gun onto the grease fitting and fill with grease until the grease starts to seep out. Coil-over shock a...

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    35 www.Factoryfive.Com 508-291-3443 the rear springs are 250#. Other springs are available for different ride characteristics.  warning! Incorrect assembly and maintenance of this part can cause serious injury or death.  the front shocks extended measurement is 15.15” center to center. They are 2....

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    36 www.Factoryfive.Com 508-291-3443 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 assemble the coil over shock..

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    37 www.Factoryfive.Com 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 against the end of the shock..

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    38 www.Factoryfive.Com 508-291-3443 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. Check to make sure that the spring is seated correctly on the shock. Run zip ties through the hole...

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    39 www.Factoryfive.Com 508-291-3443 install 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 spacers on either side of the spherical joint..

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    40 www.Factoryfive.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 mallet spindle assembly.

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    41 www.Factoryfive.Com 508-291-3443.

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    42 www.Factoryfive.Com 508-291-3443 assemble the spindles (passenger side is on the left, driver side is 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 t...

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    43 www.Factoryfive.Com 508-291-3443 install 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” spacer on top of the ball joint stud (ffr# 14406).

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    44 www.Factoryfive.Com 508-291-3443 install the spindles 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 arm hardware then torque these fasteners to...

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    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..

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    46 www.Factoryfive.Com 508-291-3443 front suspension torque specs chart item nm lbft front lower control arm to frame 135-162 100-110 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 7...

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    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..

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    48 www.Factoryfive.Com 508-291-3443 install the slider grease boots on the slider pins..

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    49 www.Factoryfive.Com 508-291-3443 in the supplied hardware bag there are six 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 hanger are different end ...

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    50 www.Factoryfive.Com 508-291-3443.

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    51 www.Factoryfive.Com 508-291-3443 the two clips that are left go in the center of the caliper with the tab sticking 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 out...

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    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..

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    53 www.Factoryfive.Com 508-291-3443 look at the back side 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 pad, while the studs on the outside pads a...

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    54 www.Factoryfive.Com 508-291-3443 install the brake pads in the caliper..

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    55 www.Factoryfive.Com 508-291-3443 clean the rotor with brake cleaner and push it onto the 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 screw wil...

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    56 www.Factoryfive.Com 508-291-3443 install the calipers on the front spindles. Mount the calipers with the supplied bolts (ffr #14513). Make sure the pads are loaded into the caliper before installing it. Solid axle rear suspension solid axle preparation ¾” sockets, ¾” wrench, ½” drill bit, drill, ...

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    57 www.Factoryfive.Com 508-291-3443 if not already 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 lower control arm mount holes with a ½” drill bit..

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    58 www.Factoryfive.Com 508-291-3443 rear coil-over shock assembly snap ring pliers, ¾” wrench, ¾” socket, ratchet, ruler, marker, hack saw. Rear shock kit  the rear shocks are pre-valved at the factory in compression and rebound for good street use. The shocks can be adjusted in rebound as per koni...

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    59 www.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 shaft. Put the spring on the shock, then install the spring hat on the shaft end of the shock a...

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    60 www.Factoryfive.Com 508-291-3443 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 the spring hat. Traction lok brackets.

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    61 www.Factoryfive.Com 508-291-3443 axle bracket driver's side axle bracket passenger side.

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    62 www.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 axle.

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    63 www.Factoryfive.Com 508-291-3443 tighten 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 provide more traction than the upper holes..

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    64 www.Factoryfive.Com 508-291-3443 install the shocks onto the frame with 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 rear of the car (allo...

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    65 www.Factoryfive.Com 508-291-3443 4 link suspension place 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 going outward to the side of the car (ffr# 139...

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    66 www.Factoryfive.Com 508-291-3443 install the shocks (body down) to the rear axle assembly. Passenger side - the longer spacer (ffr# 33238) is placed at the front of the shock and the smaller 0.125” shim (ffr# 13210) is placed at the rear. Install the upper control arms onto the frame and the axle...

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    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.

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    68 www.Factoryfive.Com 508-291-3443 install the upper 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 variance and may need to be drilled out from the...

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    69 www.Factoryfive.Com 508-291-3443 attach the 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 panhard bar and the shorter one is the upper lin...

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    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..

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    71 www.Factoryfive.Com 508-291-3443 attach the lower control arm onto the frame with the provided hardware; make 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...

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    72 www.Factoryfive.Com 508-291-3443  with the rear end correctly installed with the 3-link, the rear axle will rest on the 3-link panhard 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 s...

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    73 www.Factoryfive.Com 508-291-3443 install the panhard bar into the passenger 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 frame m...

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    74 www.Factoryfive.Com 508-291-3443 3 link rear suspension torque specs chart item nm lbft 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 axle bracket ...

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    75 www.Factoryfive.Com 508-291-3443 /16 16 /16 16 l&r lower control arms, l&r upper control arms, toe arms, l&r cv axles, koni coil-over shocks, springs, fasteners, driveshaft adapter philips head screwdriver, 5 / 8 ” drill bit, 13 ”, 15 / ” wrenches, 13 ”, 15 / ” 18mm sockets, large adjustable wren...

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    76 www.Factoryfive.Com 508-291-3443 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 boss at the bottom of the ear..

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    77 www.Factoryfive.Com 508-291-3443 use a saw to cut the ear off the 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, ½”-20 lugnut, torque wrench. Rear wheel studs. Removal of the hub from the spin...

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    78 www.Factoryfive.Com 508-291-3443 use a 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 use a washer and lug nut on the front side..

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    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..

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    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..

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    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.

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    82 www.Factoryfive.Com 508-291-3443 bushing locations. Use a plastic mallet to install the polyurethane bushings marked 2048 and the longer (3 1 / 16 ”) sleeves where the front of the center section will mount..

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    83 www.Factoryfive.Com 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 components grease gun.

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    84 www.Factoryfive.Com 508-291-3443 assemble each of the upper control arms as shown. 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 grease until the ...

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    85 www.Factoryfive.Com 508-291-3443 toe adjustment arms assemble each of the toe 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 is simi...

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    86 www.Factoryfive.Com 508-291-3443 use rags to protect between the front center section mount on the frame..

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    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..

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    88 www.Factoryfive.Com 508-291-3443 flatten the center 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/longer bolts and nuts are used for the front m...

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    89 www.Factoryfive.Com 508-291-3443 torque both the front and rear bolts to 135nm (100 ft-lb). Toe adjustment arms irs toe adjustment arm components 13 / 16 ” socket, 15 / 16 ” wrench, torque wrench. Attach the toe arms to the frame below the front lower arm mount using the 1 / 8 ” thick spacer in t...

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    90 www.Factoryfive.Com 508-291-3443 attach the upper control arms to the frame with the thick tube at the front. Use the longer m16 x 110mm (~4 5 / 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 for each sid...

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    91 www.Factoryfive.Com 508-291-3443 starting with the left side using the correct axle, push the inner cv joint 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 t...

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    92 www.Factoryfive.Com 508-291-3443 slide the left spindle onto the outer cv joint and start the nut on the end..

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    93 www.Factoryfive.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 arms are installed..

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    94 www.Factoryfive.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 misalignment spacer..

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    95 www.Factoryfive.Com 508-291-3443 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 the other arms are installed..

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    96 www.Factoryfive.Com 508-291-3443 check the angle of the upper control 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 1 5 / 8 ” wrench to loosen the upper control arm large jam nut and put ...

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    97 www.Factoryfive.Com 508-291-3443 retighten the jam nut. Toe link attach the toe link arm to the spindle using the m14 x 80mm bolt and locknut. Repeat for the right hand side. Use the torque specifications page at the back of the instructions to torque the control arm to spindle bolts. Coil-over s...

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    98 www.Factoryfive.Com 508-291-3443 unpack the shocks, coil-over’s and hardware. Double check the jam nut under the rod end and 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 b...

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    99 www.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 shaft..

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    100 www.Factoryfive.Com 508-291-3443 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 against the end of the shock. Install the snap ring on the spring hat so that it holds onto the shock end. Make sure that the slot in the sna...

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    101 www.Factoryfive.Com 508-291-3443 hot rod - attach the rod end of 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 the car is complete). Torque ...

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    102 www.Factoryfive.Com 508-291-3443 jack the spindle up so the body end of the shocks can be mounted on the shock mount on the control arm using the longer 1.09” spacer on the back and 7 / 16 ” spacer in front of the shock. Torque the lower shock bolt to 54nm (40 ft-lb). Remove the floor jack. Driv...

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    103 www.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 ft-lb)..

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    104 www.Factoryfive.Com 508-291-3443 insert the driveshaft into the transmission, bolt the rear flange to the driveshaft adapter and torque the bolts to 109nm (80 ft-lb). Fluids name specification motorcraft® additive friction modifier (u.S.) xl-3 (u.S.) est-m2c118-a motorcraft® sae 75w-85 synthetic...

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    105 www.Factoryfive.Com 508-291-3443 hub to spindle 98 133 cv axle nut 98 133 then rotate 45° driveshaft adapter to pinion flange 41 55 driveshaft to driveshaft adapter 80 109 optional irs brakes download the 2015 irs brake instructions from www.Factoryfiveparts.Com/instructions and install the brak...

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    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..

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    107 www.Factoryfive.Com 508-291-3443 wilwood 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 mount then down and over to the brake caliper..

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    108 www.Factoryfive.Com 508-291-3443 pedal box ½”, 9 / 16 ” sockets, ⅜”, 11 / 32 ”, ½”, 9 / 16 ” wrenches, drill, 3 / 16 ”, ¼”, ½” drill bit, ⅛”, 9 / 32 ”, 5 / 16 ”, ” hex keys, hammer, vise or 2 pieces of 2 x 4, razor knife or file or grinder, snap ring pliers, 5 / 16 ” nut driver. Pedal components...

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    109 www.Factoryfive.Com 508-291-3443 connect the switch to the switch mount using a hex nut on each side 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 cl...

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    110 www.Factoryfive.Com 508-291-3443 attach the switch mount to the pedal box using the black #10 screw and locknut. Connect the switch to 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 y...

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    111 www.Factoryfive.Com 508-291-3443 use snap ring pliers to remove the clevis at the top of the clutch pedal..

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    112 www.Factoryfive.Com 508-291-3443 assemble the clutch quadrant to the wilwood clutch pedal as shown above..

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    113 www.Factoryfive.Com 508-291-3443 if necessary 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” button head screws, locknuts, 3 / 16 ” hex k...

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    114 www.Factoryfive.Com 508-291-3443 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 fasten using ¼”- 20 x 1.25” screws..

  • Page 116

    115 www.Factoryfive.Com 508-291-3443 master cylinders  keep the extra washers provided 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, ½” deep socket, ratchet, ½” wrench master cylinders with...

  • 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

    117 www.Factoryfive.Com 508-291-3443 put one of the master cylinders onto one of the brake master cylinder 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 p...

