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Factory Five Racing Mk4 Roadster Assembly Manual

Other manuals for Mk4 Roadster: Assembly Manual, Assembly Manual, Assembly Manual
Manual is about: Complete Kit

Summary of Mk4 Roadster

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    R e v i s i o n 4 l , o c t o b e r 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.

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    Ii www.Factoryfive.Com 508-291-3443 table of contents general information .................................................................. 8 foreword ......................................................................................... 8 safety notice .............................................

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    Iii www.Factoryfive.Com 508-291-3443 3 link rear suspension torque specs chart .......................................... 79 optional independent rear suspension – standard width ............ 80 parts needed ........................................................................................... ...

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    Iv www.Factoryfive.Com 508-291-3443 fuel filler neck ....................................................................................... 175 fuel tank install ..................................................................................... 177 fuel filter ......................................

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    V www.Factoryfive.Com 508-291-3443 cables ................................................................................................... 273 handle and cable adjustment .............................................................. 276 axle and fuel tank vents .....................................

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    Vi www.Factoryfive.Com 508-291-3443 turn signal ............................................................................................ 379 license plate light ................................................................................. 381 side exhaust .......................................

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    Vii www.Factoryfive.Com 508-291-3443 front wheel ........................................................................................... 488 rear wheel ........................................................................................... 491 finishing touches .................................

  • Page 9: General Information

    8 www.Factoryfive.Com 508-291-3443 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 h...

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    9 www.Factoryfive.Com 508-291-3443 part of the 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 l...

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    10 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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    11 www.Factoryfive.Com 508-291-3443 the procedures and recommendations contained in this book are to be used as a guide with the ultimate determination of safe construction and race-worthiness to be made by you. If you feel uneasy about whether you have the skills to build your own vehicle, do not p...

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    12 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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    13 www.Factoryfive.Com 508-291-3443 how to use this book this assembly manual is intended to help you build your factory five kit. This book will not explain such things as engine or transmission building. A secondary purpose of this book is to use it as reference for owners that want to do maintena...

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    14 www.Factoryfive.Com 508-291-3443 driveshaft: select from one of three available driveshaft’s w/fasteners to match the engine/trans of your choice. Select one of the following… 28 spline driveshaft for t-5, aod, or tremec 3550’s 31 spline driveshaft for tremec tko 500 or 600’s 31 spline driveshaft...

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    15 www.Factoryfive.Com 508-291-3443 paint: most customers will send out the body and paint work to a professional body shop. Fuel pump: you are responsible for purchasing an external carbureted or fuel injected inline fuel pump. Battery: we recommend a battery sized for a ford mustang. Wheels and ti...

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    16 www.Factoryfive.Com 508-291-3443 serial number identification factory five racing has included a certificate of origin along with a nameplate for your kit. The serial number from the certificate of origin matches the number engraved on the 2”x 2” tube going across the car at the front of the cock...

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    17 www.Factoryfive.Com 508-291-3443 tools list the following lists detail the tools and supplies that are needed to build your kit. The “helpful” items are not crucial to the assembly but make life easier. Home depot husky®, sears craftsman®, and snap-on tools are all guaranteed for life and we’ve f...

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    18 www.Factoryfive.Com 508-291-3443 required supplies stick with name brand products like eastwood , 3m , and duplicolor . The eastwood brand coatings are great for bringing weathered and oxidized parts up to show quality. Ppg brand and dupont brand paints are excellent. Engine degreaser silicone do...

  • Page 20: Disassembly Of The Kit

    19 www.Factoryfive.Com 508-291-3443 disassembly of the kit chapter 2.

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    20 www.Factoryfive.Com 508-291-3443 unpacking your kit 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 in. The kit is packaged in the order that you will be using the parts. A...

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    21 www.Factoryfive.Com 508-291-3443 body removal ⅝” socket, ratchet, ⅝” wrench, gloves, 2 friends. Be careful of the raw fiberglass edges, they can splinter into your skin unbolt the door from the hinge leaving the hinge attached to the chassis. Cut the zip ties in the door latch area. Remove the ho...

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    22 www.Factoryfive.Com 508-291-3443 unbolt the body sides from the chassis on the underside of the car. Unbolt the quick jacks and remove the body. Two people can do this but it is much easier with a third person to pull the sides clear of the chassis. When you store the body on the ground (unsuppor...

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    23 www.Factoryfive.Com 508-291-3443 putting two short 2”x 4” braces (24” long) under the windshield holes (running vertically to support the hood cowl area just forward of the doors under the windshield holes). Use these 2”x 4” ’s whenever the body is on the ground, otherwise make a body buck to sup...

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    24 www.Factoryfive.Com 508-291-3443 aluminum removal ¼” nut driver, jack stands, marker. Do one panel at a time. Be careful of the sharp aluminum edges, they can cut you. Using a marker outline the underside of each panel where it contacts the chassis. This is done to locate where to drill rivet hol...

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

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

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    27 www.Factoryfive.Com 508-291-3443 use jack-stands to position your frame in your workspace with plenty of room to move things around..

  • Page 29: Chassis Assembly

    28 www.Factoryfive.Com 508-291-3443 chassis assembly chapter 3.

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    29 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 to ...

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    30 www.Factoryfive.Com 508-291-3443 drill the panels using a 1 / 8 ” bit then clean the marker lines and labeling off using acetone or brake cleaner. Apply silicone to the panel or chassis (whichever is easier) in the areas where they will make contact..

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    31 www.Factoryfive.Com 508-291-3443 use the original #6 screws to remount the panel then drill the 1 / 8 ” rivet holes through the panel holes into the chassis. Rivet the panel in place using 1 / 8 ” short rivets, then remove the screws and replace them with rivets. Repeat for the other side..

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    32 www.Factoryfive.Com 508-291-3443 front suspension front lower control arm ⅞” socket, 5 / 16 ”, 15 / 16 ” wrenches, torque wrench front lower control arm assembly unpack the front lower control arms and hardware..

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    33 www.Factoryfive.Com 508-291-3443 screw the grease fittings into the arms using a 5 / 16 ” wrench. Mount the lower control arms using the outer set of holes on the chassis using the supplied hardware..

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    34 www.Factoryfive.Com 508-291-3443 the rear bushing mount on the chassis is wider to be able to accept oem arms so use the large shim washers provided to take up the extra space. While holding the arm parallel to the ground, torque the bolts to 135-149nm (100-110 lbft). Front upper control arm vise...

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    35 www.Factoryfive.Com 508-291-3443 put thread locker on the upper balljoint threads. Screw the upper ball joints into the control arms so that the balljoint angles out on the bottom.

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    36 www.Factoryfive.Com 508-291-3443 tighten the balljoint using the arm for leverage with a vice holding the ball joint. Screw the grease fittings in to the ball joints and tighten with a ⅜” wrench..

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    37 www.Factoryfive.Com 508-291-3443 mount the upper control arms to the chassis with the grease fittings pointed up. Use the mount holes that are vertical on the side of the 2”x 3” tube, not the top horizontal ones. Use a washer with the front locknut..

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    38 www.Factoryfive.Com 508-291-3443 do not use a washer on the rear locknut. Torque the two bolts that hold the arm to the frame to 135-149nm (100-110 lbft). Pivot endplay adjust the locknuts on the ends of the pivot shaft so that there is minimal endplay but so the pivots can still rotate easily on...

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    39 www.Factoryfive.Com 508-291-3443 slightly loosen the three pivot bolts using a ⅝” and 11 / 16 ” wrench. Loosen the jam nuts on both ends of each adjusting tubes using a 1⅛” wrench. Turn the adjusting tubes to lengthen or shorten the arm. After you have adjusted the arm to the desired length, tigh...

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    40 www.Factoryfive.Com 508-291-3443 unpack the front 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 da...

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    41 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 and hat on the shock and rotate the spring seat back up the sleeve so tha...

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    42 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. Pass the shock assembly (with the body of the shock up) through the upper a-arm and attach them to...

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    43 www.Factoryfive.Com 508-291-3443 run zip ties through the holes in the spring hat and around the spring to prevent the spring from becoming unseated. Fasten the shock to the top mount with the fasteners and 0.675” spacers provided and torque both upper and lower mounts to 40 ft-lbs..

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    44 www.Factoryfive.Com 508-291-3443 spindles 13 / 16 ” socket, torque wrench, needle nose pliers, rubber mallet spindle assembly, ifs components. Unpack and lay out the hardware for the spindles assembly. The spindles are marked dss (driver side spindle) and pss (passenger side spindle). These refer...

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    45 www.Factoryfive.Com 508-291-3443 make sure the grease boot is in place on the balljoint then mount the spindle to the lower control arm. Place the spacer under the castle nut to ensure that the cotter pin is at the correct height. Torque to 106-149nm (80-110 lbft) and install the cotter pin..

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    46 www.Factoryfive.Com 508-291-3443 attach the upper ball joint to the spindle and torque to 75 ft-lbs and install the cotter pin. The upper ball joint boot will look crushed and out of shape when the car is in the air, this is ok. The boot will seat when the car is on the ground. Bolt the steering ...

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    47 www.Factoryfive.Com 508-291-3443 the hub is a snug fit on the spindle and may require a light tap with a soft mallet to get in place. Torque the hub nut to 305-338nm (225-250 ft-lbs). Using a large socket or a flat head screwdriver and rubber mallet, hit the dust cap onto the hub. Front suspensio...

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    48 www.Factoryfive.Com 508-291-3443 front lower ball joint to spindle 106-163 80-120 upper a-arm to frame 135-162 100-110 upper ball joint to spindle 95-122 70-90 spindle hub nut 305-338 225-250 front brakes 12mm socket, ratchet, 16mm wrench, torque wrench, thread locker front 11” caliper/rotor asse...

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    49 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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    50 www.Factoryfive.Com 508-291-3443 install the slider grease boots on the slider pins..

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

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    52 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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    53 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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    54 www.Factoryfive.Com 508-291-3443 push the rubber boots over the lip on the caliper bracket to seal the slider bolts correctly. 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 st...

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

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    56 www.Factoryfive.Com 508-291-3443 install the brake pads in the caliper. Clean the rotor with brake cleaner and push it onto the hub..

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    57 www.Factoryfive.Com 508-291-3443 install the caliper on the spindle; make sure that the fluid bleeder is at the top of the caliper. Torque the caliper mounting bolts to 130nm (95 ft-lb)..

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    58 www.Factoryfive.Com 508-291-3443 solid axle rear suspension skip to the independent rear suspension if not installing a solid axle. Two bolts are included with the control arms, the other two are included in the kit with the traction lok brackets. Solid axle preparation ¾” sockets, ¾” wrench, ½” ...

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    59 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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    60 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). Axle bracket driver's side.

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    61 www.Factoryfive.Com 508-291-3443 axle bracket passenger side temporarily put the lower shock bolt through the traction lock bracket and stock shock hole on the axle..

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    62 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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    63 www.Factoryfive.Com 508-291-3443 3 link rear suspension 3 / 16 ”, ⅜”, ½” drill bits, ⅝”, ¾”, 15 / 16 ”, 1” wrenches, ⅜”, ⅝”, ¾”, 15 / 16 ” sockets, 5 / 16 ” hex key, ratchet, torque wrench, drill, ruler/tape measure, pliers, flat head screwdriver, tin snips/scissors/razor, marker. 3-link rear sus...

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    64 www.Factoryfive.Com 508-291-3443 test fit the two halves of the upper arm mount together. If it is hard to put all of the bolts in the mount holes, put in as many as you can then use a ½” drill bit through the remaining bolt holes. Attach the upper link bracket onto the axle using the fine hardwa...

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    65 www.Factoryfive.Com 508-291-3443 attach the front of the upper link axle mount to the front axle flange. Upper link install a jam nut on each of the rod ends, remembering that two of them are left hand thread. Insert the rod ends into the swedged tubes (one is right hand thread and one is left ha...

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    66 www.Factoryfive.Com 508-291-3443 attach the short upper link tube to the axle upper link mount using the ¼” spacers on either side of the rod end. Rear axle have someone help with this step, the rear axle is very heavy and mistakes can result in serious injury..

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    67 www.Factoryfive.Com 508-291-3443 use a floor jack to position the rear axle assembly under the frame. Make sure that the rear jack stands are positioned under the 4” round tube as far back as possible to prevent the frame from tipping up once the axle is mounted do not hold the end of the axle fr...

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    68 www.Factoryfive.Com 508-291-3443 with one person holding a side of the axle raise the axle so that the lower control arms can be bolted onto the frame. Attach the lower control arms to the frame mounts..

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    69 www.Factoryfive.Com 508-291-3443 jack the rear axle up and attach the upper link to the frame. Panhard bar frame mount the panhard bar frame mount is mounted to the chassis during shipping.

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    70 www.Factoryfive.Com 508-291-3443 with the axle jacked up, attach the panhard bar frame mount to the inside of the quad shock brackets, the forward leg will attach to the back of the angled 2”x 3” tube. Do not tighten the quad shock bracket bolts yet. For the front mount, use a ½” drill bit and dr...