  • Page 119

    118 www.Factoryfive.Com 508-291-3443 attach and tighten the locknuts using a ½” 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 a 6mm socket and ratchet to tighten the hos...

  • Page 120

    119 www.Factoryfive.Com 508-291-3443 tighten all the remaining hardware mounting the pedal box to the chassis. Balance bar adjustment the balance bar is an adjustable lever (usually a threaded rod), that pivots on a spherical bearing and uses two separate master cylinders for the front and rear brak...

  • Page 121

    120 www.Factoryfive.Com 508-291-3443 lever movement should be unimpeded throughout pedal travel. In the neutral position, clevises should have between .20” - .25” total clearance between the side of the pedal. The large washers between the pedal and clevis should remain loose. Make sure that the mas...

  • Page 122

    121 www.Factoryfive.Com 508-291-3443 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, packaged aluminum, firewall.

  • Page 123

    122 www.Factoryfive.Com 508-291-3443 clamp the firewall onto the frame. The bottom edge of the firewall meets the top edge of the footbox front walls. Using a marker, mark the backside of these three pieces where they come in contact with the frame. Remove the three panels. Determine how you want to...

  • Page 124

    123 www.Factoryfive.Com 508-291-3443 optional clutch cable 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 template face down on the front...

  • 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

    125 www.Factoryfive.Com 508-291-3443 final firewall install clamp all of the ⅛” aluminum pieces back onto the frame and drill the frame for each attachment point. Fasten/attach the firewall and the front footbox panels to the frame. Brake reservoir  there are two ways to plumb the brake fluid reser...

  • Page 127

    126 www.Factoryfive.Com 508-291-3443 screw in the hose barb. Loosely screw the mounting bracket onto the reservoir..

  • Page 128

    127 www.Factoryfive.Com 508-291-3443 the 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 the cowl made later in the body section..

  • Page 129

    128 www.Factoryfive.Com 508-291-3443 one reservoir use some tape on the frame or firewall then locate the brake fluid reservoir and mark the hole locations.  make sure that the top of the reservoir cap is below the top of the firewall or the cap will hit the body. Remove the reservoir and use a 5 /...

  • Page 130

    129 www.Factoryfive.Com 508-291-3443 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 the brake master cylinders..

  • Page 131

    130 www.Factoryfive.Com 508-291-3443 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 side. Position the rack in the frame..

  • Page 132

    131 www.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 bracket..

  • Page 133

    132 www.Factoryfive.Com 508-291-3443 attach the rack mount 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, use a hole saw on the plate at this loca...

  • Page 134

    133 www.Factoryfive.Com 508-291-3443 tighten all of the steering rack mounting 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 front end by eye. Fasten the...

  • Page 135

    134 www.Factoryfive.Com 508-291-3443 brake lines tubing bender, ⅜”, 7 / 16 ”, ½”, 11 / 16 ” wrenches, pliers, 3 / 16 ” drill bit, drill, rivet tool, masking tape, marker. Brake lines, insulated clip hardware, hot rod brake line components  the ¾” master cylinder is used for front and the 5 / 8 ” ma...

  • Page 136

    135 www.Factoryfive.Com 508-291-3443 route 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 45° angle section of the foot box front wall..

  • 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

    137 www.Factoryfive.Com 508-291-3443 front brake line around the location of the 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 brake line to th...

  • Page 139

    138 www.Factoryfive.Com 508-291-3443 at the end of the 20" brake line section, install the 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 with (2)...

  • Page 140

    139 www.Factoryfive.Com 508-291-3443 attach another 20” section of brake line onto the t-junction and run this 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...

  • 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 ¼” insulated line clips..

  • Page 142

    141 www.Factoryfive.Com 508-291-3443 at the end of the 60" brake line piece, 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 of the tube as the bo...

  • Page 143

    142 www.Factoryfive.Com 508-291-3443 route the brake line on the inside of the 1.5” tubes to behind the rear axle upper 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 br...

  • 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

    144 www.Factoryfive.Com 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 flexible brake line adapter..

  • Page 146

    145 www.Factoryfive.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 flexible brake line..

  • Page 147

    146 www.Factoryfive.Com 508-291-3443 loosely attach the flexible brake line to the brake caliper. Attach 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 flex...

  • Page 148

    147 www.Factoryfive.Com 508-291-3443 would ever need to reach. It is also important that the flexible line will not rub on the control arm or frame when 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 ...

  • Page 149

    148 www.Factoryfive.Com 508-291-3443 run a 60” rear brake 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 towards the passenger side of the car along th...

  • Page 150

    149 www.Factoryfive.Com 508-291-3443 run 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 the frame mount using a brake line clip..

  • Page 151

    150 www.Factoryfive.Com 508-291-3443 attach the flexible brake line by hand to the brake 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 holes. Move the ...

  • Page 152

    151 www.Factoryfive.Com 508-291-3443 reposition and rivet the brake line mount to the frame. Drill the other mounting hole and attach a rivet. Steering column ⅝” wrench, ⅝” socket, ratchet, flathead screwdriver. Steering column, steering column components.  the standard column material is brushed s...

  • Page 153

    152 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 screw..

  • Page 154

    153 www.Factoryfive.Com 508-291-3443 screw on the hazard switch onto the steering column. Steering shaft ⅛”, 5 / 32 ” hex key, ½” wrench steering shaft components  when installing the steering linkages, loosely install the entire system then tighten the bolts and set screws once it is complete.  w...

  • Page 155

    154 www.Factoryfive.Com 508-291-3443.

  • Page 156

    155 www.Factoryfive.Com 508-291-3443 attach the ¾" dd to ¾" dd joint on to the steering column output shaft using a 5 / 32 ” hex key and ½” wrench. The smaller end goes on the steering column. Install the 11 7 / 16 ” upper steering shaft in the other side of this joint and it passes through the fire...

  • Page 157

    156 www.Factoryfive.Com 508-291-3443 attach another ¾” to ¾” dd joint to the end of the shaft after it exits the firewall with the shorter end touching 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 t...

  • Page 158

    157 www.Factoryfive.Com 508-291-3443 manual steering attach the second flange bearing to 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 the ste...

  • Page 159

    158 www.Factoryfive.Com 508-291-3443 insert the 10 9 / 16 ” lower steering shaft into the flange bearing 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 15 1 / 16 ” middle dd steering joint to the end of the front ...

  • Page 160

    159 www.Factoryfive.Com 508-291-3443 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 small set screw on the firewall joint..

  • Page 161

    160 www.Factoryfive.Com 508-291-3443 electric power steering (optional) 13mm, 15mm, ⅝” sockets, 6mm, 5 / 32 ” hex key, ½”, ⅝”, 17mm wrenches, marker, grinder, hack saw electric steering components, hot rod steering shaft components.  the power steering unit may need to be rotated in order to clear ...

  • Page 162

    161 www.Factoryfive.Com 508-291-3443 attach a joint to the front of the electric steering unit. Insert the small ¾” dd shaft into the joint on the front of the electric steering unit..

  • Page 163

    162 www.Factoryfive.Com 508-291-3443 insert the ¾” 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

    163 www.Factoryfive.Com 508-291-3443 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, remove the cover on the top of the unit..

  • Page 165

    164 www.Factoryfive.Com 508-291-3443 tighten the locking screws and nuts for the front shaft..

  • Page 166

    165 www.Factoryfive.Com 508-291-3443 remove the locking bolt from the remaining splined joint with a 6mm hex key and insert the 15 1 / 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 the bolt hole to mark the position o...

  • Page 167

    166 www.Factoryfive.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 locking bolt..

  • Page 168

    167 www.Factoryfive.Com 508-291-3443 attach the splined 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 that the end is flush with the inside of the join...

  • Page 169

    168 www.Factoryfive.Com 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 joint on the firewall..

  • 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

    170 www.Factoryfive.Com 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 into the control module..

  • Page 172

    171 www.Factoryfive.Com 508-291-3443 mount the control module 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 mounted to the 1.50” square tube in front o...

  • 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

    174 www.Factoryfive.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 damage or fire..

  • Page 176

    175 www.Factoryfive.Com 508-291-3443 *failure to do so may result in a short circuit or malfunction. The heavy black wire should get grounded.  the white & purple or brown wires are used for trouble code reading and clearing. They need to be located in an accessible place such as near the master cy...

  • Page 177

    176 www.Factoryfive.Com 508-291-3443 attach the 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 center section is installed after aligning the car..

  • 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

    178 www.Factoryfive.Com 508-291-3443 front, engine sensor and rear wiring harness. Fuse panel installation 5 / 32 ” hex key, 7 / 16 ” socket, ratchet, 3 / 16 ” drill bit, ⅜” wrench  read all of the instructions thoroughly before starting the actual installation. If you have any technical questions ...

  • Page 180

    179 www.Factoryfive.Com 508-291-3443 attach the fuse block to the aluminum mount plate using the ¼” 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 pedal box area with the fuses facing towards the...

  • Page 181

    180 www.Factoryfive.Com 508-291-3443 clamp the fuse block mount plate into place to the right of the pedal box mounting location. Drill into the 1.5" square tube (firewall mounting surface tube) and the ¾" tube (lower one) which triangulates the pedal box mounting location. Install the panel with ri...

  • Page 182

    181 www.Factoryfive.Com 508-291-3443 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 signal. Make sure to ground the flashers..

  • 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

    184 www.Factoryfive.Com 508-291-3443 starting at the firewall, 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 the cockpit area, go under the 1” tube an...

  • Page 186

    185 www.Factoryfive.Com 508-291-3443 here, the battery cable stops and 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 the rear of the frame so the ...

  • Page 187

    186 www.Factoryfive.Com 508-291-3443 locate the fuel tank wires in the rear harness and run them forward just behind the rear 1.5" square tube to which the roll bar is attached.  if you need more length on the fuel system wires, pull the loom back and cut the electrical tape so the wires can move f...

  • Page 188

    187 www.Factoryfive.Com 508-291-3443 zip tie the rear light wires to the rear brake 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 ⅝” insulated clips. Front harness razor knife, ...

  • Page 189

    188 www.Factoryfive.Com 508-291-3443 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 the front of the transmission tunnel..

  • Page 190

    189 www.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 / 16 ” plate..

  • Page 191

    190 www.Factoryfive.Com 508-291-3443 zip tie the 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 side headlight forward to the front of the frame..

  • Page 192

    191 www.Factoryfive.Com 508-291-3443 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 rear lower control arm mount..

  • 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. Starter solenoid wiring locate the starter solenoid wires..

  • Page 196

    195 www.Factoryfive.Com 508-291-3443 wire the solenoid on the back side of the starter. The battery cable goes to one of the large posts on the solenoid. On the 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 termina...

  • Page 197

    196 www.Factoryfive.Com 508-291-3443 connect the purple wire which was removed from the brake pedal plug and install it on one of the spades on the brake pedal switch. Clutch safety switch  a clutch safety switch is used to prevent starting the car while in gear. It requires pushing the clutch peda...

  • Page 198

    197 www.Factoryfive.Com 508-291-3443 if a switch is not going to be used, connect the two wires together by either soldering the wires or using a butt connector from the “misc. Electrical components” assembly in the factory five racing main kit pack. Fuel inertia switch drill, ¼” nut driver use the ...

  • Page 199

    198 www.Factoryfive.Com 508-291-3443 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 on the side of the headlight switch..

  • Page 200

    199 www.Factoryfive.Com 508-291-3443 ignition switch wiring  if you are using a one wire alternator with the chassis harness, the brown alternator ignition power wire is not necessary. Locate the ignition switch wires and make the following connections to the ignition switch itself. Ignition wiring...

  • 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

    201 www.Factoryfive.Com 508-291-3443 steering column wiring plug the steering column into the chassis 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 the...

  • Page 203

    202 www.Factoryfive.Com 508-291-3443 cut the yellow and white rear turn signal light wires off the turn signal connectors that are for the dash turn signal switch so that the turn signal lights do not back feed and light the front turn signals when the brakes are pressed. Fan wiring follow the direc...

  • Page 204

    203 www.Factoryfive.Com 508-291-3443 attach the alternator plugs to the 1987-1993 alternator.  if you are using a one-wire alternator, cut the large plug off the wires and attach two 10-12 gauge ring connectors to the two large wires and attach them to the post on the alternator. The other plug and...

  • Page 205

    204 www.Factoryfive.Com 508-291-3443 install the battery on the platform centered behind 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 battery tra...

  • Page 206

    205 www.Factoryfive.Com 508-291-3443 remove 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 cable has a good connection to the chassis..

  • Page 207

    206 www.Factoryfive.Com 508-291-3443 install the battery and mount it in place with the j-bolts. Pass the looped section through the frame and then use the supplied nuts and washers on the top to fasten the center mount cross bar hold down to the battery. Attach the chassis side of the ground strap ...

  • Page 208

    207 www.Factoryfive.Com 508-291-3443 connect the ground strap to the battery. We advise you not to install the positive lead to 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 ...

  • Page 209

    208 www.Factoryfive.Com 508-291-3443 the other location is the side body mount which is described in the following 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 t...

  • 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

    210 www.Factoryfive.Com 508-291-3443 cut 2” off the end 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 ¼” female connectors included then crimp the conn...

  • Page 212

    211 www.Factoryfive.Com 508-291-3443 cut the same 2”off the green horn power wire and strip the ends of both wires. Twist the chassis harness green wire and small wire ground together and insert them into one of the ¼” female connectors included with the horns then crimp the connector on. Attach the...

  • Page 213

    212 www.Factoryfive.Com 508-291-3443 attach the two horns to the backside of the side body mount behind the driver side front wheel using the supplied ¼” bolt. Engine, transmission and driveshaft  if installing a small block chevy, ls or ford coyote engine, go to www.Factoryfiveparts.Com/instructio...

  • 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

    214 www.Factoryfive.Com 508-291-3443 purchase 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. 2003 4.6l explorer part number #1l2z-6881-aa.

  • Page 216

    215 www.Factoryfive.Com 508-291-3443  the 4.6l engine ends up extremely close to the firewall. Cut any extra length off the bolts to prevent damaging the firewall. Install the engine mount mounts onto the frame with the ½"-20 hardware (ffr# 33454 & 25619). It is helpful to only bolt the top of the ...

  • Page 217

    216 www.Factoryfive.Com 508-291-3443 with the help of some friends install the engine and transmission into the chassis. Make sure to bolt the energy suspension engine mounts to the engine before installing the engine. If the chassis is powdercoated you may want to protect the engine bay down tubes....

  • Page 218

    217 www.Factoryfive.Com 508-291-3443 the transmission mount plate is fully adjustable and can be positioned on the chassis to provide more adjustment to the front or the rear depending on the transmission choice. Lift on the rear of the transmission and slide this bracket into place. It is fastened ...

  • Page 219

    218 www.Factoryfive.Com 508-291-3443 install the drive shaft next. Begin by inserting 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 engine and transm...

  • Page 220

    219 www.Factoryfive.Com 508-291-3443 optional clutch cable clutch cable, insulated clip hardware  for use with optional manual transmission components. Slide the clutch cable end through the clutch cable spacer and loop the cable over the quadrant. Route the clutch cable down to the bellhousing. Us...

  • Page 221

    220 www.Factoryfive.Com 508-291-3443 engine ground sand paper or grinder bit, ½” 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 side of the engine..

  • 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, ¼”, 25 / 64 ” drill bits, 5 / 32 ” hex key, riv-nut tool, grinder.

  • Page 226

    225 www.Factoryfive.Com 508-291-3443 cooling components, secondary body fasteners, radiator assembly, front grill. 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 ...

  • 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 ¼” mounting holes in the radiator mount tabs..

  • Page 229

    228 www.Factoryfive.Com 508-291-3443 lay the radiator back on the grill and check the hole alignment by putting the ¼” button head screws in as many holes as possible. If necessary, with the radiator and screws in the grill, use the ¼” drill bit and drill to “align” the holes..

  • Page 230

    229 www.Factoryfive.Com 508-291-3443 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 radiator now using the a/c instructions..

  • Page 231

    230 www.Factoryfive.Com 508-291-3443 if not mounting an a/c condenser, attach the radiator to the grill using the ¼-20 x ¾” screws provided. Fan thermostat switch teflon tape, 11 / 16 ” wrench cooling components, front grill  if you are not running the thermostat switch, this hole can be plugged wi...

  • 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

    232 www.Factoryfive.Com 508-291-3443 electric fan ⅛” hex key, ⅜” 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 will allow the fan to sit tight agai...

  • Page 234

    233 www.Factoryfive.Com 508-291-3443 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 other. It should be a tight fit..

  • Page 235

    234 www.Factoryfive.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 / 64 ” drill bit..

  • Page 236

    235 www.Factoryfive.Com 508-291-3443 attach the fan assembly to the radiator tabs using 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 ...

  • Page 237

    236 www.Factoryfive.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 the grill..

  • Page 238

    237 www.Factoryfive.Com 508-291-3443 attach the grill to the grill mounts using the ¼” 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, wire crimpers cooling...

  • Page 239

    238 www.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 the fan..

  • Page 240

    239 www.Factoryfive.Com 508-291-3443 install a ring terminal on the black wire coming from the fan itself. Then connect this wire to the thermostat 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 gril...

  • Page 241

    240 www.Factoryfive.Com 508-291-3443 lower 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 ¼” off the end of the larger hose. Push the large hose onto the water pump inlet..

  • Page 242

    241 www.Factoryfive.Com 508-291-3443 attach the large hose to the water pump using 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 corrugated radiator ...

  • Page 243

    242 www.Factoryfive.Com 508-291-3443 route the corrugated tube over towards the steering shaft and into the 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 t...

  • 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

    244 www.Factoryfive.Com 508-291-3443 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 it using a 7mm socket and ratchet..

  • Page 246

    245 www.Factoryfive.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 the engine outlet..

  • Page 247

    246 www.Factoryfive.Com 508-291-3443 attach the large hose to the engine outlet using 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 inlet and use ...

  • Page 248

    247 www.Factoryfive.Com 508-291-3443 remove and cut the corrugated 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. Push the large hose over the adapter on...

  • Page 249

    248 www.Factoryfive.Com 508-291-3443 attach the hose to the radiator 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 to the water pump and radiator using...

  • Page 250

    249 www.Factoryfive.Com 508-291-3443  after running the car for the first time once coolant is added and while the system is still warm, retighten the hose clamps used on the cooling system. Overflow tank cooling components  the overflow tank can either get mounted to the radiator as shown in the ...

  • Page 251

    250 www.Factoryfive.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 than the filter..

  • Page 252

    251 www.Factoryfive.Com 508-291-3443 clamp the 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 attach the filter to the frame with 3 / 16 ” rivets..

  • Page 253

    252 www.Factoryfive.Com 508-291-3443 fuel tank fuel line components, fuel tank components, insulated clip hardware 9 / 16 ” wrench, 5 / 16 ” hex key, ⅜” 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 th...

  • Page 254

    253 www.Factoryfive.Com 508-291-3443 temporarily attach the trunk hinge 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 which is located above the fu...

  • Page 255

    254 www.Factoryfive.Com 508-291-3443 position the tank in the frame so that is about even on both sides with the side 1.5" square frame rails. The tank should be slid all the way forward just before the front face of the tank comes into contact with the 1" down-tubes. Make sure the rear face of the ...

  • Page 256

    255 www.Factoryfive.Com 508-291-3443 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 ⅜” drill bit. Place the tank back into the frame but do not fasten for now..

  • Page 257

    256 www.Factoryfive.Com 508-291-3443 fuel tank vent ¼”, 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

    259 www.Factoryfive.Com 508-291-3443 run the vent hose down to the ¾” 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 fuel pick-up. Drill, pliers, 1 / ...

  • Page 261

    260 www.Factoryfive.Com 508-291-3443 remove and discard the rubber piece on the end of the return line, this can affect the fuel pressure at the engine. Starting with a ¼” drill bit drill out the end of the send line then change to a 9 / 32 ” or 19 / 64 ”drill bit, the pressed end is a little restri...

  • Page 262

    261 www.Factoryfive.Com 508-291-3443 starting with a ¼” 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 head screwdriver.

  • 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

    263 www.Factoryfive.Com 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 in the mounting area.

  • Page 265

    264 www.Factoryfive.Com 508-291-3443 use a hammer and flat 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. Fuel level sending unit hammer, large flat ...

  • 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

    266 www.Factoryfive.Com 508-291-3443 insert the 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 making sure that all three tabs catch the ring..

  • Page 268

    267 www.Factoryfive.Com 508-291-3443  make sure that the lock ring is held by all three locking 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 f...

  • Page 269

    268 www.Factoryfive.Com 508-291-3443 install the fuel fill tube onto the fuel tank and attach it with the supplied hose clamp. Install the fuel 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 pl...

  • Page 270

    269 www.Factoryfive.Com 508-291-3443  the 5 / 16 ” line is used for the feed and the ¼” 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 first...

  • Page 271

    270 www.Factoryfive.Com 508-291-3443 decide where you would 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 firewall. Mount fuel pressure regulator if you ar...

  • 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

    272 www.Factoryfive.Com 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” side of the fuel filter..

  • Page 274

    273 www.Factoryfive.Com 508-291-3443 position the end of the 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 back of the tube.  do not fasten...

  • 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 ¾” tube and under the top 1.50” tube..

  • Page 276

    275 www.Factoryfive.Com 508-291-3443 run the fuel line down sharply to the lower inside of the side 1.50” tube. The lower the better (but above the bottom of the tube) to keep it away from the exhaust if you are going to run the side exit pipes. Position insulated line clamps to hold the fuel line e...