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    71 www.Factoryfive.Com 508-291-3443 tighten the bolts on the quad shock brackets. Lower the rear axle. 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. Rear coil-over shock assembly snap ring pliers, ¾” ...

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    72 www.Factoryfive.Com 508-291-3443 unpack the rear 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. The center high part of the set should be poin...

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    73 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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    74 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. Assembled solid axle koni coil-over shock..

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    75 www.Factoryfive.Com 508-291-3443 attach the body end of the shock to the upper shock mount using the two equal length (1.09”) spacers. Jack the rear axle up so the rod end of the shocks can be mounted on the axle through the shock mount hole. Passenger side.

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    76 www.Factoryfive.Com 508-291-3443 driver side install the kit ½”x 4” bolts are provided for each lower shock mount. From the rear, the bolt goes through the bracket, ⅛” shim, shock, then the long spacer (1.09”) followed by the bracket and axle. Use a ¾” socket and torque wrench to tighten both upp...

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    77 www.Factoryfive.Com 508-291-3443 run zip ties through the holes in the spring hat and around the spring to prevent the spring from becoming unseated..

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    78 www.Factoryfive.Com 508-291-3443 panhard bar the panhard bar mounts to the car using the ⅝”x 3” bolts and spacers. Install the panhard bar to the passenger side traction lock bracket. Three spacers are used in the front (2) 0.375" (ffr# 14064) and (1) 0.25" (ffr# 14065). The rear uses the thin 0....

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    79 www.Factoryfive.Com 508-291-3443 attach the panhard bar to the frame mount using the spacers provided. There should never be less than ¾” of threads screwed into either the panhard bar or the upper arm. To set the pinion angle, make sure that your ride height is where you want it, and then adjust...

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    80 www.Factoryfive.Com 508-291-3443 optional independent rear suspension – standard width 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 /16 ”, 15 / 16 ” wrenches, 1...

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    81 www.Factoryfive.Com 508-291-3443 mustang irs specifications 2.3l ecoboost 3.7l v6 5.0l coyote housing steel aluminum steel weight 93lb 78lb 93lb gear ratios 3.15:1, 3.31:1, 3.55:1 3.15:1, 3.55:1 3.15:1, 3.55:1 brakes 12.6" (320mm) solid rotor, 45mm single piston aluminum caliper 12.6" (320mm) sol...

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    82 www.Factoryfive.Com 508-291-3443 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. 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 jus...

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    83 www.Factoryfive.Com 508-291-3443 hubs hammer, vise, ratchet, ½”-20 lugnut, torque wrench. Rear wheel studs. Removal of the hub from the spindle is not necessary but can make things easier. Use a vise to lightly hold the side of the wheel stud head then use a hammer to bang out the mustang studs. ...

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    84 www.Factoryfive.Com 508-291-3443 insert one of the included wheel studs into the hub from the back and use a washer and lug nut on the front side. Use a ratchet to draw the wheel stud into the hub and torque the stud to 135nm (100lb-ft)..

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    85 www.Factoryfive.Com 508-291-3443 repeat for the other wheel studs. If the hub was removed, use loctite on the threads and reattach to the spindle. Torque the bolts to 133nm (98ft-lb)..

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    86 www.Factoryfive.Com 508-291-3443 center section 5 / 8 ” drill bit, drill. 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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    87 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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    88 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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    89 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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    90 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. Use a friend to help with the heavy center section...

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

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    92 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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    93 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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    94 www.Factoryfive.Com 508-291-3443 center section vent pliers, wire cutters, hammer vent hose, vent nipple, insulated clips, secondary body fasteners. Remove the plug at the top of the rear cover..

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    95 www.Factoryfive.Com 508-291-3443 use a hammer on the end of the barb to put the nipple in the rear cover. Push the 12.00” piece of 5 / 16 ” fuel hose onto the barb..

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    96 www.Factoryfive.Com 508-291-3443 run the hose up to the 1” tube that goes across the back of the irs and use one of the kit 5 / 8 ” insulated clips and 3 / 16 ” rivet to hold it in place. Toe adjustment arms irs toe adjustment arm components 13 / 16 ” socket, 15 / 16 ” wrench, torque wrench. If u...

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    97 www.Factoryfive.Com 508-291-3443 attach the toe arms to the frame below the front lower arm mount using the 1 / 8 ” thick spacer in the back and the ¼” spacer on the front side of the rod end. Use the 5 / 8 ” x 2.25” bolts to attach them to the frame. Torque bolts to 135nm (100 ft-lb). Lower cont...

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    98 www.Factoryfive.Com 508-291-3443 attach the control arms to the frame with the shock mount towards the rear and spindle brackets up. Use the longer m16 x 110mm (~4 5 / 16 ”) bolts. Hold the arm horizontal and torque the bolts to 135nm (100 ft-lb). Upper control arms irs upper control arm componen...

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    99 www.Factoryfive.Com 508-291-3443 pass the upper control arm thick tube through the triangular area as shown in between the frame mounts. 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 join...

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    100 www.Factoryfive.Com 508-291-3443 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 the cv axle nut on the end h...

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

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    102 www.Factoryfive.Com 508-291-3443 wait to torque the bolts until after the other arms are installed. 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 misalig...

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    103 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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    104 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. Toe link attach the toe link arm to the spindle using the m14 x 80mm bolt and locknut..

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    105 www.Factoryfive.Com 508-291-3443 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 shock assembly snap ring pliers, ¾” wrench, ¾” socket, ratchet, floor jack shock set, insulated clip hardware....

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    106 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 and hat on the shock and rotate the spring seat back up the sleeve so th...

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    107 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. Attach the rod end of the shock to the upper shock mount using the two equal length 1.09” kit spa...

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    108 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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    109 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)..

  • Page 111

    110 www.Factoryfive.Com 508-291-3443 fluids name specification motorcraft® additive friction modifier (u.S.) xl-3 (u.S.) est-m2c118-a motorcraft® sae 75w-85 synthetic hypoid gear lubricant xy-75w85-ql wss-m2c942-a fill the rear axle with fluids. Capacities fluid amount sae 75w-85 synthetic hypoid ge...

  • Page 112

    111 www.Factoryfive.Com 508-291-3443 alignment specs camber: -0.5 to -0.75° total toe: 1/8” toe in torque specifications lb-ft nm center section to frame front 129 175 center section to frame rear 129 175 brake caliper to caliper bracket 24 32 brake caliper bracket to spindle 129 175 brake hose banj...

  • Page 113

    112 www.Factoryfive.Com 508-291-3443 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. Optional irs brakes download the 2015 irs brake instructions from www.Factor...

  • Page 114

    113 www.Factoryfive.Com 508-291-3443 e-brake cables make sure the ffr cables go through the upper bracket in the transmission tunnel until the sheath end clicks in place..

  • Page 115

    114 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..

  • Page 116

    115 www.Factoryfive.Com 508-291-3443 wilwood e-brake adapter insert the cable end into the bent bracket then bolt the bracket to the e-brake lever..

  • Page 117

    116 www.Factoryfive.Com 508-291-3443 make sure to run the other end of the brake cables under the 4” crossmember and connect them to the e-brake handle and adjust. Firewall & driver front footbox aluminum drill, 1 / 8 ” drill bit, rivet tool, caulk gun, silicone firewall and driver footbox front alu...

  • Page 118

    117 www.Factoryfive.Com 508-291-3443 rivet the firewall in position on the chassis. The footbox front for the wilwood pedal box is packaged with the pedalbox in the kit. The one that is shipped on the chassis is for the oem mustang pedalbox. Mark, drill, and rivet in place the driver’s side footbox ...

  • Page 119

    118 www.Factoryfive.Com 508-291-3443 pedal box ½”, 9 / 16 ” sockets, ¼”, ⅜”, ½” wrenches, ¼” drill bit, drill, philips head screwdriver, 3 / 16 ”, 5 / 16 ” hex key, snap ring pliers pedal components, pedal box hardware. This pedal box is set-up to use either a hydraulic clutch or a cable clutch. The...

  • Page 120

    119 www.Factoryfive.Com 508-291-3443 connect the switch to the switch mount using a hex nut on each side of the mount bracket. See the chassis harness instructions for connecting the switch. Clutch safety switch mount the clutch switch mount attaches the same way as the brake switch mount..

  • Page 121

    120 www.Factoryfive.Com 508-291-3443 place the switch mount between the clutch pedal mount tabs on the side closest to the clutch pedal pivot holes and drill a 3 / 16 ” hole through the switch mount hole and the pedal box. Attach the switch mount to the pedal box using the black #10 screw and locknu...

  • Page 122

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

  • Page 123

    122 www.Factoryfive.Com 508-291-3443 quadrant assembly order for kits older than 6/21/16.

  • Page 124

    123 www.Factoryfive.Com 508-291-3443 quadrant assembly order for kits newer than 6/21/16. Assemble the clutch quadrant to the wilwood clutch pedal as shown above..

  • Page 125

    124 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. Attach the wilwood pedals to the underside of the mounting bracket using four 5 / 16 ” button head screws, locknuts, 3 / 16 ” hex key and ½” wrench..

  • Page 126

    125 www.Factoryfive.Com 508-291-3443 clutch quadrant stop attach the clutch pedal stop mount to the bottom of the pedal box using two ¼” socket head screws, spacers and locknuts. Thread the jam nut onto the ⅜”x 1.25” screw provided in the quadrant box..

  • Page 127

    126 www.Factoryfive.Com 508-291-3443 from the underside, push the screw through the quadrant pedal stop mount plate and hand tighten the locknut on the screw. Frame installation place the pedal box assembly in the driver’s footbox. Make sure that the brake pedal goes in front of the ¾” cross tube on...

  • Page 128

    127 www.Factoryfive.Com 508-291-3443 unpack the pedal box hardware from the secondary chassis components box. Insert three ⅜” x 1” socket head screws from the pedal box hardware assembly and the one included in this pedal assembly through the front of the footbox and through the pedal box mount..

  • Page 129

    128 www.Factoryfive.Com 508-291-3443 push the rear pedal box mount onto the master cylinder mount studs and use a few of the jam nuts from the wilwood pedal assembly to temporarily hold the rear mount in place. Tighten two of the front ⅜” screws then use a marker to mark the locations of the rear mo...

  • Page 130

    129 www.Factoryfive.Com 508-291-3443 loosen the bolts and remove the pedal box assembly from the footbox then use a ¼” drill bit and drill to drill through the ¾” tubes at the locations marked for the rear mount. Reinstall the pedal box assembly in the driver’s footbox; use the ¼”x 1.50” screws from...

  • Page 131

    130 www.Factoryfive.Com 508-291-3443 master cylinders with the jam nut on the threaded shaft, cut 5 / 8 ” off each of the master cylinders. Screw the 90° brake line adapter into the end of the master cylinder making sure that the opening points up when tight..

  • Page 132

    131 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 133

    132 www.Factoryfive.Com 508-291-3443 attach and tighten the locknuts using a ½” wrench and ½” deep socket 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...

  • Page 134

    133 www.Factoryfive.Com 508-291-3443 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 brakes. Most balance bars are part of a pedal assembly that also provides a mo...

  • Page 135

    134 www.Factoryfive.Com 508-291-3443 make sure that the master cylinder pushrods remain true in relationship to the cylinder during entire pedal travel; pushrods should not be pushing master cylinder pistons at an angle. In its non-depressed position, the pedal and balance bar should allow the pushr...

  • Page 136

    135 www.Factoryfive.Com 508-291-3443 use one ¼”x ¾” screw and locknut from the pedal box hardware position the accelerator pedal using the top hole in the accelerator pedal mount so that the top of the pedal lines up with the accelerator cable hole so the cable will come out straight. Mark the lower...

  • Page 137

    136 www.Factoryfive.Com 508-291-3443 unpack the throttle cable and cut the cylinder end off. Make sure your cutters are very sharp so as not to fray the cable. Thread the inner cable through the cable retaining lock nut from the accelerator cable components assembly..

  • Page 138

    137 www.Factoryfive.Com 508-291-3443 route the cable through the hole in the firewall and slide the sheath back over the cable. Tighten the cable sheath to the firewall with the retaining nut. A piece of tape on the end of the cable will help prevent it from backing out of the sheath. Check the full...

  • Page 139

    138 www.Factoryfive.Com 508-291-3443 steering system steering rack needle nose pliers, ¾” wrench, ¾” socket, ratchet steering rack assembly, steering system hardware the inner tie rod extensions are for stock power steering racks only. The inner tie rod extensions are not for the ffr manual steering...

  • Page 140

    139 www.Factoryfive.Com 508-291-3443 push the bushings and sleeves into the mounting bosses on the rack. Center the steering rack. Line up the steering shaft and adapter and push the rack onto the steering shaft..

  • Page 141

    140 www.Factoryfive.Com 508-291-3443 bolt the rack into the frame. It is easier to do the driver side first then swing the passenger side down into the mount. Screw the grease nipple into the outer tie rod end..