  • Page 277

    276 www.Factoryfive.Com 508-291-3443 with the tank positioned correctly, position the end of the ¼” 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 ¼” line down to the backside of the 1.50” horizontal tube and across to the right ...

  • Page 278

    277 www.Factoryfive.Com 508-291-3443 run the ¼” 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 ¼” line or put the line in the larger line clip then pull the rivets holding the line clips to the frame using the rivet tool..

  • Page 279

    278 www.Factoryfive.Com 508-291-3443 it is helpful to slightly flatten 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 ¼” barb off the fuel line. Attach a 3” piece of the ¼” rubber fuel line to the two bar...

  • Page 280

    279 www.Factoryfive.Com 508-291-3443 attach the fuel line to the tank and the ¼” hard fuel line. Front fuel lines use the ¼” and 5 / 16 ” unions to connect another piece of 60" fuel line..

  • Page 281

    280 www.Factoryfive.Com 508-291-3443 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 depending on your fuel system..

  • Page 282

    281 www.Factoryfive.Com 508-291-3443 fuel tank final install the tank using the ⅜” 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. Some of the pictures show the ol...

  • Page 283

    282 www.Factoryfive.Com 508-291-3443  the 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 runs the exhaust back under the tail lights..

  • 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

    285 www.Factoryfive.Com 508-291-3443 attach the shorty pipe to the shorty header 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 the shorty pipe b...

  • Page 287

    286 www.Factoryfive.Com 508-291-3443 attach the front exhaust pipe assembly to the shorty pipe with the supplied 3 / 8 " hardware. Make sure to install the supplied gasket (ffr# 33369) between the two square flanges. Loosely install the exhaust clamp and mount onto the muffler. The inlet to the muff...

  • Page 288

    287 www.Factoryfive.Com 508-291-3443 clamp the exhaust mounts to the frame to hold the assembly in place. Attach the tip section of the tail pipe 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 f...

  • Page 289

    288 www.Factoryfive.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 holes on the frame..

  • Page 290

    289 www.Factoryfive.Com 508-291-3443 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 past the surface of the floor..

  • Page 291

    290 www.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 provided..

  • Page 292

    291 www.Factoryfive.Com 508-291-3443 once you are happy with the placement of all the exhaust 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 the so...

  • Page 293

    292 www.Factoryfive.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 floor must sit..

  • Page 294

    293 www.Factoryfive.Com 508-291-3443 rear exit exhaust ½”, 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 tips are 1.50” below the aluminum...

  • Page 295

    294 www.Factoryfive.Com 508-291-3443.

  • Page 296

    295 www.Factoryfive.Com 508-291-3443 attach the engine shorty pipes and mufflers 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 rear exit exhaust to the...

  • Page 297

    296 www.Factoryfive.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 razor or hack saw..

  • 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

    299 www.Factoryfive.Com 508-291-3443 the remainder of the installation must be done after the body is mounted if not 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 ...

  • Page 301

    300 www.Factoryfive.Com 508-291-3443 stock cut tip.

  • Page 302

    301 www.Factoryfive.Com 508-291-3443 attach the exhaust tips and locate them so that they are below the tail lights. Move the rubber hanger if necessary. Adjust the exhaust so that it does not hit/sit any frame member or the back of the body. Use the tube bend over the axle as a lever to rotate the ...

  • Page 303

    302 www.Factoryfive.Com 508-291-3443 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 made with a 3 / 16 ” drill bit..

  • Page 304

    303 www.Factoryfive.Com 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 nuts using a 9 / 16 ” wrench..

  • Page 305

    304 www.Factoryfive.Com 508-291-3443 cut any rubber that sticks up past the top of the frame tubes. Chapter 3 - interior assembly interior aluminum drill, ⅛” drill bit, rivet tool, silicone, silicone gun packaged aluminum, mounted aluminum, secondary body fasteners.

  • Page 306

    305 www.Factoryfive.Com 508-291-3443 install the rear cockpit 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 panel can now be installed. If you ...

  • 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 ”, ½” 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

    311 www.Factoryfive.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 the fixed gear..

  • Page 313

    312 www.Factoryfive.Com 508-291-3443 put the other ratchet to handle mount on shoulder bolt from the other side of the fixed gear. Using a 3 / 16 ” hex key and ½” 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...

  • Page 314

    313 www.Factoryfive.Com 508-291-3443 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 as shown in the picture..

  • Page 315

    314 www.Factoryfive.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 mount holes..

  • Page 316

    315 www.Factoryfive.Com 508-291-3443 push the included spring pin through the ratchet mount plates and the ratchet tooth using a pair of channel lock pliers. Slide 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 i...

  • 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

    318 www.Factoryfive.Com 508-291-3443 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 the ¼” flange head bolt and locknut..

  • Page 320

    319 www.Factoryfive.Com 508-291-3443 insert 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 ½” wrench. Leave the locknut slightly loose so positioning can be done on the frame later..

  • 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

    321 www.Factoryfive.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 ¼”x 1.50” socket head bolt and locknut. Just start the nut for now, do not tighten it..

  • Page 323

    322 www.Factoryfive.Com 508-291-3443 transmission tunnel cover jig saw or air saw, ¼” drill bit, drill, marker, masking tape, ¼” hex drive bit, silicone, sanding tool, measuring tape, clamps. Mounted aluminum/components, body finish components, shifter boot components  the pictures shown are of the...

  • Page 324

    323 www.Factoryfive.Com 508-291-3443 cut the center of the transmission tunnel so that it sits down on the transmission tunnel flange. Shifter hole measure forward from the rear side of the driveshaft loop to the center of the shifter handle..

  • 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

    326 www.Factoryfive.Com 508-291-3443 push down on the sides of the ring so that the ring forms to the shape of the 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 th...

  • Page 328

    327 www.Factoryfive.Com 508-291-3443 cut the area marked with a jigsaw.  the tunnel sits on top of the aluminum floors and all the way up to the front of the footboxes and the 1.5” square bulkhead cross member.  depending on the thickness of the fiberglass, you may have to sand the inside of the r...

  • Page 329

    328 www.Factoryfive.Com 508-291-3443 position the transmission tunnel cover 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 ½” socket, ratchet, 5 / 16 ”...

  • Page 330

    329 www.Factoryfive.Com 508-291-3443 from the under side of the frame, drill up through the frame e-brake handle mount ¼” 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 location of the ...

  • Page 331

    330 www.Factoryfive.Com 508-291-3443 insert a carriage bolt through 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 keeping it close to the tunnel so tha...

  • Page 332

    331 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 area..

  • Page 333

    332 www.Factoryfive.Com 508-291-3443 remove and drill the front hole location 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 hoop at the back of ...

  • Page 334

    333 www.Factoryfive.Com 508-291-3443 route the brake cables over 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 rear shock or through the lower h...

  • Page 335

    334 www.Factoryfive.Com 508-291-3443 attach 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 rod end and attach them to the cable ends..

  • Page 336

    335 www.Factoryfive.Com 508-291-3443 adjust the rod end so that the ¼” bolt goes through the rod end and both clevises and the cable is tight. Put the locknut back on the ¼” bolt hand tight. Slowly pull up on the handle to set the brake pads and remove any slack from the brake cables..

  • Page 337

    336 www.Factoryfive.Com 508-291-3443 release the brake and if necessary remove the ¼” clevis bolt and readjust the rod end so that the cable is tight..

  • Page 338

    337 www.Factoryfive.Com 508-291-3443 reinstall the clevises and ¼” bolt then tighten the bolt so that the clevis ends are closed, this will prevent the cable ends from coming out. Test fit the handle with both bolts sitting in the holes. Pull the handle up. If the bolt for the rod end hits the alumi...

  • Page 339

    338 www.Factoryfive.Com 508-291-3443 attach the ball stud to the top hole of the accelerator pedal. Position the throttle pedal where it feels comfortable for you and mark the mounting holes on the aluminum. Hold the accelerator pedal in position and push the top up so that the top of the pedal is a...

  • Page 340

    339 www.Factoryfive.Com 508-291-3443 mark 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. Seat install drill, ⅛” drill bit, marker seats.

  • Page 341

    340 www.Factoryfive.Com 508-291-3443 with the body still on, set the rear cockpit fiberglass piece 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 a...

  • Page 342

    341 www.Factoryfive.Com 508-291-3443 remove the seat and verify that the location of the mounting points intersects 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 in...

  • Page 343

    342 www.Factoryfive.Com 508-291-3443 mount the accelerator pedal to the aluminum footbox using two ¼”-20 x ¾” 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 mount portion of the throttle pedal...

  • Page 344

    343 www.Factoryfive.Com 508-291-3443 attach the pedal arms to the mount bushing. Accelerator cable 5 / 64 ” hex key, ⅜”, 7 / 16 ”, ½” wrenches, wire cutters. Accelerator cable components, insulated clip hardware  the cable design is set up for a 96-04 4.6l mustang engine with an oem pedal but using...

  • Page 345

    344 www.Factoryfive.Com 508-291-3443 put a dab of silicone 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 applications. Cut the barrel fitting off the e...

  • Page 346

    345 www.Factoryfive.Com 508-291-3443 push and twist the ball stud retainer onto the end of the cable and attach the ball stud retainer using a 5 / 64 ” hex key. Push the ball stud retainer onto the ball on the bottom of the throttle body. Make sure the accelerator cable is tied up and out of the way...

  • Page 347

    346 www.Factoryfive.Com 508-291-3443 accelerator cable mounted on ’96 2 valve intake. 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 the ball stud....

  • Page 348

    347 www.Factoryfive.Com 508-291-3443 push and twist the ball stud retainer onto the end of the cable and attach the ball stud retainer using a 5 / 64 ” hex key. Attach the engine end of the cable sheath to the cable mount on the engine using ⅜” and 7 / 16” wrenches. Put a dab of silicone on the rear...

  • Page 349

    348 www.Factoryfive.Com 508-291-3443 push the ball stud retainer onto the throttle pedal. While pulling the cable tight, push the accelerator pedal up until it hits the frame and align the ball stud retainer with the cable. Mark on the cable where the retainer ends. Measure ⅜” from the mark on the c...

  • Page 350

    349 www.Factoryfive.Com 508-291-3443 adjust the length of the shoulder straps to fit. Fasten the belts with the ½” fasteners to the bottom of the plate. Install lap portion of the harnesses to the mounts on the chassis with the supplied hardware. It is a good idea to mount the belt on the outside of...

  • Page 351

    350 www.Factoryfive.Com 508-291-3443 2015 irs once the car has been aligned, use a 1 5 / 8 ” wrench to loosen the upper control arm large jam nut and put some loctite on the threads where the jam nut will sit. Retighten the jam nut. Fluid levels and grease grease gun, chassis grease, ratchet, rags t...

  • Page 352

    351 www.Factoryfive.Com 508-291-3443 general double check all your hardware, make sure your wiring and hoses are away from extreme heat and moving parts. Make sure the steering turns freely lock to lock, and make sure your brake flex lines have enough slack for the full range of wheel movement. Get ...

  • Page 353

    352 www.Factoryfive.Com 508-291-3443 the brake pedal balance bar and brake pedal bearing looks like this. Chapter 4 – body work trunk upper aluminum drill, ¼” hex driver, clamps, ruler, tin snips mounted aluminum, secondary body fasteners set the upper floor of the trunk in place..

  • Page 354

    353 www.Factoryfive.Com 508-291-3443 if necessary, trim the aluminum around frame welds so that the aluminum sits flat against frame tubes. Door hinge 9 / 16 ”, ¾” 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 u...

  • Page 355

    354 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 stops..

  • Page 356

    355 www.Factoryfive.Com 508-291-3443 body (temporary) tape measure, 5 / 16 ” drill bit, (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 th...

  • Page 357

    356 www.Factoryfive.Com 508-291-3443 use two people to mount the body, 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 tuck the front sections of the ...

  • 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

    358 www.Factoryfive.Com 508-291-3443 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 body with a 5 / 16 ” drill bit..

  • 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

    360 www.Factoryfive.Com 508-291-3443 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, clamps door hinge assembly.

  • Page 362

    361 www.Factoryfive.Com 508-291-3443 push 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 ⅛” thick (to account for the bushing flange thicknesses) on top of the door hinge standoff mounted on the frame..

  • 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

    363 www.Factoryfive.Com 508-291-3443 remove the ruler 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 edge of the ruler location on the back of the body..

  • Page 365

    364 www.Factoryfive.Com 508-291-3443 door sill body mounts ⅛” drill bit, drill, ¼” 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 the ends and center of the doo...

  • Page 366

    365 www.Factoryfive.Com 508-291-3443 drill through the remaining marks in the body only using an ⅛” drill bit. Pedal box/master cylinder access panels. Tin snips, marker, ruler packaged aluminum  the passenger side access panel is helpful when installing the windshield and checking on wiring and su...

  • Page 367

    366 www.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 panel..

  • Page 368

    367 www.Factoryfive.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 test fit..

  • 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 ⅜” 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

    370 www.Factoryfive.Com 508-291-3443 cut the inner line for the access panels. Firewall marker, square, masking tape, drill, 3 / 16 ” or ¼” drill bit, rivet tool or 5 / 32 ” hex key and 7 / 16 ” wrench. Secondary body fasteners decide how the firewall will attach to the body, whether 3 / 16 ” rivets...

  • 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

    372 www.Factoryfive.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 access cover locations..

  • Page 374

    373 www.Factoryfive.Com 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 holes for the bolts..

  • 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, ¾” 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

    382 www.Factoryfive.Com 508-291-3443 put the gasket on the light/bezel assembly 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 out of the circuit boar...

  • Page 384

    383 www.Factoryfive.Com 508-291-3443 hold 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 the bezel studs using a 3 / 16 ” drill bit..

  • Page 385

    384 www.Factoryfive.Com 508-291-3443 drill the light wire hole using a ¾” hole saw. Gauges ⅛”, 7 / 16 ” drill bits, drill, marker, ⅞”, 2”, 3” hole saws, file gauge set, packaged aluminum.  the gauge template is the ffr proposed center dash gauge and switch layout..

  • 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

    387 www.Factoryfive.Com 508-291-3443 lay the template on the dash and either mark the centers of the holes or clamp 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...

  • Page 389

    388 www.Factoryfive.Com 508-291-3443 door hinge slots 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

    392 www.Factoryfive.Com 508-291-3443 test the hinge arms to make 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 straight towards or slightly in from whe...

  • Page 394

    393 www.Factoryfive.Com 508-291-3443 if necessary, remove the arm and cut more of the slot out. Remove the arms from the standoffs. Door fitment orbital sander, 80 grit sand paper, 5 / 16 ” drill bit, drill, masking tape, jig saw or air saw. Doors  the doors are cut oversized at the factory to allo...

  • 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

    395 www.Factoryfive.Com 508-291-3443 use a 5 / 16 ” drill bit in opposite corners of the marked areas then cut the rectangles out. Door frame prep for power windows  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 ...

  • Page 397

    396 www.Factoryfive.Com 508-291-3443.

  • Page 398

    397 www.Factoryfive.Com 508-291-3443 use the bracket to double 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 left side door frame hole to the correct s...

  • Page 399

    398 www.Factoryfive.Com 508-291-3443 use a ¼” drill bit to drill through the tube at the hole locations marked. Attach the bracket to the window track/motor assembly using the ¼” washer head screws provided. Use one of the shorter screws on the right motor mount so that the screw does not hit the mo...

  • Page 400

    399 www.Factoryfive.Com 508-291-3443 attach the upper mount to the lower track mount..

  • Page 401

    400 www.Factoryfive.Com 508-291-3443 attach the lower motor bracket to the door frame using a couple of the ¼”-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 of the tube, mark the middle of the ...

  • Page 402

    401 www.Factoryfive.Com 508-291-3443 remove the mount/window track assembly and drill the window track mount hole. Door hinge/frame/door assembly 3 / 16 ” hex key, ½”, ⅝” wrenches, ½”, ¾” sockets, ratchet, saw, marker, drill, ⅛”, 3 / 16 ”, 5 / 16 ”, ½” drill bits, ¾” hole saw, masking tape, bubble l...

  • Page 403

    402 www.Factoryfive.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 hinge arm standoffs..

  • Page 404

    403 www.Factoryfive.Com 508-291-3443 tighten 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 enough so that the mount can slide if pushed..

  • Page 405

    404 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 door..

  • 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

    406 www.Factoryfive.Com 508-291-3443 attach the hinge arms to the door frame using the ½” carriage bolts and a ¾” 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 accent trim and that the door is flush ...

  • Page 408

    407 www.Factoryfive.Com 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 with a saw if necessary..

  • 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

    409 www.Factoryfive.Com 508-291-3443 move the hinge arms so that they are straight or as far towards the center 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 ...

  • Page 411

    410 www.Factoryfive.Com 508-291-3443 push the latch mount forward so that it touches the door. Tighten the carriage bolts with a ½” wrench or socket. Use an ⅛” drill bit and drill through door through the top hole in the door latch mount..

  • Page 412

    411 www.Factoryfive.Com 508-291-3443 recheck 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 lower mounting hole on the door frame rear plate..

  • Page 413

    412 www.Factoryfive.Com 508-291-3443 if the door latch mount carriage bolts 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 marked. Cut the templates b...

  • Page 414

    413 www.Factoryfive.Com 508-291-3443 clear zinc latches locate the 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 the door slightly so that the ...

  • Page 415

    414 www.Factoryfive.Com 508-291-3443 if using the clear zinc latches and it is needed, grind 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 corr...

  • Page 416

    415 www.Factoryfive.Com 508-291-3443 drill an ⅛” hole through door at the sticker location. Remove the material between the two ½” holes using a hacksaw blade or jig saw..

  • Page 417

    416 www.Factoryfive.Com 508-291-3443  you should now have three door latch mount holes, the slot for lever and a small hole where the striker would go. Without the door frame, hold the door up to the body, align and tape it in place..

  • Page 418

    417 www.Factoryfive.Com 508-291-3443 using an ⅛” 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 a ¾” hole saw..

  • Page 419

    418 www.Factoryfive.Com 508-291-3443 attach the striker to the striker mount using a ¾” socket and ⅝” 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 ½” socket an...

  • Page 420

    419 www.Factoryfive.Com 508-291-3443  if it is not possible to center the striker in the hole, remove the striker mount and grind the built- in washer. Tighten the striker mount using a ½” socket. Tighten the striker on the mount using a ¾” socket and ⅝” wrench. Door latches ruler, marker, ⅜” socke...

  • Page 421

    420 www.Factoryfive.Com 508-291-3443 if external door handles are going to be used, an additional 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...

  • Page 422

    421 www.Factoryfive.Com 508-291-3443 attach the door latch to the door frame through the holes drilled earlier using the ¼” 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 ¼” drill bit to drill a hole t...

  • 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, ½” socket, pliers 33 door handle components.

  • Page 424

    423 www.Factoryfive.Com 508-291-3443 insert the release lever into the latch and use pliers to hold it at the base. Screw the locknut onto the lever. Test the lever and remove any door material if necessary so that the latch works correctly. Striker cover drill, ⅛” drill bit, rivet tool, silicone, s...

  • Page 425

    424 www.Factoryfive.Com 508-291-3443 with the door hinge and latch adjusted, position the striker cover. Silicone and rivet the panel in place. Fuel tank side cover drill, ⅛” drill bit, rivet tool, silicone, silicone gun packaged aluminum, secondary body fasteners.

  • Page 426

    425 www.Factoryfive.Com 508-291-3443 push weatherstrip onto the top, outside and front edges of the cover panel. Insert and locate the panel so that the weatherstrip seals against the outside body and behind the door. Silicone and rivet the panel in place. Cockpit rear cover 1¾” hole saw, drill, mar...

  • Page 427

    426 www.Factoryfive.Com 508-291-3443 set the upholstered top cover on the rear 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 excess flange. Mark th...

  • Page 428

    427 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 aluminum..

  • Page 429

    428 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

    429 www.Factoryfive.Com 508-291-3443 mark the lower edge 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 aluminum along the bottom edge of the cover...

  • Page 431

    430 www.Factoryfive.Com 508-291-3443 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 section later for vinyl covering.

  • 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

    432 www.Factoryfive.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 cockpit trim panel..

  • Page 434

    433 www.Factoryfive.Com 508-291-3443 turn the panel upside down and drill the hole positions marked using a 1¾” hole saw. Make sure that the hole saw is angled like the rollbar would be and not perpendicular to the panel surface. Look at the bottom edge mark drawn on the rear cockpit aluminum. The m...

  • Page 435

    434 www.Factoryfive.Com 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 small ones are too small..

  • Page 436

    435 www.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 trunk. Remove the trunk. Trim the flange around the trunk opening so that it is ¾” wide..

  • Page 437

    436 www.Factoryfive.Com 508-291-3443 trunk hinges 5 / 32 ”, 3 / 16 ” hex keys, 7 / 16 ” wrench, marker, ½” socket, ratchet, shop light, 3 / 16 ”, 25 / 64 ” drill bits, drill, masking tape, rivnut tool trunk hinge assembly if not already in place, attach the hinge arms to the frame using the bushings...

  • 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

    438 www.Factoryfive.Com 508-291-3443 tape the trunk 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 slots and the mount is on the trunk mounting a...

  • 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

    440 www.Factoryfive.Com 508-291-3443 drill the center of the slot marks with a 3 / 16 ” drill bit then open them up with a 25 / 64 ” bit for rivnuts. Install a ¼”-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 ...

  • Page 442

    441 www.Factoryfive.Com 508-291-3443 push the 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 trunk, more material will have to be removed..

  • Page 443

    442 www.Factoryfive.Com 508-291-3443 trunk aluminum ruler, marker, tin snips, ¼” nut driver. Kit aluminum 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...