  • Page 142

    141 www.Factoryfive.Com 508-291-3443 thread the outer tie rod and jam nut 1”-2” down onto the steering rack inner tie rod. The outer tie rods may come with either a castle nut and cotter pin or a nylon locknut..

  • Page 143

    142 www.Factoryfive.Com 508-291-3443 attach the tie rod to the spindle, torque the nut to 25 ft-lbs. If a castle nut is used, torque the nut then install the cotter pin. If the tie rod has a locknut instead of a castle nut, torque to 80nm (59 ft-lb)..

  • Page 144

    143 www.Factoryfive.Com 508-291-3443 steering shaft 1 / 8 ”, 5 / 32 ”, 3 / 16 ”, 5 / 16 ” hex keys, ½”, 9 / 16 ”, 10mm wrenches, marker, drill, 3 / 16 ” drill bit, philips head screwdriver, 15mm deep socket, ratchet. Steering bearings/hardware, steering shaft, manual steering rack and adapter. Unpac...

  • Page 145

    144 www.Factoryfive.Com 508-291-3443 remove the splined adapter from the end of the steering shaft using an 1 / 8 ” hex key. Loosen the set screw, align the set screw with the flat side on the input shaft then slide the new adapter down onto the rack as far as possible..

  • Page 146

    145 www.Factoryfive.Com 508-291-3443 slide the bearing onto the steering shaft so that the locking flange is away from the u-joint loosely mount the top pillow block to the chassis with the set screw toward the rear of the car..

  • Page 147

    146 www.Factoryfive.Com 508-291-3443 slide the steering shaft into the footbox from the engine bay. Insert the lower u-joint into the steering adapter..

  • Page 148

    147 www.Factoryfive.Com 508-291-3443 tighten the adapter set screws using an 1 / 8 ” hex key. Attach the flange bearing to the front of the footbox using the 5 / 16 ” x 1” button head screws, 3 / 16 ” hex key and ½” wrench..

  • Page 149

    148 www.Factoryfive.Com 508-291-3443 tighten the adapter set screw and nut using a 5 / 32 ” hex key and 9 / 16 ” wrench. Upper steering shaft 5 / 32 ”, 3 / 16 ”, 5 / 16 ” hex keys, ½” wrench, rubber mallet steering system hardware use thread locker on all the steering shaft screws that do not have j...

  • Page 150

    149 www.Factoryfive.Com 508-291-3443 slide the steering shaft through the upper bearing and start it in the lower shaft. Turn the steering shaft so the recessed bosses for the spring washers are facing up and set the washers in place. Then tap the upper shaft down until the upper clip just disappear...

  • Page 151

    150 www.Factoryfive.Com 508-291-3443 tighten the upper and lower bearings. Also tighten the set screw on the upper shaft. Cockpit aluminum drill, ⅛” drill bit, rivet tool, silicone, caulking gun, #8 self tapping screws, #8 hex nut driver, ruler, marker, acetone or carburetor cleaner, rags. Packaged ...

  • Page 152

    151 www.Factoryfive.Com 508-291-3443 passenger footbox locate the passenger footbox top and drill and mark the holes in the top flat surface only. Silicone this panel where it meets the chassis and rivet along the bottom of the 2” square frame crossbar only. Use one of the original screws to tempora...

  • Page 153

    152 www.Factoryfive.Com 508-291-3443 drill the tunnel front a-shaped piece where it meets the chassis and silicone and rivet it in place. Mark and drill the two vertical edges of the passenger footbox inside wall..

  • Page 154

    153 www.Factoryfive.Com 508-291-3443 silicone and rivet the panel to the front tunnel “a” and the footbox top. Mark the holes in the passenger footbox front panel upper and outer edges but do not drill yet..

  • Page 155

    154 www.Factoryfive.Com 508-291-3443 silicone the panel and install with the temporary screws then drill through both panels and rivet it in place..

  • Page 156

    155 www.Factoryfive.Com 508-291-3443 mark and drill all three flanges on the passenger outer footbox top. Silicone the flange between the outer top and the outer wall and attach the two pieces together using the temporary screws..

  • Page 157

    156 www.Factoryfive.Com 508-291-3443 silicone the remaining flanges then install the outer wall/top on the footbox with rivets. Make sure the rear edge is flush to the chassis and not caught up on the door hinge before you start riveting. Passenger floor drill the passenger side floor where it was m...

  • Page 158

    157 www.Factoryfive.Com 508-291-3443 silicone the chassis where the aluminum floor will touch. The main chassis rails are not riveted to but still need a bead of silicone run along the tops. The top edge of the tunnel is not riveted yet but gets silicone as well. Drill and rivet the floor in place t...

  • Page 159

    158 www.Factoryfive.Com 508-291-3443 drill, silicone, and rivet the right side under door piece in place. Leave the rivets out of the rear vertical flange for now. Driver floor drill silicone and install the driver’s footbox floor. The outer flange does not get drilled yet..

  • Page 160

    159 www.Factoryfive.Com 508-291-3443 silicone, drill, and install the driver side floor. Install the left side under door aluminum like the right side..

  • Page 161

    160 www.Factoryfive.Com 508-291-3443 drill, silicone and install the inner footbox wall. The front flange tucks in behind the front wall that was left unriveted. Put a little silicone on both sides of this flange. U-joint cover mark the rear tunnel cover where it meets the chassis then silicone and ...

  • Page 162

    161 www.Factoryfive.Com 508-291-3443 transmission tunnel rear corners the inner rear corner pieces tuck behind the tunnel sides and sit on top of the floor. Mark the rivet spacing on the top edge and silicone and rivet the three flanges that make contact..

  • Page 163

    162 www.Factoryfive.Com 508-291-3443 cockpit rear corners the outer cockpit corners get marked on the bottom flange and where they meet the chassis. Drill silicone and rivet these in place. Fuel system 9 / 16 ” and 5 / 16 ” deep sockets, ratchet, 7 / 16 ” wrench, rubber mallet, hammer, marker, punch...

  • Page 164

    163 www.Factoryfive.Com 508-291-3443 unpack the fuel strap fasteners. Unpack the ¾” square plastic end caps from the secondary body fasteners..

  • Page 165

    164 www.Factoryfive.Com 508-291-3443 push the two plastic end caps into the tubes hanging down in front of the gas tank area. Put the fuel tank bolts in the gas tank front frame mounts..

  • Page 166

    165 www.Factoryfive.Com 508-291-3443 hang the fuel tank straps from the rear mount of the chassis using two of the strap fasteners. The longer strap goes on the passenger side. Fuel tank vent ¼”, 5 / 16 ” sockets, ratchet, (2) 1” wrenches, teflon tape, razor knife.

  • Page 167

    166 www.Factoryfive.Com 508-291-3443 unpack the oem fuel tank components including the tank and straps. Screw the vent into the plastic bushing and tighten..

  • Page 168

    167 www.Factoryfive.Com 508-291-3443 insert the small rubber vent gasket in the small hole on the top of the tank. Push the vent into the grommet..

  • Page 169

    168 www.Factoryfive.Com 508-291-3443 fuel pick-up this install shows the set-up for a pick-up with an inline fuel pump. See www.Factoryfiveparts.Com/instructions for in-tank fuel pump set-up. Prep if the car will have a high horsepower fuel injected engine there are a few “tweeks” we recommend get d...

  • Page 170

    169 www.Factoryfive.Com 508-291-3443 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 restrictive. Starting with a ¼” drill bit drill out the end of the return line then change to a 9 / 32 ” or 19 / 64 ”drill...

  • Page 171

    170 www.Factoryfive.Com 508-291-3443 install set the rubber o-ring gaskets in place for the fuel pump pickup. Slide the pickup down into the tank; you will have to rotate as you go to get the tubes into the sump and line up the tabs on the pick-up and slots on the tank. You can see this looking thro...

  • Page 172

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

  • Page 173

    172 www.Factoryfive.Com 508-291-3443 with the pickup all the way down slide the mounting collar and tap tightly into place with a punch and hammer. Make sure that the lock ring is held by all three locking tabs on the tank or the sender will leak..

  • Page 174

    173 www.Factoryfive.Com 508-291-3443 fuel gauge sender set the rubber o-ring in place for the fuel level sending unit. Insert the fuel level sender into the tank..

  • Page 175

    174 www.Factoryfive.Com 508-291-3443 ] tap the locking ring tightly into place with a punch and hammer. Make sure that the lock ring is held by all three locking tabs on the tank or the sender will leak..

  • Page 176

    175 www.Factoryfive.Com 508-291-3443 fuel filler neck insert the large rubber filler neck gasket in the side of the tank. Slide the filler neck tube into the tank. A little oil or wd40 on the rubber gasket helps..

  • Page 177

    176 www.Factoryfive.Com 508-291-3443 slide the retaining bracket down the filler tube and mark its mounting location on the tank. Move the retainer out of the way and make sure your mark is outside the weld that holds the two tank halves together..

  • Page 178

    177 www.Factoryfive.Com 508-291-3443 drill a ¼” hole through the tank flange on the mark made. Use the ¼”bolt and locknut to attach the retainer to the tank. Fuel tank install at the locations on the tank where the tank straps come near the tank, use a pair of pliers and bend the bent parts flat..

  • Page 179

    178 www.Factoryfive.Com 508-291-3443 put the metal tank in the plastic tank cover. Using a jack, raise the tank up into place on the chassis. Make sure the plastic cover is in position below the tank..

  • Page 180

    179 www.Factoryfive.Com 508-291-3443 bolt the straps in with the strap fasteners and drop the jack. Tighten only the driver’s side strap as the passenger one will be removed for aluminum fitment later on. Fuel filter tube bender, 3 / 16 ”drill bit, drill, rivet tool, marker, tape measure, flat head ...

  • Page 181

    180 www.Factoryfive.Com 508-291-3443 insulated clip hardware, fuel line components, ¼”, 5 / 16 ” fuel lines, oem fuel tank components. 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...

  • Page 182

    181 www.Factoryfive.Com 508-291-3443 clamp the filter in place on the mount with the filter flange oriented as shown. Attach the short nylon fuel line to the filter and the tank to show where your mounting location must be. The elbow end can attach to either end as shown here; we have attached it to...

  • Page 183

    182 www.Factoryfive.Com 508-291-3443 hold the filter up to the 2”x 3” chassis tube, mark the holes, then drill and rivet the bracket on using 3 / 16 ” rivets. Hard lines unpack the fuel lines and the fuel line assembly which is in the secondary chassis components box..

  • Page 184

    183 www.Factoryfive.Com 508-291-3443 the larger 5 / 16 ” line is the send fuel line to the engine. If you are running a return system then there is ¼” line provided for that as well. There are barbed fittings provided for both sizes. The fuel line routing will depend on your style of fuel pump, whet...

  • Page 185

    184 www.Factoryfive.Com 508-291-3443 from the filter we generally run the lines down the 2”x 3” tube behind the rear cockpit wall and alongside the outside of the main 4” frame tube. Which side you run down may depend on where you are hooking up to your fuel rail, carburetor, or pressure regulator. ...

  • Page 186

    185 www.Factoryfive.Com 508-291-3443 run the lines up the inside of the right footbox. Attach a 25” section of 5 / 16 ” fuel line and fuel line clamp onto the vent..

  • Page 187

    186 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. Brake system tube bender, 3 / 16 ”, ¼”, 7 / 16 ”, ⅝” drill bits, drill, rivet gun, marker, tape measure, razor knife, round file or sand paper, brake fluid. Pedal co...

  • Page 188

    187 www.Factoryfive.Com 508-291-3443 screw in the hose barb. Loosely screw the mounting bracket onto the reservoir. Make sure to mount the reservoir high enough so the top of the reservoir is higher than the master so the master can suck the fluid in to bleed the system..

  • Page 189

    188 www.Factoryfive.Com 508-291-3443 the brake reservoir mounts to the front of the footbox just inside the hood opening. Take the reservoir with cap and line it up so the reservoir can be filled with the body on. Mark the holes. The picture above shows the reservoir hose going through the accelerat...

  • Page 190

    189 www.Factoryfive.Com 508-291-3443 use a 5 / 16 ” hex driver to screw the self-drilling screw into the footbox plate. Drill an 1 / 8 ” hole through the mounting bracket for the second hole location..

  • Page 191

    190 www.Factoryfive.Com 508-291-3443 screw the other mounting screw in. Attach the reservoir to the mounting bracket..

  • Page 192

    191 www.Factoryfive.Com 508-291-3443 if drilling a hole for the reservoir hose, drill a ⅝” hole one inch down from the bottom of the reservoir. Take extra time with a file and round all the edges making sure there are no burrs left or sharp spots. Route the fluid line for the master cylinders throug...

  • Page 193

    192 www.Factoryfive.Com 508-291-3443 connect and split the hose to the two master cylinders using the y provided. Make sure that the line cannot get in the way of moving parts, especially the brake pedal! Attach the master cylinder hose adapter to the master cylinder and use insulated clips from the...

  • Page 194

    193 www.Factoryfive.Com 508-291-3443 front flexible brake lines unpack the hardware from the brake line components. The crossed off parts in the picture above are for the stock mustang master cylinder and flexible brake lines so are not used. The u-nuts, washers and button head screws are for the e-...

  • Page 195

    194 www.Factoryfive.Com 508-291-3443 lay out the various lengths of brake line so you can see what you have to work with. Like the fuel lines, there are many ways to run these lines but you must be very careful to keep them protected from moving parts, heat, or being to close to the bottom of the ca...

  • Page 196

    195 www.Factoryfive.Com 508-291-3443 push the brake line adapters through the brackets from the outside in and install the clips that hold them in place. Attach the front brake line to the caliper making sure there is a crush-washer on either side of the fitting and then screw the other end of the l...

  • Page 197

    196 www.Factoryfive.Com 508-291-3443 screw the brake line t fitting into the end of the drivers side brake adapter and tighten. Make sure that your flex lines will not interfere with anything in the suspension, wheels during travel or turning full lock to lock. Torque the front flexible brake line t...

  • Page 198

    197 www.Factoryfive.Com 508-291-3443 hard brake lines front the ¾” master cylinder is used for front and the 5 / 8 ” master cylinder is used for the rear brakes..

  • Page 199

    198 www.Factoryfive.Com 508-291-3443 run a 60” brake line from the ¾” front master cylinder out the front of the pedalbox along the ¾” tube to the front suspension. Attach the brake line t to the flexible brake line mount and run the brake line into the end of the t..

  • Page 200

    199 www.Factoryfive.Com 508-291-3443 run another 60” brake lines from the t fitting over to the right side flexible mount. The line will bend very easy but be careful not to kink it. When you are happy with the routing use the small insulated line clips and 3 / 16 ” rivets to hold it in place. Mount...

  • Page 201

    200 www.Factoryfive.Com 508-291-3443 use a long 60” brake line and route from the 5 / 8 ” master cylinder out the front and down the front of the footbox. From the front of the footbox angle into the 4” main tube under where the footbox floor would be..

  • Page 202

    201 www.Factoryfive.Com 508-291-3443 use a union to attach the another 60” brake line. Run the brake line up the back of the 2”x 3” tube using line clips and rivets on the 2”x 2” tubes. At this point your routing will depend on your rear brakes. 87-93 mustang solid axles have a single flex line that...

  • Page 203

    202 www.Factoryfive.Com 508-291-3443 solid axle using the ffr rear brakes, we attached the flexible brake line mount to the driver side diagonal ¾” tube with the brake line clip. Attach the “t” adapter to the flexible brake line and route the hard brake line coming from the front to the “t”..

  • Page 204

    203 www.Factoryfive.Com 508-291-3443 run a 60” brake line from the “t” up the ¾” tube to the front fuel tank mount tubes and over to the passenger side ¾” tube. An alternative to running it this way would be to run it across the backside of the 2”x 3” tube. Attach the passenger side flexible brake l...

  • Page 205

    204 www.Factoryfive.Com 508-291-3443 make sure that your flex lines will not interfere with anything in the suspension, wheels during travel or turning full lock to lock. Tighten the banjo bolts on the calipers 2015 irs run the brake line up the 2”x 3” tube and 1” square tube up to the flexible brak...

  • Page 206

    205 www.Factoryfive.Com 508-291-3443 there are a couple of different possibilities for flexible brake line mounts with the irs, on the angled 1” tube as shown above (just make sure to leave enough room for the t junction on the left side) or mount to the 2”x 3” tube near the shock mount as shown in ...

  • Page 207

    206 www.Factoryfive.Com 508-291-3443 banjo bolt torque specs front brake hose to caliper banjo bolt – (39nm) 29lbft rear brake caliper hose to caliper banjo bolt – (43nm) 32lbft when your system is finished being plumbed, go back and check all the fittings for tightness. Fill the system with fluid a...

  • Page 208

    207 www.Factoryfive.Com 508-291-3443 chassis wiring harness the chassis wiring harness routing and instruction are included with the harness. Trunk aluminum 1 / 8 ” drill bit, silicone, rivet gun, caulk gun, 9 / 16 ” wrench, 5 / 16 ” hex key. Mounted aluminum, packaged aluminum, secondary body faste...

  • Page 209

    208 www.Factoryfive.Com 508-291-3443 silicone and rivet in the trunk side panels. Remove the rear bolt of the passenger side gas tank strap. With the rear taillight harness tied up and secure, silicone and install the lower trunk floor. Re-install the gas tank strap and tighten..

  • Page 210

    209 www.Factoryfive.Com 508-291-3443 silicone and install the trunk inner corner pieces. Silicone and rivet the fuel tank strap patch panel from the packaged aluminum assembly..

  • Page 211

    210 www.Factoryfive.Com 508-291-3443 drill and silicone the upper trunk floor. Bend it in the middle to get it into position. Work the corners of the panel down over the roll bar mounts and seat harness tabs a little at a time on each side..

  • Page 212

    211 www.Factoryfive.Com 508-291-3443 once the panel lies flat, finish rivet it into place. The rivets along the front 2”x 3” tube should be close to the back as possible for drill and rivet gun access. Cockpit rear wall mark and drill the rear cockpit wall. Silicone the chassis and aluminum flanges ...

  • Page 213

    212 www.Factoryfive.Com 508-291-3443 battery mounting and cable drill, 1” hole saw, 3 / 16 ”, ¼”, 5 / 16 ” drill bits, rivet gun, marker, 7 / 16 ” deep socket, ratchet, ½” wrench, 3 / 16 ” hex key. Secondary body fasteners, battery mounting kit, insulated clip hardware, misc. Electrical components, ...

  • Page 214

    213 www.Factoryfive.Com 508-291-3443 position the battery with mounting bracket in the trunk for mounting. It is centered side to side with just enough room for the mounting bracket between it and the front of the trunk. Drop the j-bolts in the mounting holes and mark where they hit the trunk floor..

  • Page 215

    214 www.Factoryfive.Com 508-291-3443 drill the ¼” mounting holes in the floor. Hook the j-bolts through the floor and bolt the battery down. Hold the j-bolts with a vice grip and be careful not to over tighten and crack or distort the battery..

  • Page 216

    215 www.Factoryfive.Com 508-291-3443 remove any coating from the small circle in the trunk closer to the ground terminal of your battery. Drill through the center of the circle and put a washer down in the cut out..

  • Page 217

    216 www.Factoryfive.Com 508-291-3443 bolt the ground strap to the chassis, the battery terminal is left off for now while the rest of the system is being routed. Drill out the hole you didn’t use for the ground with a 1” hole saw..

  • Page 218

    217 www.Factoryfive.Com 508-291-3443 install one of the grommets in the hole. Route the small end of the batter cable from through the floor from the top and hook to the battery terminal..

  • Page 219

    218 www.Factoryfive.Com 508-291-3443 attach the battery positive terminal and leave enough slack to be able to remove the terminal easily. Cover the remaining positive cable that runs underneath the car with the provided conduit to protect it from the elements..

  • Page 220

    219 www.Factoryfive.Com 508-291-3443 on the right engine mount there is a 5 / 16 ” hole for the engine ground cable. Grind any coating from in and around the hole to give a good engine ground. Drivetrain install if installing a coyote engine, call or check our parts catalog online for install instru...

  • Page 221

    220 www.Factoryfive.Com 508-291-3443 trim it flush or just below the pad for the transmission mount. Engine prep engine hoist, chain, ¾”, 15 / 16 ” sockets, ratchet, extension engine, polyurethane engine/transmission mount kit the easiest method to install the drivetrain is with the engine and trans...

  • Page 222

    221 www.Factoryfive.Com 508-291-3443 unpack the engine mounts and attach to the engine. Don’t forget to attach the engine ground strap to a right side engine mount bolt. 87-95 oil filter relocator ⅞” wrench, razor knife, teflon tape, chassis grease, ⅜” hex key oil filter relocating kit, oil, oil fil...

  • Page 223

    222 www.Factoryfive.Com 508-291-3443 place the o-ring in the adapter groove. If the o-ring will not seat properly, put it in the freezer for 15 minutes and use a small amount of chassis grease to hold it in place while spinning on the adapter. Tighten ½ turn after solid resistance is felt. The outle...

  • Page 224

    223 www.Factoryfive.Com 508-291-3443 use teflon tape on the threaded barbs and thread them into the oil filter relocator. Thread the short end of the threaded nipple into the relocator..

  • Page 225

    224 www.Factoryfive.Com 508-291-3443 mark the hole locations for the oil filter relocator on the old ac bracket or on the front frame x member (preferred location). If you’re going to mount the relocate bracket on the x member. Drill the mounting holes for the relocator. Make sure to drill this befo...

  • Page 226

    225 www.Factoryfive.Com 508-291-3443 engine/transmission installation lower the engine and transmission into place. The more hands you have to help the better. Go very slowly and make sure the transmission tail-shaft is above the rear cross-member..

  • Page 227

    226 www.Factoryfive.Com 508-291-3443 install the engine mount to chassis nuts and tighten down all the engine mount hardware. Make sure the alignment pins on the mounts are in the holes on the chassis pads. Engine ground sand paper or grinder bit, ½” socket, ratchet, 3 / 16 ” hex key electrical syst...

  • Page 228

    227 www.Factoryfive.Com 508-291-3443 bolt the ground strap to the hole on the frame engine mount. Transmission mount 5 / 16 ” hex key, 9 / 16 ”, ¾” socket, ratchet, ¾” wrench, floor jack transmission mount/hardware.

  • Page 229

    228 www.Factoryfive.Com 508-291-3443 unpack the a-frame transmission mount and hardware. Jack the transmission up and mount the a-frame underneath it. Normally this mounts above the frame tabs but can be mounted underneath if extra clearance is needed..

  • Page 230

    229 www.Factoryfive.Com 508-291-3443 install the bolts that hold the transmission to the mount and tighten all the hardware on the mount and a-frame. Driveshaft 14mm wrench, thread locker driveshaft unpack the driveshaft and slip it up into the rear of the transmission. The most room to do this is u...

  • Page 231

    230 www.Factoryfive.Com 508-291-3443 solid axle the driveshaft bolts are in the box with the driveshaft and should have thread locker on them already. If thread locker is not there, put a small bead on each bolt. Fit the driveshaft snug against the yoke and install the bolts and tighten. You can put...

  • Page 232

    231 www.Factoryfive.Com 508-291-3443 2015 irs insert the driveshaft into the transmission, bolt the rear flange to the driveshaft adapter and torque the bolts to 109nm (80 ft-lb). Headers and j-pipes 7 / 16 ”, 9 / 16 ” wrenches, 7 / 16 ” socket, ratchet, extension, 5 / 16 ” hex key headers or straig...

  • Page 233

    232 www.Factoryfive.Com 508-291-3443 mount up your headers to the engine. If you are using full length headers they bolt in place with the gaskets and hardware provided. Thread locker is recommended. If you are using shorty headers or stock manifolds bolt them back on. On a small block (302 or 351) ...

  • Page 234

    233 www.Factoryfive.Com 508-291-3443 if you are using the cats or j-pipes bolt them to the headers. The shorter pipe will go on the passenger side. Fuel line to engine flat head screwdriver fuel line components, external fuel pressure regulator (if used).

  • Page 235

    234 www.Factoryfive.Com 508-291-3443 finish running your fuel system by hooking up either to your carburetor or fuel rail. Here we mounted a pressure regulator on the firewall and ran a single line over to the rail. Oil filter relocator razor knife, flathead screwdriver oil filter relocating kit, oi...

  • Page 236

    235 www.Factoryfive.Com 508-291-3443 hook the oil lines up to the oil filter relocator and the adapter on the engine. Make sure that the lines go to the correct ports or the engine will be starved for oil. The out on the engine goes to the in on the relocator and the out on the relocator goes to the...

  • Page 237

    236 www.Factoryfive.Com 508-291-3443 route the clutch cable down to the bellhousing. Using zip ties or insulated clips tie the cable safely away from the headers and the moving steering components. It can be fastened to the engine using the bracket on the cable to the front lower bolt that holds the...

  • Page 238

    237 www.Factoryfive.Com 508-291-3443 thread the cable end adjuster nut on so that the cable has no play in it. Adjust the pedal closer or further away as desired by screwing the pedal stop screw up or down. Check the full range of travel for the clutch pedal. Accelerator cable accelerator cable comp...

  • Page 239

    238 www.Factoryfive.Com 508-291-3443 cut the barrel fitting off the end of the cable. 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..

  • Page 240

    239 www.Factoryfive.Com 508-291-3443 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 of moving or hot parts as well. Check the idle screw underneath the throttle body to see if the throttle arm is hitting it....

  • Page 241

    240 www.Factoryfive.Com 508-291-3443 using a pair of wire cutters, cut the barrel fitting off the cable. 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 eng...

  • Page 242

    241 www.Factoryfive.Com 508-291-3443 thread the inner cable through the cable retaining lock nut from the accelerator cable components assembly. Tighten the accelerator cable locknut. Push the ball stud retainer onto the throttle pedal. While pulling the cable tight, push the accelerator pedal up un...