  • Page 444

    443 www.Factoryfive.Com 508-291-3443 use 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 frame using one of the holes for rivets..

  • 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 trunk prop rod 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

    449 www.Factoryfive.Com 508-291-3443 the rubber stop on 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, ¼” hex driver, marker, needle nose ...

  • Page 451

    450 www.Factoryfive.Com 508-291-3443.

  • Page 452

    451 www.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 handle..

  • 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

    453 www.Factoryfive.Com 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 now so it can be adjusted..

  • 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

    456 www.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 bracket..

  • Page 458

    457 www.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 trunk floor..

  • Page 459

    458 www.Factoryfive.Com 508-291-3443 striker clamp, marker, ruler, drill, 25 / 64 ” drill bit, rivnut tool, square, 5 / 32 ”, 3 / 16 ” hex keys, ½” wrench trunk latch assembly, secondary body fasteners close the trunk and mark the center of the latch location on the trunk..

  • Page 460

    459 www.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 finger..

  • Page 461

    460 www.Factoryfive.Com 508-291-3443 attach the striker shoulder bolt to the striker 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 aligned with the mark ma...

  • Page 462

    461 www.Factoryfive.Com 508-291-3443 clamp the striker to the trunk. Mark the center of the mount slots on the trunk. Remove the striker assembly. Drill ⅛” holes through the trunk liner and the 1 / 8 " aluminum inside of the trunk then open the holes up with a 25 / 64 ” bit and install rivnuts at th...

  • Page 463

    462 www.Factoryfive.Com 508-291-3443 install the trunk latch striker mount with ¾” flange head screws onto the trunk centered on the bolts. Try closing the trunk. If necessary, adjust the various components to allow it to close. If necessary, grind the head of the shoulder bolt. Remove the rear latc...

  • 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

    464 www.Factoryfive.Com 508-291-3443 set 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 that the hood just sits down in the opening..

  • Page 466

    465 www.Factoryfive.Com 508-291-3443 put a yard stick across the hood and cowl and look at any gap below the straight edge in the middle. 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...

  • Page 467

    466 www.Factoryfive.Com 508-291-3443  make sure that there 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, ¼” drill bit, drill, 5 / 32 ” hex key, 7 / 16 ” wrench nose...

  • Page 468

    467 www.Factoryfive.Com 508-291-3443 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 vertical lip along the front..

  • Page 469

    468 www.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 grill..

  • Page 470

    469 www.Factoryfive.Com 508-291-3443 if necessary, sand some material off the bottom of the grill so the nose cone can lie flush on the bottom edge. 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 an...

  • Page 471

    470 www.Factoryfive.Com 508-291-3443 drill through the frame mount for the nose cone. This is the same piece of 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 ¼” screw and at the 4 and 8 o’cl...

  • 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 ⅛”- 3 / 16 ” gap. Trim and sand the front of the hood..

  • Page 474

    473 www.Factoryfive.Com 508-291-3443 remove the hood. 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, ¼” drill bit. Engine side covers trim the top of the side co...

  • Page 475

    474 www.Factoryfive.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 cover sits on..

  • Page 476

    475 www.Factoryfive.Com 508-291-3443 use a couple of washers or cut some small rubber bumpers so that they are about ⅛” high and place them at the front and back of the body lip that the side cover will sit on..

  • Page 477

    476 www.Factoryfive.Com 508-291-3443 cut one 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 that the grill leaves a line in the cardboard..

  • 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

    479 www.Factoryfive.Com 508-291-3443 mark the grill along the line.  this cardboard process should be done separately for each side of the grill, the fitment on each side is different. Trim the side cover a little at a time so that there is a ⅛” gap at the back of the cover against the body and at ...

  • Page 481

    480 www.Factoryfive.Com 508-291-3443 mark and trim the bottom edge of the hood so that there is a ⅛”- 3 / 16 ” gap between the hood and top of the side cover. Drill a 3 / 16 ” hole through the engine side panel mount flange and the grill..

  • Page 482

    481 www.Factoryfive.Com 508-291-3443 drill a 3 / 16 ” hole through the engine side panel mount flange and the body. Remove the side cover and enlarge the holes in the side cover to ¼”. For the rear body mount holes, drill the body hole out to 25 / 64 ” and install a ¼” rivnut. For the front hole eit...

  • Page 483

    482 www.Factoryfive.Com 508-291-3443 temporarily attach the panel to the grill with ¼”-20 flange head fasteners..

  • Page 484

    483 www.Factoryfive.Com 508-291-3443 drill through the flange on the bottom of the panel and through the body in two or three locations with a ¼” drill bit. Remove the side panel and enlarge the body flange holes and install ¼” rivnuts in the body.  headlights are bolted through the side covers. If...

  • Page 485

    484 www.Factoryfive.Com 508-291-3443 have to thread each wire through the nut and have to realign the headlight each time a good idea is to make a spacer to go on the radiator mount and cut the side covers to go around the spacer so headlight removal is not necessary. Hood cable release drill, 3 / 3...

  • 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

    488 www.Factoryfive.Com 508-291-3443 mark the hole for the hood release pull under the dash on inner 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 s...

  • Page 490

    489 www.Factoryfive.Com 508-291-3443 attach 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 forward. Push the cable sheath into the handle..

  • Page 491

    490 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 firewall..

  • Page 492

    491 www.Factoryfive.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 latch for assembly..

  • 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

    494 www.Factoryfive.Com 508-291-3443 insert the wire end through the wire stop. 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.  check that the pull handle releases the latch by adjusting the cable...

  • 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

    497 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 shown).

  • Page 499

    498 www.Factoryfive.Com 508-291-3443 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 bracket touches the hood..

  • 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 ¼”-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

    502 www.Factoryfive.Com 508-291-3443 properly align hood and then tighten up the mounting bolts starting 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 openin...

  • 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 ¼”–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

    505 www.Factoryfive.Com 508-291-3443 firewall 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 outboard when maxing out the horizontal slots..

  • Page 507

    506 www.Factoryfive.Com 508-291-3443 drill and install ¼”-20 riv-nuts. Mount the brackets to the hood centering the slots on the screws..

  • Page 508

    507 www.Factoryfive.Com 508-291-3443 striker adjustment 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 grill clearance, tighten the mounting screws..

  • 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

    510 www.Factoryfive.Com 508-291-3443 with hood 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 drilling. Drill a 3 / 16 ” pilot hole at the point mar...

  • Page 512

    511 www.Factoryfive.Com 508-291-3443 use a ¾” 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

    512 www.Factoryfive.Com 508-291-3443 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 screws to allow for adjustment..

  • Page 514

    513 www.Factoryfive.Com 508-291-3443 partially close the hood, align pins with receivers, and close hood 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 c...

  • Page 515

    514 www.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 side shown..

  • 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

    516 www.Factoryfive.Com 508-291-3443 check to make sure that the hood does not fall off the 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 in this ...

  • 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

    519 www.Factoryfive.Com 508-291-3443 drill a 3 / 32 ” pilot hole and use a self tap mounting screw into fiberglass. Windshield install masking tape, marker, drill, ¼” drill bit, tape measure, 3mm hex key, 10mm wrench, loctite™ windshield  these instructions correctly locate the windshield to allow ...

  • 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

    522 www.Factoryfive.Com 508-291-3443 from the beginning of the hood opening, measure back along the centerline and mark 7.50”. This is the location of the middle 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 wi...

  • Page 524

    523 www.Factoryfive.Com 508-291-3443 if necessary remove material on the windshield so that the correct 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 outlin...

  • Page 525

    524 www.Factoryfive.Com 508-291-3443 drill the ¼” holes in the body which you just marked 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 it touch the rubber gasket then stop!  do not over tighten...

  • Page 526

    525 www.Factoryfive.Com 508-291-3443 having a friend help you, set the windshield back in place. Use a 3mm hex key to hold the stud while tightening the lock nut. In order for the soft top to mount correctly on the car, the angle of the windshield needs to be correct. Make sure the top corner of the...

  • Page 527

    526 www.Factoryfive.Com 508-291-3443 optional hardtop drill, marker, masking tape, measuring tape, square, 1.75” hole saw, ¼”, 25 / 64 ” drill bit, ⅜” wrench, rivnut tool hardtop package.

  • Page 528

    527 www.Factoryfive.Com 508-291-3443 with the hardtop sitting upside 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 the front of the hardtop along both...

  • Page 529

    528 www.Factoryfive.Com 508-291-3443 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 middle rear of the top is found..

  • 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

    530 www.Factoryfive.Com 508-291-3443 repeat for the opposite side. If the soft top will get used, the mount locations behind the doors should be made using the measurements for the body mount in the appendix and not the measurement given below. On the sides behind the window, mark 2.75” in from the ...

  • 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 ¼” 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 1 1 / 16 ” from each of the marks. Use a 1.75” hole saw to drill a hole at each of the marks..

  • Page 534

    533 www.Factoryfive.Com 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 shown in the above picture..

  • Page 535

    534 www.Factoryfive.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 on the body properly..

  • 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

    536 www.Factoryfive.Com 508-291-3443 on the rear of the top, use a marker in the hole saw holes to mark the body through the ¼” drilled holes. Remove the hardtop and use a tape measure at the front top corners of the door to locate and mark the middle of the front windshield area..

  • Page 538

    537 www.Factoryfive.Com 508-291-3443  if you plan to switch back and forth between the hard 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 appendix fo...

  • Page 539

    538 www.Factoryfive.Com 508-291-3443 /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 ¼” drill bit. On the rear of the hardtop area, drill the marked locations with a 25 ” drill bit..

  • Page 540

    539 www.Factoryfive.Com 508-291-3443 insert and attach ¼” rivnuts in the 25 / 64 ” holes drilled in the 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 ¼” bolts provided and a 3 / 8 ” wrench. Double check that the molded trim l...

  • Page 541

    540 www.Factoryfive.Com 508-291-3443 from the underside of the body in the windshield area, use a marker through the ¼” 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...

  • Page 542

    541 www.Factoryfive.Com 508-291-3443 necessary, slot the 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 ¼” rivnuts in the 25 / 64 ” holes just drilled.  if installing the rollbar under the hardtop, jump to the rollbar i...

  • Page 543

    542 www.Factoryfive.Com 508-291-3443 remount the hard top for the final time and fasten the top to the body using the ¼” bolts from the underside of the dash in the windshield area fasten the top to the body using the ¼” bolts from the top on the back of the top..

  • 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

    544 www.Factoryfive.Com 508-291-3443 starting at 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 below the hard top as close as possible to the door..

  • Page 546

    545 www.Factoryfive.Com 508-291-3443 power windows  only do the window installation after the hard top has been bolted to the car. If this is not done, the door slots will be in the wrong place.  if the switches do not fit on the flange with the mounting bracket, the switches can be mounted indivi...