  • Page 243

    242 www.Factoryfive.Com 508-291-3443 the hole in the firewall extension can be used to pass wires through from the engine to behind the dash and we often mount the computer inside the cockpit with the wires running through here. There is a cover plate that can be drilled to a smaller hole as well..

  • Page 244

    243 www.Factoryfive.Com 508-291-3443 silicone and rivet the dash extension in position. Cooling system marker, hack saw, insulated clip hardware, drill, ¼” drill bit, 3 / 16 ” hex key, 7 / 16 ”, ½” wrenches, ruler, flathead screwdriver. Fan mounting components, stainless radiator hose kit, roadster ...

  • Page 245

    244 www.Factoryfive.Com 508-291-3443 fan mounting unpack the fan and push the four mounting brackets into the angled tab mounts. Center the fan on the radiator and mark the brackets to trim off the excess..

  • Page 246

    245 www.Factoryfive.Com 508-291-3443 remove and trim the brackets then bolt the assembly together using the hardware provided. Make sure and tighten the hardware that came pre-installed on the mounts. Radiator mounting zip tie the radiator in place on the chassis. The bottom section can just hang by...

  • Page 247

    246 www.Factoryfive.Com 508-291-3443 mark the center of the radiator and the center of the chassis and offset the radiator by ⅝”. Drill the holes to mount the radiator top flange to the two small mounting tubes on the chassis..

  • Page 248

    247 www.Factoryfive.Com 508-291-3443 mount the radiator top to the flange with the hardware provided. The bottom stays zip tied for now. Stainless radiator hoses unpack the stainless radiator hose kit and remove the hose connectors from the boxes..

  • Page 249

    248 www.Factoryfive.Com 508-291-3443 use the smaller sections of tube inside the adapters to fit them to smaller fittings on the radiator and intake..

  • Page 250

    249 www.Factoryfive.Com 508-291-3443 then fit the larger adapters over them. Upper radiator hose start at the engine and route the tube above the “x” and to the upper radiator hose location. The inline filler neck goes in the upper hose. Mark the tube where it needs to be cut so that the tube will j...

  • Page 251

    250 www.Factoryfive.Com 508-291-3443 mount the inline filler neck where it is both accessible and as high as possible. Lower radiator hose connect the lower radiator tube to the engine. Run the tube next to the 4” main rail and under the steering rack to the radiator. Route the lower tube with enoug...

  • Page 252

    251 www.Factoryfive.Com 508-291-3443 make sure that the lower hose is not hanging down. If necessary, zip tie the hose to the frame. Mark the tube where it needs to be cut so that the tube will just touch the attaching location. Remove the tube/hose assembly from the vehicle. Cut the tube using a ha...

  • Page 253

    252 www.Factoryfive.Com 508-291-3443 overflow tank unpack the overflow assembly. Bolt the mounting tabs loosely onto the tank so they can be slid around to fit..

  • Page 254

    253 www.Factoryfive.Com 508-291-3443 pick the mounting location for the tank and mark the holes. Make sure the tank is accessible and visible inside to check the level on the finished car then bolt it in place. Mount the overflow tank to the frame/aluminum. Route the overflow hose from the filler to...

  • Page 255

    254 www.Factoryfive.Com 508-291-3443 make sure you attach the hose to the tube that runs off the bottom of the tank and not the one that extends up into the tank. Put the radiator cap in place on the filler for now so it doesn’t get lost..

  • Page 256

    255 www.Factoryfive.Com 508-291-3443 if you did not use the hole in the f-panel for your hose routing then silicone and rivet the cover panel in place. For a cleaner look run the rivets you can get to from the engine bay out. There is a thermostatic fan switch provided to activate the fan. In your e...

  • Page 257

    256 www.Factoryfive.Com 508-291-3443 fan wiring wire crimp tool misc. Electrical components. Attach the cooling fan wires according to the wiring harness manual. Speedometer sending unit 11mm deep socket, ratchet, wire crimping tool speedometer sending unit components, misc. Electrical components th...

  • Page 258

    257 www.Factoryfive.Com 508-291-3443 install the gear on the end of the sender and hold it in place with the clip. Put a little oil on the o-ring and install the sender in your transmission. Use the original bolt to hold the sending unit in place..

  • Page 259

    258 www.Factoryfive.Com 508-291-3443 connect the plug and plug it into the sender. If you are running fuel injection you may also need to send this signal to the computer as well depending on your system. Emergency brake e-brake handle 5 / 32 ”, 3 / 16 ” hex keys, 7 / 16 ”, ½” wrenches, channel lock...

  • Page 260

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

  • Page 261

    260 www.Factoryfive.Com 508-291-3443 unpack the emergency brake handle components. Push a nylon bushing into one side of the fixedgear..

  • Page 262

    261 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 263

    262 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 264

    263 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 below..

  • Page 265

    264 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 266

    265 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 267

    266 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 268

    267 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 269

    268 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 270

    269 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 271

    270 www.Factoryfive.Com 508-291-3443 check the fit of the emergency brake cable end in the brake cable clevis..

  • Page 272

    271 www.Factoryfive.Com 508-291-3443 if necessary, use a drill bit and drill or a dremel tool to open up the slot slightly..

  • Page 273

    272 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. Attach the handle to the frame using the 5 / 16 ” carri...

  • Page 274

    273 www.Factoryfive.Com 508-291-3443 this picture is shown without aluminum for easier viewing. Tighten the mount bracket to fixed gear carriage bolts. Cables solid axle your e-brake cables should be from the same car as your rear brakes. 87-92 mustang cables or the ffr cables mount to the bracket u...

  • Page 275

    274 www.Factoryfive.Com 508-291-3443 for 87-92 and ffr cables route them through the upper bracket in the transmission tunnel until the sheath end clicks in place. The following picture is shown without aluminum for easier viewing. For 87-92 and ffr cables route the inner cable down under the chassi...

  • Page 276

    275 www.Factoryfive.Com 508-291-3443 solid axle route the cables back to the calipers and attach. Make sure your routing is out of the way of any moving parts and the cable has slack to move with the axle. Emergency brake cable in caliper bracket..

  • Page 277

    276 www.Factoryfive.Com 508-291-3443 handle and cable 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 278

    277 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..

  • Page 279

    278 www.Factoryfive.Com 508-291-3443 slowly pull up on the handle to set the brake pads and remove any slack from the brake cables. Release the brake and if necessary remove the ¼” clevis bolt and readjust the rod end so that the cable is tight..

  • Page 280

    279 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. Axle and fuel tank vents razor knife oem fuel tank components, insulated clip hardware.

  • Page 281

    280 www.Factoryfive.Com 508-291-3443 if using the ffr rear axle, attach the ¼” rubber fuel line to the vent tube on the rear axle or center section. Tie the top of the tube up high under the trunk allowing room for the axle to move. Attach the two foot section of ¼” rubber fuel line attach to the fu...

  • Page 282

    281 www.Factoryfive.Com 508-291-3443 aluminum panels transmission tunnel cover drill, 1 / 8 ” drill bit, silicone, caulking gun, rivet gun roadster secondary body fasteners components, packaged aluminum, mounted aluminum silicone and install the transmission tunnel top. Silicone and install the shif...

  • Page 283

    282 www.Factoryfive.Com 508-291-3443 silicone and install the tunnel plug patch panel. Driver footbox side aluminum 1 / 8 ” drill bit, drill, rivet gun, caulking gun, silicone mounted aluminum, packaged aluminum, secondary body fasteners silicone and install the drivers side footbox outer wall. The ...

  • Page 284

    283 www.Factoryfive.Com 508-291-3443 silicone and install the front patch panel. Seats 5 / 16 ” drill bit, drill, 3 / 16 ” hex key, ½” deep socket, marker seat mount hardware, seats unpack the seats and set them in the cockpit. Sit in the seats and locate them in the position you are most comfortabl...

  • Page 285

    284 www.Factoryfive.Com 508-291-3443 lift up the bottom of the cushion to reveal the seat frame. Using the rivet heads as a guide mark where the rails of the seat frame are above the seat mounting plates..

  • Page 286

    285 www.Factoryfive.Com 508-291-3443 drill the first hole for the seat mounting and install the bolt. Drill the remaining holes for mounting the seats and install the bolts. Nameplate 1 / 8 ” drill bit, rivet gun, drill.

  • Page 287

    286 www.Factoryfive.Com 508-291-3443 secondary body fasteners, certificate of origin envelope factory five racing has included a certificate of origin along with a nameplate for your kit. The serial number from the certificate of origin matches the number engraved on the 2”x 2” tube going across the...

  • Page 288

    287 www.Factoryfive.Com 508-291-3443 unpack the dash, dash cover and the gauges. Depending on which gauges you are using you may need to open up the dash holes for the tachometer and speedometer. If you need the larger holes the take a tin snip and cut through from the smaller hole to the tracing fo...

  • Page 289

    288 www.Factoryfive.Com 508-291-3443 take a pair of pliers and snap the tabs off to get the larger opening..

  • Page 290

    289 www.Factoryfive.Com 508-291-3443 the ignition switch hole also needs opened up the same way. File the hole smooth and test fit the switch. Clean the dash off with some brake cleaner or acetone and spray the front surface and the back surface of the dash pad with adhesive. (3m super 77 or super 9...

  • Page 291

    290 www.Factoryfive.Com 508-291-3443 stick the dash to the pad leaving about an inch border all around the top, the bottom will be bigger for the flange. Taping the ends of the pad helps to keep it flat. After giving the front adhesive time to set spray the bottom flange and pad and adhesive them to...

  • Page 292

    291 www.Factoryfive.Com 508-291-3443 wrap the dash pad around to the back and glue it. Use some heavy books to hold the pad in place until the adhesive has a chance to dry. If you are having trouble getting the pad to stick on the bottom of the dash you can screw the corners down using some of the t...

  • Page 293

    292 www.Factoryfive.Com 508-291-3443 using a razor knife, cut the gauge holes and switch holes out of the dash pad, cut the holes in from the aluminum about 1 / 8 ”. Do not cut out the steering shaft hole. Using the razor knife cut a “+” sign pattern into the middle of the steering shaft hole..

  • Page 294

    293 www.Factoryfive.Com 508-291-3443 with the dash lying face down on a clean tabletop, bend the edges of the dash down 1.25” in from the ends so they are at a 45° angle. Install the gauges in the dash. Wire the gauges according to the instructions provided with them and with the dash section of the...

  • Page 295

    294 www.Factoryfive.Com 508-291-3443 line the dash up with the hoop on the chassis. The corners of the dash support tube are 3 / 16 ” below the top edge of the dash. The tube will be lower as it goes to the middle. Drill for the dash mounting screws (5 evenly spread) through the dash and chassis wit...

  • Page 296

    295 www.Factoryfive.Com 508-291-3443 unpack the dash support panels from the packaged aluminum. Rivet the panels to the chassis and then use the trim screws to attach them to the bottom of the dash. Install your switches and horn button. The factory five vintage gauges have built-in indicator lights...

  • Page 297

    296 www.Factoryfive.Com 508-291-3443 mount the turn signal switch and high low beam switch as well as indicators in the dash. These can be mounted wherever you like, use a ½” drill bit for the holes on both the switches and indicator lights. Horns 14mm wrench, wire cutters, wire crimpers, 5 / 32 ” h...

  • Page 298

    297 www.Factoryfive.Com 508-291-3443 attach one horn to the included bracket using one of the 14mm lock washers and nuts included. Note the orientation of the wire connectors when tightening the bracket so that it will be correct when installed. The flat horn outlet is pointed right. Mounting bracke...

  • Page 299

    298 www.Factoryfive.Com 508-291-3443 holding the horns the connectors should be spaced so that the wires will not hit each other. Locate the chassis harness horn wires on the front chassis harness. Cut 2” off the end of the chassis harness horn ground wire and strip the end of the chassis harness gr...

  • Page 300

    299 www.Factoryfive.Com 508-291-3443 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 connector on. Cut the same 2”off the green horn power wire and strip the ends of both wires..

  • Page 301

    300 www.Factoryfive.Com 508-291-3443 locate the horns on the upper radiator down tube and drill a 3 / 16 ” mounting hole. Attach the two horns to the radiator down tubes using a supplied #14 screw. Then drill a second 3 / 16 ” hole so the horns will not rotate..

  • Page 302

    301 www.Factoryfive.Com 508-291-3443 attach the second #14 screw. 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..

  • Page 303

    302 www.Factoryfive.Com 508-291-3443 attach the chassis harness horn wires to one horn and push the jumper wires on to the other horn. Either connector on the horn will work. Steering wheel philips head screw driver, 10mm wrench, 5 / 16 ” hex key steering wheel/hardware.

  • Page 304

    303 www.Factoryfive.Com 508-291-3443 unpack the steering wheel hardware. Bolt the steering wheel to the boss. The pattern is not symmetrical so it will only line up in one direction..

  • Page 305

    304 www.Factoryfive.Com 508-291-3443 bolt the steering wheel assembly to the steering shaft. Use thread-locker on this bolt. Rollbar ½” wrench, 3 / 16 ” hex key, 5 / 16 ” drill bit, drill driver side rollbar assembly.

  • Page 306

    305 www.Factoryfive.Com 508-291-3443 unpack the rollbar and mounting hardware. Slide the rear leg of the bar down into the chassis mount..

  • Page 307

    306 www.Factoryfive.Com 508-291-3443 slide the main hoop into the chassis mounts and wiggle or tap with a soft mallet until it lines up with the rear leg. Slide the rear leg up over the mount on the hoop and make sure it comes all the way up flush. Clamp the rear leg up with a pair of vise grips. Th...

  • Page 308

    307 www.Factoryfive.Com 508-291-3443 drill a hole all the way through each of the lower mounts and rollbar main hoop. With the thick tubing and curved surface it is much easier to start small and work your way up to a 5 / 16 ” drill bit. Insert one of the bolts after drilling each hole to ensure tha...

  • Page 309

    308 www.Factoryfive.Com 508-291-3443 make sure the rear leg is tight up against the main hoop and drill the upper hole. This bolt will be visible so keep this in mind when deciding the orientation. Install the bolt loosely to keep the leg in place. Drill the remaining mount and install and tighten a...

  • Page 310

    309 www.Factoryfive.Com 508-291-3443 rolling chassis check front suspension now is a good time to 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 en...

  • Page 311

    310 www.Factoryfive.Com 508-291-3443 transmission fill the transmission with fluid and install the shifter assembly. Leave the shift handle and knob off for now..

  • Page 312

    311 www.Factoryfive.Com 508-291-3443 engine fill the engine with oil and coolant. Both these fluids should be rechecked after you have started the engine for the first time. Make sure there is some coolant in the overflow to start out, about 1 / 3 full is good..

  • Page 313

    312 www.Factoryfive.Com 508-291-3443 suspension all of the suspension and steering components that have grease fitting need to be greased. With a grease gun squeeze grease into each fitting on all the control arms, including rear lowers on a slid axle, and tie rods. Irs axle nuts torque wrench, 36mm...

  • Page 314

    313 www.Factoryfive.Com 508-291-3443 have a friend sit in the car and step on the brakes. Torque the rear axle nuts to 175 ft-lbs. Wheels install and torque your wheels. Make sure they rotate freely and do not interfere with the brake calipers, lines, or any suspension components. Rattle patrol revi...

  • Page 315

    314 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. If you need to you can temporarily bolt your side-pipes in place to keep things quieter. If you have the space...

  • Page 316

    315 www.Factoryfive.Com 508-291-3443 pivot location a small adjustment will make a large difference. Set the pedal height of the clutch with the stop and cable adjuster, usually about ½” above the brake pedal. Make sure that your feet are comfortable on the pedals and you can press them all without ...

  • Page 317

    316 www.Factoryfive.Com 508-291-3443 driver footbox aluminum rivet the remaining inner cockpit wall flange to the firewall. Silicone and install the footbox inside top panel. Leave the top flange un-riveted for now; use some clamps or tape to hold it in place..

  • Page 318

    317 www.Factoryfive.Com 508-291-3443 silicone and install the outer footbox top section. Your rolling chassis is now complete!.

  • Page 319: Body Section

    318 www.Factoryfive.Com 508-291-3443 body section chapter 4.

  • Page 320

    319 www.Factoryfive.Com 508-291-3443 the body and panel mounting are a critical part of how your car will end up looking when it is finished. Whether you are having a body shop paint your car or doing it yourself, the best results will be from fully mounting the body, all the panels and getting them...

  • Page 321

    320 www.Factoryfive.Com 508-291-3443 the rectangular adhesive backed weatherstrip runs along the top of the chassis tubes on either side of the hood opening and the top of the curved trunk hoop. The push-on weather strip goes across the top of the firewall.

  • Page 322

    321 www.Factoryfive.Com 508-291-3443 the push-on weather strip goes across the top of the trunk walls and rear floor. Mounting the body rear quick jacks ⅝” wrench, ⅝” socket, ratchet quick jack bumper components the main locating points for the body are the rear quick jack mounts; these will set the...

  • Page 323

    322 www.Factoryfive.Com 508-291-3443 find the quick jack hardware that came mounted on the chassis. The long sleeves go between the body and chassis with washers on both ends of all sleeves..

  • Page 324

    323 www.Factoryfive.Com 508-291-3443 the nut and bolt use a ⅝” wrench and socket to attach the rear quick jack bolts to the frame and body. Even with the quick jacks removed, it is still a good idea to wrap the bolts with some rags and duct-tape to save yourself from painful cuts or bruises..

  • Page 325

    324 www.Factoryfive.Com 508-291-3443 front quick jacks/front mounts ⅝” wrench, ⅝” socket, ratchet quick jack fasteners do not tighten the bolts until directed to do so. The body mounting bracket goes on the back side of the frame front mount..

  • Page 326

    325 www.Factoryfive.Com 508-291-3443 assemble the quick jack parts in the order shown, the bolts can be installed either way around depending on personal preference. Use the shipping carriage bolt through the turn signal mounting hole until the turn signals are mounted. Center the body over the fram...

  • Page 327

    326 www.Factoryfive.Com 508-291-3443 the car by lining it up with the front “x” member so that the tape measure is parallel. Make this measurement on each side of the body so that the front of the body is centered over the frame. Move the front of the body as necessary. If the body will not stay whe...

  • Page 328

    327 www.Factoryfive.Com 508-291-3443 check the outside corners of the dash tube. Make sure there is a ½” or so gap between the body and frame. Try pushing down on the body here, it should move. If the tube touches it will affect the door front corner fitment. Use an adjustable or ¾” wrench to bend t...

  • Page 329

    328 www.Factoryfive.Com 508-291-3443 the hood has been trimmed slightly oversized to allow the panel gaps to be sanded down to fit. Set the hood in place and make sure it will fit the opening in the body, if needed sand or file the edges to allow the panel to just fit with a very small gap all aroun...

  • Page 330

    329 www.Factoryfive.Com 508-291-3443 use 1 / 8 ” long rivets to attach the bumpers through the body and into the frame. Once you are happy with the alignment you can set the panel gap and radius the edges. Place a couple of heavy objects like an alternator or driveshaft on the hood so that it will n...

  • Page 331

    330 www.Factoryfive.Com 508-291-3443 sand, grind or cut the panel back so the marker line can not be seen. Remount the panel and the resulting gap should be the same around the whole panel, about 3 / 16 ”. Use paint sticks around the edge to check the gap. Repeat this gap procedure later after mount...

  • Page 332

    331 www.Factoryfive.Com 508-291-3443 hood hinge 3 / 16 ” drill bit, drill, measuring tape, rivet gun, marker, 3 / 16 ” hex key, ½” wrench hood hinge the hood hinge pivot mounts attach to the hood using rivets, the holes are predrilled in the hood liner but you may need to clean them out with a 3 / 1...

  • Page 333

    332 www.Factoryfive.Com 508-291-3443 install the ball pivots for the hood struts on the hood using 3 / 16 ” rivets. The ball points toward the inside of the car. Press the bronze bushings into the holes in the hinge arms as shown. The short hinge arms are both the same. Left side long arm shown. Rig...

  • Page 334

    333 www.Factoryfive.Com 508-291-3443 short arm with bushings pressed in. Attach the hinge arms to the arm support plate as shown on the following pages using the ⅜” shoulder bolts, wave washers, washers and nylon lock nuts. The flange of the bronze bushings should contact the arm plate. Tighten the ...

  • Page 335

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

  • Page 336

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

  • Page 337

    336 www.Factoryfive.Com 508-291-3443 right side shown attach the hinges to the chassis using the carriage bolts, these push in from the outside for easier adjustment..

  • Page 338

    337 www.Factoryfive.Com 508-291-3443 leave the bolts loose enough so that the hinge assembly can be positioned to match the hood. Set the hood in place and attach the two arms to the brackets from the underside of the body..

  • Page 339

    338 www.Factoryfive.Com 508-291-3443 if not already done, install the threaded ball studs in the hole on the long hinge arms with the ball pointed toward the outside of the car using a 5 / 16 ” locknut. Then snap the gas piston shaft onto the ball. Attach the piston body end to the ball on the hood..

  • Page 340

    339 www.Factoryfive.Com 508-291-3443 hood handles 1 / 8 ”, 7 / 64 ”, 3 / 16 ”, ⅝” drill bits, drill, measuring tape, philips head screwdriver, pliers, marker, 2.5mm hex key, file. Three lock set and fasteners measure the center of the hood liner rib along the trailing edge of the hood and mark it. M...

  • Page 341

    340 www.Factoryfive.Com 508-291-3443 drill through the hood and the liner starting with smaller bits working up to a ⅝” hole. The larger bits sometimes work better by running the drill in reverse so they do not tear the fiberglass. Remove the hood handles from the three lock set and break off the bo...

  • Page 342

    341 www.Factoryfive.Com 508-291-3443 set the handles in the holes drilled in the hood so that they are lined up squarely with the edge and mark the screw holes on the hood. Drill the holes with a 7 / 64 ” bit then screw the handles down using the screws from the set..

  • Page 343

    342 www.Factoryfive.Com 508-291-3443 shut the hood and mark the body where the hood handles line up. Open the hood and drill two 3 / 16 ” holes in the hood opening recess ¼” on either side of the centerline and ¼” back from the edge of the opening. These are for mounting the hood catch brackets..

  • Page 344

    343 www.Factoryfive.Com 508-291-3443 the latch brackets are in the handle assembly, center them on the line with the corner edge up against the inner radius of the hood opening and mark the two holes. Drill the two holes just marked with a 7 / 64 ” bit and file the edged of the bracket round with a ...

  • Page 345

    344 www.Factoryfive.Com 508-291-3443 the four remaining screws are used to hold these brackets in place. They can either be countersunk into the body or used to hold down the hood bumpers to hide them completely. Attach the cam wedge to the underside of the hood handles and adjust for tightness usin...

  • Page 346

    345 www.Factoryfive.Com 508-291-3443 hood scoop, secondary body fasteners. On the top side of the hood scoop mark a line 0.25” in from the edge of the hood scoop flange all the way around the scoop. Mark the line 0.50” back from the front edge of the scoop..

  • Page 347

    346 www.Factoryfive.Com 508-291-3443 mark the scoop every 3” along the straight sides of the scoop. At the front of the scoop, measure across the front and find the center then mark the top of the scoop..

  • Page 348

    347 www.Factoryfive.Com 508-291-3443 on the underside of the scoop, measure from the front back 19.50” and mark the scoop on both sides. At the lines marked, measure across and mark the center of the scoop..

  • Page 349

    348 www.Factoryfive.Com 508-291-3443 use a square to transfer the mark to the back edge of the scoop then mark the top side of the scoop as well. Where the scoops starts to curve measure from the last straight rivet location 2.50” back and mark the line then another 2.50”..

  • Page 350

    349 www.Factoryfive.Com 508-291-3443 this should make the rivet spacing look even and have a rivet hole in the back center. Drill 3 / 16 ” holes around the edge of the scoop..

  • Page 351

    350 www.Factoryfive.Com 508-291-3443 windshield philips head screwdriver, marker, ½” drill bit, drill, hack saw, ¾” wrench, ratchet, ¾” socket, friend. Windscreen box. The strips along the sides of the windshield that the screws go into are brass. The brass threads strip easily so take your time and...

  • Page 352

    351 www.Factoryfive.Com 508-291-3443 with the help of a friend, slide the windshield down through the slots in the body until the bottom edge is resting on the body and mark the chassis mounting holes on the arms. If the arms are too long and prevent the windshield from sitting down then pull them b...

  • Page 353

    352 www.Factoryfive.Com 508-291-3443 slide the windshield into position and bolt in place using the windshield mounting hardware. The windshield should remain bolted down while you fit the doors. Doors 3 / 16 ” hex key, marker, ⅝” socket, ratchet, air saw, orbital sander, 3 / 16 ” drill bit, drill, ...

  • Page 354

    353 www.Factoryfive.Com 508-291-3443 if you have removed them, remount the door hinges on the chassis. The square nuts sit alongside the tube so only one hex wrench is needed for adjustment..

  • Page 355

    354 www.Factoryfive.Com 508-291-3443 use a jack under the side of the car to make sure the body is up against the bottom of the frame. Leave the jack so that the body can be moved in and out when pulled. Start with the body all the way in. Position the door in the body to see where it may need to be...

  • Page 356

    355 www.Factoryfive.Com 508-291-3443 hold or tape the door in position and attach the hinge to the studs. Adjust the door with the hinge until the panel surfaces are lined up with the body. Start at the top of the door and match the curved surfaces..

  • Page 357

    356 www.Factoryfive.Com 508-291-3443 once the front of the door is good, reuse one of the #10 self-tapping screws that the body was originally mounted with to lock the location in. Screw it up into the 2”x 2” tube near the front of the door. Push or pull the back of the body to line it up with the d...