  • 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 ½” 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

    548 www.Factoryfive.Com 508-291-3443 measure 3 / 8 ” out from the line drawn and draw another line down the length of the door. Check the length of the cut out using both the edge of the glass and one of the pre cut window wipe rubber pieces. Cut the outer lines marked using a jigsaw or air saw. Che...

  • Page 550

    549 www.Factoryfive.Com 508-291-3443 carefully push the felted rubber seal onto the top of the door. If necessary use tin snips 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 th...

  • Page 551

    550 www.Factoryfive.Com 508-291-3443 hold a tape measure up to the track starting at the bottom and measure 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 m...

  • Page 552

    551 www.Factoryfive.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 allow for adjustment..

  • Page 553

    552 www.Factoryfive.Com 508-291-3443 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. Power window switch template..

  • Page 554

    553 www.Factoryfive.Com 508-291-3443 use the template above to mark the switch location between the seats on the bottom 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 fl...

  • Page 555

    554 www.Factoryfive.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 fuse on the circuit..

  • Page 556

    555 www.Factoryfive.Com 508-291-3443 use the red butt connectors 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 the switch works the desired way when pushing...

  • Page 557

    556 www.Factoryfive.Com 508-291-3443 on the backside of the 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 connecting the center points and mark...

  • Page 558

    557 www.Factoryfive.Com 508-291-3443 /64 drill 13 ” holes at the ½” 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 in the slots for adjustment later..

  • Page 559

    558 www.Factoryfive.Com 508-291-3443 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 and through the door frame mount..

  • Page 560

    559 www.Factoryfive.Com 508-291-3443 make sure that the interior door latch cable 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 ½” socket and ratchet. Attach the window glass holder to t...

  • Page 561

    560 www.Factoryfive.Com 508-291-3443 slide the glass down into the door and into the glass holder. The taller end 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 practic...

  • Page 562

    561 www.Factoryfive.Com 508-291-3443 close the door then raise the window up using the switch..

  • Page 563

    562 www.Factoryfive.Com 508-291-3443 slide the glass back 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. This will make it easier to locate the glass ...

  • Page 564

    563 www.Factoryfive.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 the door..

  • Page 565

    564 www.Factoryfive.Com 508-291-3443 with the top of the glass resting on something soft such as a towel or a glove as shown, locate the rubber strip and window glass holder 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 gl...

  • Page 566

    565 www.Factoryfive.Com 508-291-3443 remount the 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 window track where the bottom of the plastic guide...

  • 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

    567 www.Factoryfive.Com 508-291-3443 unbolt and remove the window track. The easiest way to 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 at the a...

  • Page 569

    568 www.Factoryfive.Com 508-291-3443 place one of the 10-32 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 window track. Remove the locknut and open...

  • Page 570

    569 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

    570 www.Factoryfive.Com 508-291-3443 as 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 locknut and open the hole up to 13 / 64 ”..

  • Page 572

    571 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 loose.

  • Page 573

    572 www.Factoryfive.Com 508-291-3443 slowly close the door 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 track mounts so that the angle of the wind...

  • Page 574

    573 www.Factoryfive.Com 508-291-3443 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 touch the window and not put a lot of.

  • Page 575

    574 www.Factoryfive.Com 508-291-3443 pressure on the glass to bog the motor down or push 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 door handle  the passenger (right) side is shown...

  • Page 576

    575 www.Factoryfive.Com 508-291-3443 mark 3¼” 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

    577 www.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 closed..

  • Page 579

    578 www.Factoryfive.Com 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 through the inner skin only..

  • 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

    580 www.Factoryfive.Com 508-291-3443 on the handle control lever measure and mark 5 / 8 ” and 1.25” from the center of the ¼” square hole. With the lever in a vise or drill press, drill a ¼” hole in the center of the lever at the points marked..

  • 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

    583 www.Factoryfive.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 / 8 ” deep socket..

  • Page 585

    584 www.Factoryfive.Com 508-291-3443 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 (shown) 1” from the spring coil..

  • 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

    587 www.Factoryfive.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 3 / 8 ” deep socket..

  • Page 589

    588 www.Factoryfive.Com 508-291-3443 attach one of the un-pressed clevis’ to the control lever using one of the ¼” flange 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 h...

  • Page 590

    589 www.Factoryfive.Com 508-291-3443 attach another ¼” flange head screw in the other hole as shown above. Only 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,...

  • Page 591

    590 www.Factoryfive.Com 508-291-3443 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 barrel fitting into the clevis..

  • 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 ¼” screw head..

  • Page 593

    592 www.Factoryfive.Com 508-291-3443 without the door 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 the hole on the door frame followed by anoth...

  • 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

    594 www.Factoryfive.Com 508-291-3443 attach the clevis using a ¼” flange head screw and locknut along with a 7 / 16 ” wrench and 3 / 32 ” hex key. Tighten the locknut so that the clevis can still rotate freely but there is not a lot of slop, this will bend the clevis slightly. Install the cable ball...

  • Page 596

    595 www.Factoryfive.Com 508-291-3443 raise the rollbar to the desired location but no closer than ½” or a finger width to the 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 rollb...

  • Page 597

    596 www.Factoryfive.Com 508-291-3443 install the rear cockpit cover. Measure up and mark the rear cockpit cover in the corners under the rollbar holes the distance just measured.  the rear cockpit cover should now be marked 1” below the top of the rollbar frame mount. Looking down from above so tha...

  • Page 598

    597 www.Factoryfive.Com 508-291-3443  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 behind the seat and can not be seen..

  • Page 599

    598 www.Factoryfive.Com 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 open the hole up slightly..

  • Page 600

    599 www.Factoryfive.Com 508-291-3443 roadster rollbar installation  if installing a soft top, the maximum height to the top of the rollbar is 24.50”  if you plan to change back and forth between the hardtop and the roadster so that the rollbar is high and close to the hardtop and then lower when u...

  • Page 601

    600 www.Factoryfive.Com 508-291-3443 install the rear cockpit cover. Measure up and mark the rear cockpit cover in the corners under the rollbar holes the distance just measured.  the rear cockpit cover should now be marked 1” below the top of the rollbar frame mount. Looking down from above so tha...

  • Page 602

    601 www.Factoryfive.Com 508-291-3443  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 behind the seat and can not be seen..

  • Page 603

    602 www.Factoryfive.Com 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 open the hole up slightly..

  • Page 604

    603 www.Factoryfive.Com 508-291-3443 final prep sand paper  if using fenders, now is a good time to fit and prep them. Make sure the car is aligned before cutting if doing bike fenders. All of the exterior body accessories, headlights, windshield and exhaust must be mounted to the car to obtain the...

  • 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

    605 www.Factoryfive.Com 508-291-3443 the body comes out of the mold with a wax release compound and a thorough cleaning with a wax remover is the best way to begin this job. A lot of time and energy was spent on the mold so that the body work can be kept to a minimum. Allow the bodywork or repairs p...

  • Page 607

    606 www.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 harness.

  • Page 608

    607 www.Factoryfive.Com 508-291-3443 install the gauges and toggle switches in the dash.  do not install the headlight or ignition switches yet as these are easier to just leave attached to the chassis harness and install them after the body is mounted. If the dash area where the ignition or headli...

  • Page 609

    608 www.Factoryfive.Com 508-291-3443 wiring use a pair of pliers to turn the bulbs in the gauges 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 switch ...

  • Page 610

    609 www.Factoryfive.Com 508-291-3443 wire the gauges in the dash using the chassis harness dash harness. Use the connection instructions provided with the gauges. Attach the gauge light power wire to one of the small gauges and connect the remaining small gauges in series using the small jumper wire...

  • 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/c defroster ducts  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

    615 www.Factoryfive.Com 508-291-3443 extend the length of these wires by approximately a foot (wire included with kit) 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 ...

  • Page 617

    616 www.Factoryfive.Com 508-291-3443 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 plug to hold the connectors in place..

  • Page 618

    617 www.Factoryfive.Com 508-291-3443 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 ½ moon weatherstrip around the door openings starting at the front..

  • Page 619

    618 www.Factoryfive.Com 508-291-3443 finish the ½ moon weatherstrip just below the top sill. Push the aluminum weatherstrip onto the trunk sides..

  • Page 620

    619 www.Factoryfive.Com 508-291-3443 final body install  once the body comes back from paint, we recommend you to 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...

  • Page 621

    620 www.Factoryfive.Com 508-291-3443 it is helpful to have a friend or two when mounting the painted body. One person on each side pulling out slightly and one in the rear is the easiest way to do this. Also make sure that the exhaust tip is not installed as it protrudes though the body. You can lea...

  • 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

    623 www.Factoryfive.Com 508-291-3443 drill and 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. Mount the body to the chassis with 3 / 16 " rivets..

  • Page 625

    624 www.Factoryfive.Com 508-291-3443 after the body is mounted for the final 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”. Stick one of the felt pad...

  • Page 626

    625 www.Factoryfive.Com 508-291-3443 mount a few rubber bumpers on cowl. Use the small and large 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 aluminu...

  • 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

    627 www.Factoryfive.Com 508-291-3443 on the rear edge of the lower 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 key fuel filler assembly inser...

  • Page 629

    628 www.Factoryfive.Com 508-291-3443 attach the ground strap to the screw closest to the side aluminum.  the ground strap is to prevent any static electric build-up in the filler which is important when filling the tank. Locate one of the steel tubes behind the side aluminum by finding a row of riv...

  • Page 630

    629 www.Factoryfive.Com 508-291-3443 attach the fuel filler neck to the body at all of the bolt locations. 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 ...

  • Page 631

    630 www.Factoryfive.Com 508-291-3443.

  • Page 632

    631 www.Factoryfive.Com 508-291-3443 start with the front transmission tunnel cover. If you cannot get it to sit on the curve correctly, cut the piece if necessary. Next do the rear transmission tunnel cover. You may need to cut a hole for the shifter depending on the transmission used. Glue the cen...

  • Page 633

    632 www.Factoryfive.Com 508-291-3443 install the under door carpet. 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 section out for the prop rod stud and th...

  • Page 634

    633 www.Factoryfive.Com 508-291-3443 the best thing to do for the spot where 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 philips head screwdriver, ⅛” ...

  • Page 635

    634 www.Factoryfive.Com 508-291-3443 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 frame using the 5 / 16 ” carriage bolts..

  • Page 636

    635 www.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 at a time.

  • Page 637

    636 www.Factoryfive.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 the screws provided..

  • Page 638

    637 www.Factoryfive.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 latch assembly.

  • Page 639

    638 www.Factoryfive.Com 508-291-3443  there are a couple ways to connect the 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 ” hole in the driver si...

  • Page 640

    639 www.Factoryfive.Com 508-291-3443 push the included grommet onto the trunk latch release cable so that it is oriented as shown in the picture above. 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 ...

  • Page 641

    640 www.Factoryfive.Com 508-291-3443 run the cable forward along the 1.5” square tube to where the handle will attach trunk release handle philips head screwdriver, ⅛” drill bit, drill, razor knife  if not installing a trunk release handle, skip this section. Using a razor knife, cut the trunk rele...

  • Page 642

    641 www.Factoryfive.Com 508-291-3443 pull the trunk 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 ⅛” mounting holes through the aluminum. Attach the handle to the aluminum using a philips head screwdriver and oval hea...

  • Page 643

    642 www.Factoryfive.Com 508-291-3443 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 cable to the trunk latch assembly..

  • Page 644

    643 www.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 screws..

  • Page 645

    644 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 desired..

  • Page 646

    645 www.Factoryfive.Com 508-291-3443 tail lights wire strippers, wire crimpers, electrical tape, drill, 11 / 32 ” drill bit electrical system components, 33 tail light components. Drill an 11 / 32 ” hole in the left side of the trunk to pass the harness wires into the trunk. Install a grommet in the...

  • Page 647

    646 www.Factoryfive.Com 508-291-3443 cut the connector off the tail light wires which 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. Twist the license plat...

  • Page 648

    647 www.Factoryfive.Com 508-291-3443 put the license plate lights in the license plate bracket. Mark the bottom center of 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 br...

  • Page 649

    648 www.Factoryfive.Com 508-291-3443 attach the bracket with one 3 / 16 ” rivet 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 over to the cent...

  • 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

    650 www.Factoryfive.Com 508-291-3443 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 and rotate them as desired..

  • Page 652

    651 www.Factoryfive.Com 508-291-3443 put wire loom over the wires. Put 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  make sure the headlight a...

  • Page 653

    652 www.Factoryfive.Com 508-291-3443 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 the setscrew locking it in place..

  • Page 654

    653 www.Factoryfive.Com 508-291-3443 install the ignition switch in the dash 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 switch itself. Connect t...

  • Page 655

    654 www.Factoryfive.Com 508-291-3443 inner door panels marker, razor knife, cardboard, 7 / 64 ”, ⅛”, ¼” 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 ...

  • Page 656

    655 www.Factoryfive.Com 508-291-3443 pull 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 template. Make sure it is pointed the correct way..

  • Page 657

    656 www.Factoryfive.Com 508-291-3443 mark around the inside of the trim piece. Use a ¼” 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 mount correctly..

  • Page 658

    657 www.Factoryfive.Com 508-291-3443 use tin snips to connect the drilled holes along the line marked. Lay 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 doo...

  • Page 659

    658 www.Factoryfive.Com 508-291-3443 hold 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 the flange on the door with a ⅛” drill bit..

  • Page 660

    659 www.Factoryfive.Com 508-291-3443 enlarge the holes 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 the trim piece is centered at the other en...

  • Page 661

    660 www.Factoryfive.Com 508-291-3443 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. Repeat this for the other side..

  • Page 662

    661 www.Factoryfive.Com 508-291-3443 center armrest marker, ⅛”, 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 trees will hit the aluminum..

  • Page 663

    662 www.Factoryfive.Com 508-291-3443 use a marker to mark the location of the trees..

  • Page 664

    663 www.Factoryfive.Com 508-291-3443 drill the marked locations using an ⅛” drill bit first then open up with a 17 / 64 ” drill bit. Install the center armrest over the tunnel aluminum. Cockpit rear cover super 77 spray adhesive, razor knife, measuring tape, sand paper, masking tape. Carpet box – vi...

  • 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

    665 www.Factoryfive.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 side rollbar..

  • Page 667

    666 www.Factoryfive.Com 508-291-3443 vinyl installation sand the surface 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 still very hard to do w...

  • Page 668

    667 www.Factoryfive.Com 508-291-3443 rough cut the vinyl on the sides 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 the center and spray glue ...

  • Page 669

    668 www.Factoryfive.Com 508-291-3443 work from the middle towards the top and bottom then towards the side, smoothing the vinyl out on the fiberglass. Trim the vinyl as you go so there is 1” of overhang that will go onto the back of the fiberglass panel.  do not trim the rollbar area yet. Spray glu...

  • Page 670

    669 www.Factoryfive.Com 508-291-3443 cut the rollbar hole vinyl into pie 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 the frame and attach with...

  • Page 671

    670 www.Factoryfive.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 is attached.

  • Page 672

    671 www.Factoryfive.Com 508-291-3443 if building the car as a roadster, install the rear cockpit trim piece. The hardtop footprint is covered by this piece if you are going to run both. Attach this piece so you can remove it by using velcro, silicon or anything of your choice. Final hardtop installa...

  • Page 673

    672 www.Factoryfive.Com 508-291-3443 with the help of a friend, turn the hardtop upside down and place it on towels or something to protect the paint. Mask the recessed headliner area off so that no glue gets on the outside of the area. Place the headliner upside down on newspapers or kit packing pa...

  • Page 674

    673 www.Factoryfive.Com 508-291-3443 final install reattach the hardtop using the fasteners used during the first fitting. Headlights wire cutters, soldering iron, wire strippers, ruler, electrical tape, ⅛” drill bit, drill, tin snips, file. Headlight assembly, extra harness wires. Insert the headli...

  • 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

    675 www.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 mounting bolt..

  • Page 677

    676 www.Factoryfive.Com 508-291-3443 move the mounting bolt to the end of the wires..

  • Page 678

    677 www.Factoryfive.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 through the bolt together..

  • 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

    679 www.Factoryfive.Com 508-291-3443 solder the indicator black wire to the black headlight wire. 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 indicator l...

  • Page 681

    680 www.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 ⅛” holes in the corners of the area marked..

  • 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

    682 www.Factoryfive.Com 508-291-3443 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 in towards the grill. Place the headlight into the housing..

  • Page 684

    683 www.Factoryfive.Com 508-291-3443 install the trim 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 head light stand off is in place when installi...

  • Page 685

    684 www.Factoryfive.Com 508-291-3443 if necessary install the supplied spacer between the side of the hood and the grill mount. Fasten 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 ...

  • Page 686

    685 www.Factoryfive.Com 508-291-3443 the front light connector is the white five hole connector shown above. Install the head lights in the body. Attach the wires from the lights to the connectors included with the wiring harness. Connect the common wires such as the grounds together from both light...

  • Page 687

    686 www.Factoryfive.Com 508-291-3443 congratulations we would like to congratulate 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 procedures.  recheck ...

  • Page 688

    687 www.Factoryfive.Com 508-291-3443 appendix 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 from the ground to the bottom of the frame..

  • Page 689

    688 www.Factoryfive.Com 508-291-3443 appendix b: headlight alignment  make sure that the car is at the correct ride height before the alignment procedure is done.  it is important that the headlights are aimed properly in order for it to perform at their best. Lights that are aimed incorrectly wil...

  • Page 690

    689 www.Factoryfive.Com 508-291-3443 figure 1: headlight alignment (centerline) on a piece of masking tape, draw one horizontal line on the wall at a height exactly 2 inches lower than measurement a. On the line, make vertical marks both to the right and left of the vehicle centerline mark at the di...

  • Page 691: Appendix C:  Final Check

    690 www.Factoryfive.Com 508-291-3443 appendix c: final check the following are general guidelines we when we are finished building a vehicle. It is by no means to be considered a complete list but gives a good starting point for anyone checking over their own car before leaving the garage bay. It is...

  • Page 692

    691 www.Factoryfive.Com 508-291-3443 electrical battery charged battery mount and connections secure brake lights functioning all wires free and clear of moving or hot parts rear suspension shock mounting bolts tight spring collars tight axles free play checked air pressure set lug nuts torqued tran...

  • Page 693

    692 www.Factoryfive.Com 508-291-3443 appendix d: technical support our success depends on you being able to build your kit without problems or frustration. We are counting on you to build and drive this car and in so doing, provide us with the most important advertising of all. If you have purchased...

  • Page 694

    693 www.Factoryfive.Com 508-291-3443.

  • Page 695

    694 www.Factoryfive.Com 508-291-3443 appendix e: registration and titling you are building a race car. It was designed with closed course competition as its focus. If you choose to use this vehicle on a public road, you are responsible for complying with all state and federal regulations governing h...

  • Page 696

    695 www.Factoryfive.Com 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 hp torque rear susp. Transmissio n wheels 235@460 280@400 93' mustang cobra 302, 5.0l 0 0 solid axle t-5 17"x8" 93' mustang co...

  • Page 697

    696 www.Factoryfive.Com 508-291-3443 1996-97 sohc 215 @ 4400 285 @ 3500 sfi 9.5:1 1998 sohc 225 @ 4400 290 @ 3500 sfi 9.0:1 1999-04 sohc 260 @ 5250 302 @ 4000 sfi 9.4:1 transmissions year type 1st 2nd 3rd 4th 5th 6th r max torque lbs-ft part number weig ht 1983.5 t-5 2.95 1.94 1.34 1.00 0.725 n/a 2....

  • Page 698

    697 www.Factoryfive.Com 508-291-3443 kit. (more brake component information can be found in the high performance braking systems section of this manual) year rear end width rear brake type 87-93 59.25" 9" drum 94-98 61.125" 10.50" solid disc (gt) 11.65" vented rotor (cobra) 99-04 62.52" 10.50" solid...

  • Page 699

    698 www.Factoryfive.Com 508-291-3443 oxygen sensor signals are not used by the computer, because the computer has a built in program to run the engine rich at wide open throttle. Oxygen sensors will usually be most effective when placed near the collection point of headers because the exhaust will r...

  • Page 700

    699 www.Factoryfive.Com 508-291-3443 appendix g: wheel/tire specifications  these values represent wheels and tires used by factory five on the ’33 hot rod and do not imply any limits on max / min diameters, widths, backspacing, etc. Anyone referencing this information can be confident that using a...

  • Page 701

    700 www.Factoryfive.Com 508-291-3443 billet specialties apex-g wheels front: 18x9 255/35-18 5.5” backspace rear: 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...

  • Page 702

    701 www.Factoryfive.Com 508-291-3443 hot rods with fenders the following wheel and tire recommendations 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 an...

  • Page 703

    702 www.Factoryfive.Com 508-291-3443 appendix h: soft top diagrams.

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    703 www.Factoryfive.Com 508-291-3443.

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    704 www.Factoryfive.Com 508-291-3443.

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    705 www.Factoryfive.Com 508-291-3443.

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    706 www.Factoryfive.Com 508-291-3443 appendix i: driveshaft lengths.

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    707 www.Factoryfive.Com 508-291-3443.

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    708 www.Factoryfive.Com 508-291-3443 appendix j: additional torque specifications general bolt torque specifications (standard) thread sae english zinc plated ft-lb. ¼ -20 8 ¼ -28 10 5 / 16 -18 17 5 / 16 -24 19 ⅜ -16 30 ⅜ -24 34 7 / 16 -14 48 7 / 16 -24 54 ½ -13 75 ½ -20 83 9 / 16 -12 100 9 / 16 -18...

  • Page 710

    709 www.Factoryfive.Com 508-291-3443 appendix k: fluid specifications and capacities engine oil type capacity 302 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 q...