  • Page 358

    357 www.Factoryfive.Com 508-291-3443 once the body is painted and final mounted rivet the bottom lip of the body to the chassis using the long 3 / 16 ” rivets. Set the gaps on the doors as you did with the hood using a marker. Door latch ½” wrench, 1 / 8 ” drill bit, drill, philips head screwdriver,...

  • Page 359

    358 www.Factoryfive.Com 508-291-3443 remove the door latch striker from the original mounting bracket and keep only the striker and the washers. The bracket and nut will not be used. Bolt the striker onto the chassis putting enough shims on the striker to bring the base of the striker head flush wit...

  • Page 360

    359 www.Factoryfive.Com 508-291-3443 latch the door latch onto the striker and close the door. Adjust the striker if needed to fit the latch to the door cut out. You can also use the door latch spacers to help with this alignment. With the door lined up and the striker in place, mark and drill the 1...

  • Page 361

    360 www.Factoryfive.Com 508-291-3443 bolt everything together to double check fit and operation. The door latches will be tight at first but break in quickly with use. Trunk air saw, orbital sander, marker trunk trim the trunk lid edges enough so that it just fits into the opening..

  • Page 362

    361 www.Factoryfive.Com 508-291-3443 trunk hinge ½” wrench, 3 / 16 ” hex key trunk hinge components. Press the bushings into the hinge arms from either side. Use the carriage bolts and 5 / 16 ” locknuts to bolt the mounting pads to the arms leaving them just snug so they can be moved without looseni...

  • Page 363

    362 www.Factoryfive.Com 508-291-3443 hang the hinge arms on the chassis using the shoulder bolts. You do not need the nuts for just doing fitment. Screw the trunk to the mounting pads also leaving them loose enough that they will just move..

  • Page 364

    363 www.Factoryfive.Com 508-291-3443 close the trunk and wiggle it into position then open and tighten the bolts. This may take a little adjustment to get the trunk to sit down right. You can also use some of the rubber bumpers from the hood opening as a temporary means of holding the surfaces level...

  • Page 365

    364 www.Factoryfive.Com 508-291-3443 find the trunk latch and components in the 3 lock set. Screw the trunk latch to the holder with the short #14 screws lining the small square hole with the hole for the handle..

  • Page 366

    365 www.Factoryfive.Com 508-291-3443 bolt the handle to the trunk running the bolts through the trunk and the latch mount. Latch pin close the trunk and with the latch in the locked position, mark the lip of the body where the latch is located..

  • Page 367

    366 www.Factoryfive.Com 508-291-3443 use the latch sleeve on the latch to see the center height of the latch sleeve compared to the edge. Make sure the sleeve is 90 degrees to the latch. In the picture this is just above the edge but this is dependent on the gap around the trunk that you make. Use t...

  • Page 368

    367 www.Factoryfive.Com 508-291-3443 use a paint stick or what was used to set the gap of the trunk to draw a line on the body where the edge of the trunk will be. With the pin location compared to the trunk edge known and the trunk edge marked on the body along with the lowest mount point of the pi...

  • Page 369

    368 www.Factoryfive.Com 508-291-3443 drill the body location with a 3 / 16 ” drill bit..

  • Page 370

    369 www.Factoryfive.Com 508-291-3443 put the pin screw through the body and up to the frame. Use a level and a square to locate the end of the screw..

  • Page 371

    370 www.Factoryfive.Com 508-291-3443 measure the height of the screw location from the lower ¾” tube. Transfer this measurement to the backside of the plate. Do the same for the side location..

  • Page 372

    371 www.Factoryfive.Com 508-291-3443 install the long screw that holds the latch pin in place. It goes through the plastic cap then the body then the sleeve and into the chassis plate. Close the trunk and test fit the latch..

  • Page 373

    372 www.Factoryfive.Com 508-291-3443 if the latch is loose, it can be bent with channel lock pliers to snug it down..

  • Page 374

    373 www.Factoryfive.Com 508-291-3443 body stripes/centerline use the outside radius of the headlight area to measure across and find the center of the body on the front deck. Use the oil cooler hole to find the center in this area. Use the inside rearview mirror for the center near the cockpit..

  • Page 375

    374 www.Factoryfive.Com 508-291-3443 at the top front of the trunk measure across and mark the top of body area. Use the trunk latch hole for this area of the body. Use a single piece of masking tape from the front lower oil cooler area to the bottom back of the body then cut the cockpit area out, t...

  • Page 376

    375 www.Factoryfive.Com 508-291-3443 locate the template in the appendix and only cut out around the outside diameter of the circle. Tape the circle in the gas cap recess of the body. Use a 3½” hole saw for the center opening. If you do not have a hole saw this size, you can cut the center circle ou...

  • Page 377

    376 www.Factoryfive.Com 508-291-3443 locate the cap in the hole so that when open the cap will not hit the body and you will have access with a gas station filler handle. Use an ⅛” drill bit through the flange holes to mark all of the outer screw holes on the body..

  • Page 378

    377 www.Factoryfive.Com 508-291-3443 remove the cap and finish drilling the 1 / 8 ” holes. For one of the holes on the inside of the body use a 7 / 32 ” bit drill for the grounding strap bolt..

  • Page 379

    378 www.Factoryfive.Com 508-291-3443 tail light drill, 7 / 32 ” drill bit, 1¼” hole saw, file, scissors. Tail light template, red rear light use a 7 / 32 ” bit to drill the two outer holes for the taillight studs then cut out the center using a 1¼” hole saw. There are marks on the body that locate t...

  • Page 380

    379 www.Factoryfive.Com 508-291-3443 test fit the lights and file the holes to fit if needed. Turn signal drill, 7 / 32 ” drill bit, 1¼” hole saw, marker. Turn signal template, amber front turn signal lights.

  • Page 381

    380 www.Factoryfive.Com 508-291-3443 remove the gasket from the turn signal box and use it to center and trace the mounting holes and large center hole for the turn signal. Drill the outer holes with a 7 / 32 ” drill bit and the inner with a 1¼” hole saw..

  • Page 382

    381 www.Factoryfive.Com 508-291-3443 test fit a light and adjust if needed. License plate light drill, ¼”, ⅜” drill bits, scissors, masking tape, marker, ruler license plate light template, license plate light and bracket. This kit is only a collection of parts designed for use primarily as a race c...

  • Page 383

    382 www.Factoryfive.Com 508-291-3443 use a ruler to measure and mark the ends and the middle of the light area. Mark the top center of the light area..

  • Page 384

    383 www.Factoryfive.Com 508-291-3443 align and tape the drill template in place. Remove the license plate light cover and use it to double check the template location..

  • Page 385

    384 www.Factoryfive.Com 508-291-3443 drill the two mounting holes and the wire hole only. Push the light into the trunk and drill through the license plate mounting holes with a 3 / 16 ” drill bit..

  • Page 386

    385 www.Factoryfive.Com 508-291-3443 side exhaust drill, 2½” hole saw, air saw or jig saw. Side exhaust template the pattern for the standard exhaust cut out is pre traced on the body. Using a 2½” hole saw cut the upper two corners of the pattern out..

  • Page 387

    386 www.Factoryfive.Com 508-291-3443 using a jig saw cut the remaining straight sections and radius on the lower rear corner. Headlights drill, 1 / 8 ”, ¼”, 7 / 16 ” drill bit, razor knife, masking tape, air saw or jig saw, level. Headlight template, headlight components,.

  • Page 388

    387 www.Factoryfive.Com 508-291-3443 cut out the headlight templates from the back of the manual on the outermost diameter and tape them in the center of the fender with the line level with the ground. Cut the center of the template out and trace the inner circle with a marker..

  • Page 389

    388 www.Factoryfive.Com 508-291-3443 drill the two smaller corner holes with a ¼” drill bit to mark their location. Follow this with a 7 / 16 ” drill bit. Using a jig saw, cut the inner hole out of the body, use a larger drill bit to make a hole to start your cut..

  • Page 390

    389 www.Factoryfive.Com 508-291-3443 test fit the light bucket and rubber gasket making sure that they sit flat and the bucket is centered on the fender. Mark and drill the four mounting screws for the headlight bucket using a 1 / 8 ” drill bit. Side louver drill, 1¼” hole saw, jig saw or air saw, m...

  • Page 391

    390 www.Factoryfive.Com 508-291-3443 use the template and measurements in the picture below to locate the template on the body. Use a 1¼” hole saw to cut the corners on the traced opening for the side louver. Connect the flush surfaces of the holes with a jig saw..

  • Page 392

    391 www.Factoryfive.Com 508-291-3443 hood drill, 3 / 16 ”, 3 / 8 ” drill bit, marker, ruler, tape measure, jig saw or air saw, rivet gun. Hood, secondary body fasteners. With the hood marked for its centerline, transfer this to the underside with another piece of tape..

  • Page 393

    392 www.Factoryfive.Com 508-291-3443 from the front edge of the hood measure back 19 inches and mark the underside of the hood. Place the hood scoop on the underside of the hood then use a square to locate the scoop left to right and the front marks to locate it to forward/backward..

  • Page 394

    393 www.Factoryfive.Com 508-291-3443 mark around the edge of the hood scoop.

  • Page 395

    394 www.Factoryfive.Com 508-291-3443 mark 1 inch in from the sides..

  • Page 396

    395 www.Factoryfive.Com 508-291-3443 use the hood scoop to mark 1 inch in for the curved end..

  • Page 397

    396 www.Factoryfive.Com 508-291-3443 mark the hood 2 inches back from the 19” front mark. Use a ruler to connect the two sides at the 2” mark..

  • Page 398

    397 www.Factoryfive.Com 508-291-3443 mark the inner line to make sure the wrong line is not cut. Drill ¼ inch holes at the front corners of the area marked.

  • Page 399

    398 www.Factoryfive.Com 508-291-3443 cut the opening in the hood using a jig saw or air saw. On the top side of the hood measure back from the front and mark the hood at 19”..

  • Page 400

    399 www.Factoryfive.Com 508-291-3443 locate the scoop using the straight edge and two marks..

  • Page 401

    400 www.Factoryfive.Com 508-291-3443 drill two of the rivet holes on opposite sides of the scoop and the back center rivet hole using an 1 / 8 ” drill bit. After drilling each hole place a rivet in the hole so that the scoop does not move. Drill out the remaining rivet holes putting a rivet in each ...

  • Page 402

    401 www.Factoryfive.Com 508-291-3443 separate the two pieces for painting. Roll bar drill, 1¾” hole saw, air saw or jig saw, file 1.50” driver side rollbar..

  • Page 403

    402 www.Factoryfive.Com 508-291-3443 the roll bar holes are marked on the body and need to be cut out using a 1¾” holes saw. The front two holes are cut centering the saw in the marked circle and drilling vertically to match the angle the bar comes through the body. To cut the rear roll bar leg, mak...

  • Page 404

    403 www.Factoryfive.Com 508-291-3443 the rear of the hole is then finished using the whole saw vertically. Trim the remaining flash on the opening with a file or jig saw..

  • Page 405

    404 www.Factoryfive.Com 508-291-3443 put the rear rollbar leg through the body and onto the frame. If using rollbar grommets, put the rear ring and grommet on as well. If using rollbar grommets, put the front rings and grommets onto the rollbar hoop then put the hoop through the body and on to the f...

  • Page 406

    405 www.Factoryfive.Com 508-291-3443 if necessary, use a plastic mallet to seat the rollbar hoop down and make sure the rear leg goes all the way up onto the hoop. Rollbar drilling 1 / 8 ”, 3 / 16 ”, 5 / 16 ” drill bits, drill..

  • Page 407

    406 www.Factoryfive.Com 508-291-3443 step drill the top of the rear leg first using an 1 / 8 ” bit followed by a 3 / 16 ” then a 5 / 16 ” bit. Insert the bolt through the top rollbar hole..

  • Page 408

    407 www.Factoryfive.Com 508-291-3443 repeat the step drilling through the rollbar for both front lower mounts. After drilling each hole, put the bolt in the hole so the rollbar stays in the correct location. Drill the rear leg lower hole last making sure to drill through the frame mount..

  • Page 409

    408 www.Factoryfive.Com 508-291-3443 optional rollbar grommets 1 / 8 ” drill bit, drill locate the rear grommet so that it sits flat then drill the holes using an 1 / 8 ” drill bit..

  • Page 410

    409 www.Factoryfive.Com 508-291-3443 locate and drill the front grommet holes. Remove the rollbar and drill any of the holes that were hard to reach.

  • Page 411

    410 www.Factoryfive.Com 508-291-3443 final prep sand paper all of the exterior body accessories, windshield and side exhaust must be mounted to the car to obtain the correct body location in order to create the correct gaps and opening sizes on the car before it is painted. Refer to appendix a for a...

  • Page 412

    411 www.Factoryfive.Com 508-291-3443 the curled under side body edges are not as visible but just taking a little time here to get the lines straight and a small radius makes for a much nicer finish as well. The headlight, taillight, fuel cap, turn signal, quick jack, and trunk openings all are cove...

  • Page 413

    412 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. The body comes out of the mold with a wax release compound and a thorough cleaning with a wax remover is t...

  • Page 414: Final Assembly

    413 www.Factoryfive.Com 508-291-3443 final assembly chapter 5.

  • Page 415

    414 www.Factoryfive.Com 508-291-3443 radiator aluminum drill, ¼” nut driver, ⅛”, 3 / 16 ” drill bits, rivet tool, floor jack, marker, ruler, silicone, caulk gun. Secondary body fasteners, engine bay aluminum. Use care when handling aluminum, the edges are sharp and can cut you. The radiator and its ...

  • Page 416

    415 www.Factoryfive.Com 508-291-3443 pass the radiator floor piece through the nose. Position the radiator floor aluminum so that it goes under the body lip and goes across to the bottom of the radiator. Clamp the floor piece to the nose..

  • Page 417

    416 www.Factoryfive.Com 508-291-3443 attach the radiator floor piece to the bottom of the radiator with a couple of self-tapping screws on the marks or use a couple of clamps..

  • Page 418

    417 www.Factoryfive.Com 508-291-3443 drill, silicone and rivet the radiator floor aluminum to the bottom radiator lip. Silicone and rivet the aluminum to the nose lip using three 3 / 16 ” rivets..

  • Page 419

    418 www.Factoryfive.Com 508-291-3443 pass the radiator sidepieces through the nose and put them on their respective sides. Trimming aluminum may be necessary if you use the press-on rubber bulb seal weather-stripping. Line up the edge of the radiator fins with the edge of the side aluminum and attac...

  • Page 420

    419 www.Factoryfive.Com 508-291-3443 from the backside of the panel, mark the location of the ¾” tube. If using the press on bulb weatherstrip, make sure there is ⅜”-½” of gap between the edge of the panel and the body..

  • Page 421

    420 www.Factoryfive.Com 508-291-3443 remove the side panel then measure, mark, drill rivet locations where the ¾” tube is located and press on the bulb weatherstrip..

  • Page 422

    421 www.Factoryfive.Com 508-291-3443 reinsert the side panel then silicone and rivet the panel to the ¾” tube and the radiator floor aluminum. Repeat this procedure for the driver side panel..

  • Page 423

    422 www.Factoryfive.Com 508-291-3443 carpet razor knife, silicone, caulking gun, spray glue, brake cleaner or acetone. Interior trim/carpet the adhesive used to hold the carpet down is the same as we used on the dash pad. 3m ® super77™ or super90™ work best. Wipe down the bare aluminum with acetone ...

  • Page 424

    423 www.Factoryfive.Com 508-291-3443 double check the aluminum edges and corners for any areas that look like they are not sealed. Run a small bead of silicone in these corners, seams and around the slots where the seat harness mounts poke through. Start with the large rear cockpit wall of carpet. P...

  • Page 425

    424 www.Factoryfive.Com 508-291-3443 the cockpit rear corners go on next. Be very careful spraying the adhesive once some carpet is mounted. Guard the carpet with masking tape or cardboard..

  • Page 426

    425 www.Factoryfive.Com 508-291-3443 test fit the rear and main tunnel covers. While you are fitting cut the handle opening for the e-brake and shifter. Glues down the tunnel top..

  • Page 427

    426 www.Factoryfive.Com 508-291-3443 the tunnel rear section is slightly oversized to make sure it can cover small variances in the way the other pieces lay down. Trim it for a perfect fit then glue it in place. Fit and glue the passenger outside footbox wall carpet section. The carpet tucks in behi...

  • Page 428

    427 www.Factoryfive.Com 508-291-3443 fit and glue the driver’s side footbox outer carpet section. This piece also tucks behind the footbox tubing. Fit and glue the tunnel/firewall section of carpet..

  • Page 429

    428 www.Factoryfive.Com 508-291-3443 fit and glue the lower floor sections. Fit and glue the under door sections..

  • Page 430

    429 www.Factoryfive.Com 508-291-3443 the floors are the last pieces to go in. They may also need a slight trim for the best fit. Glue them down and vacuum the carpet prior to the seats going in. Seats harness lap belt ¾” wrench, ¾” socket, ½” drill bit, drill, ratchet seat harness/fasteners.

  • Page 431

    430 www.Factoryfive.Com 508-291-3443 unpack the seat harnesses and hardware. Drill through the inner lap belt mount into the tunnel with a ½ in. Bit..

  • Page 432

    431 www.Factoryfive.Com 508-291-3443 bolt the lap harness in position with the inner most nut inside the transmission tunnel. Emergency brake boot 1 / 8 ” drill bit, drill, philips head screwdriver interior trim/carpet.

  • Page 433

    432 www.Factoryfive.Com 508-291-3443 unpack the e-brake boot and a few of trim screws. Fit the boot over the handle and check the handle actuation. When you are in a position where the boot clears the handle movement drill through the material into the tunnel and screw it into place..

  • Page 434

    433 www.Factoryfive.Com 508-291-3443 seat final install drill back up through your seat mounting holes to put holes through the carpet and re-mount the seats. Seat harness shoulder belts razor knife, ¾” wrench, ¾” socket, ½” drill bit, drill, ratchet seat harness/fasteners, misc. Electrical componen...

  • Page 435

    434 www.Factoryfive.Com 508-291-3443 use some of the serrated grommeting from the electrical assembly to cover the edge where the harness passes through. Cut the carpet with a single slit to allow the harness to pass through..

  • Page 436

    435 www.Factoryfive.Com 508-291-3443 remove the mounting tab and slider from the harness. Slide the harness through the rear wall from the front. The shoulder harnesses are side specific so make sure you have the sides correct..

  • Page 437

    436 www.Factoryfive.Com 508-291-3443 replace the slider and mounting tab and bolt the tab to the chassis. Adjust the harnesses to where they fit you comfortably..

  • Page 438

    437 www.Factoryfive.Com 508-291-3443 shifter handle and boot ½” wrench, 1 / 8 ” drill bit, drill, philips head screwdriver, marker, thread lock shifter handle components unpack the shift handle and bolt it to the transmission. These bolts have a tendency to rattle loose so use a little thread locker...

  • Page 439

    438 www.Factoryfive.Com 508-291-3443 push the boot and trim rind down over the handle so it sits flush on the tunnel. Using a silver marker or white paint marker, mark your screw holes on the tunnel..

  • Page 440

    439 www.Factoryfive.Com 508-291-3443 remove the boot and drill 1 / 8 ” holes in the spots you marked. Re-install the boot and screw down to the tunnel with the countersunk screws. A small screwdriver can help to locate the holes..

  • Page 441

    440 www.Factoryfive.Com 508-291-3443 screw the two piece knob onto the shift handle and tighten so the shift pattern is in the correct orientation. Headlights philips head screwdriver headlight components.

  • Page 442

    441 www.Factoryfive.Com 508-291-3443 unpack the headlight mounting assembly. Headlight fasteners. 13419 13415 13418 13420 13416.

  • Page 443

    442 www.Factoryfive.Com 508-291-3443 screw the adjuster screws about halfway into the buckets. Push the grommet into the side of the bucket..

  • Page 444

    443 www.Factoryfive.Com 508-291-3443 run the light plug harness through from the inside line up the headlight with the bucket to get the proper orientation. The bottom of the bucket is the only screw boss that comes in from the side and the writing on the headlight should be right side up..

  • Page 445

    444 www.Factoryfive.Com 508-291-3443 screw the mounting flange onto the light with the 3 small tabs and small screws. The tabs are bent to fit around the bosses on the light. Put the gasket on the bucket with the adjuster bosses poking through the 2 larger holes. Screw the bucket to the body using t...

  • Page 446

    445 www.Factoryfive.Com 508-291-3443 plug the light into the connector and mount the bulb to the bucket. The slotted parts of the mounting flange go onto the adjusting screws between the screw head and flange..

  • Page 447

    446 www.Factoryfive.Com 508-291-3443 push the spring clip onto the boss near the bottom of the bucket. Mount the trim ring hooking it over the bucket on the top and screwing it into the bottom using the countersunk screw. Turn signals 5 / 16 ” deep socket, ratchet amber front turn signal lights.

  • Page 448

    447 www.Factoryfive.Com 508-291-3443 mount the turn signals to the body being careful not to over tighten the locknuts. Tail lights 5 / 16 ” deep socket, ratchet red rear lights.

  • Page 449

    448 www.Factoryfive.Com 508-291-3443 mount the taillights, also being careful with the mounting hardware. Gas cap philips head screwdriver aston lemans cap.

  • Page 450

    449 www.Factoryfive.Com 508-291-3443 unpack the fuel cap and mounting hardware. Put the gasket on the bottom surface of the cap..

  • Page 451

    450 www.Factoryfive.Com 508-291-3443 set the cap on the body and screw in using 5 of the countersunk screws. Leave the inside most forward hole open. The one remaining cap fastener is a longer screw and nut used for the ground strap, screw it in from the top then put the ground strap washer and nut ...

  • Page 452

    451 www.Factoryfive.Com 508-291-3443 side louvers silicone, caulking gun, duct tape side louvers unpack the side louvers. Holding the top and bottom flanges, bend the fins in so they are roughly at a 45° angle..

  • Page 453

    452 www.Factoryfive.Com 508-291-3443 hold them up to the body to see how they fit. They are designed to allow air to exit the engine bay so the flanges point from the rear edge in. Apply silicone down the top and bottom flange on the side facing the body..

  • Page 454

    453 www.Factoryfive.Com 508-291-3443 line up the louvers and tape them in place to hold them until the silicone dries. Weatherstripping razor knife, tin snips secondary body fasteners.

  • Page 455

    454 www.Factoryfive.Com 508-291-3443 if you haven’t already run the bulb seal up the sides and rear of the trunk and bolt the trunk hinges back in place and tighten. Cut out a section of the c channel where the hoop comes across to allow one piece to run the whole way..

  • Page 456

    455 www.Factoryfive.Com 508-291-3443 if you removed any of the other weatherstrip on the firewall or hood support tubes replace it now. When you are ready to mount the body, unpack the expanding foam and run a small section up the outside of each footbox just forward of the door hinge..

  • Page 457

    456 www.Factoryfive.Com 508-291-3443 final body mounting fit the body back on the chassis. Be very careful with the sides and slowly work it down into position. Pull the sides out around the chassis and make sure the body covers the rear cockpit wall and top of he dash without pulling the material o...

  • Page 458

    457 www.Factoryfive.Com 508-291-3443 re-mount the nose with the front quick jacks. Hood mounting rivet the scoop back in position on the hood..

  • Page 459

    458 www.Factoryfive.Com 508-291-3443 re-install the hood latch plates and replace the bumpers you used before on the body to line up the hood. Re-install the hood and latches. Rollbar mounting a popular option are the roll bar grommets. If installing them, do it now..

  • Page 460

    459 www.Factoryfive.Com 508-291-3443 re-mount the roll bar through the body. Make sure that the rear leg is in the correct orientation so that your holes will line up. Door and latch mount reattach the doors and latches..

  • Page 461

    460 www.Factoryfive.Com 508-291-3443 once you are happy with the door fit install the covers on the door latches. Windshield mounting position the windshield trim plates with gaskets on the body so that the notch faces the inside front corner..

  • Page 462

    461 www.Factoryfive.Com 508-291-3443 re-mount the windshield. Fuel filler neck razor knife, ⅜” socket, ratchet, 3 / 16 ” drill bit, drill aston lemans cap components.

  • Page 463

    462 www.Factoryfive.Com 508-291-3443 ground the fuel filler strap to the chassis using the screw that came in the cap hardware. This wire prevents any static charge build-up and must be used. Unpack the fuel filler neck hose and cut a 5” long section out of one end..

  • Page 464

    463 www.Factoryfive.Com 508-291-3443 install the hose between the filler neck and gas cap with the clamps that came in the cap hardware. Screw the plastic gas cap into the aston lemans style cap. Fuel tank access covers 1 / 8 ” drill bit, drill, rivet gun, silicone, caulking gun.

  • Page 465

    464 www.Factoryfive.Com 508-291-3443 secondary body fasteners, packaged aluminum silicone and install the patch panels in the trunk that cover the fuel sender and pickup access holes. Final trunk mounting tin snips, 3 / 16 ” hex key secondary body fasteners.

  • Page 466

    465 www.Factoryfive.Com 508-291-3443 push the side mount weatherstrip on the trunk opening starting at the bottom next to the latch pin hole and working all the way around just leaving a small gap for the head of the latch pin bolt. Re-mount the license plate light and trunk handle..

  • Page 467

    466 www.Factoryfive.Com 508-291-3443 re-mount the trunk to the hinges and re install the latch pin. Interior rearview mirror philips head screwdriver, drill, 1 / 16 ”, 1 / 8 ”, 3 / 16 ” drill bits, marker, measuring tape rearview mirrors/fasteners use a tape measure to find the center of the body by...

  • Page 468

    467 www.Factoryfive.Com 508-291-3443 use a tape measure to measure in from the body lip to roughly the center of the dash tube. On top of the boy measure in and mark the body for the center tube location..

  • Page 469

    468 www.Factoryfive.Com 508-291-3443 line up the rearview mirror with the center mark and mark the holes in the body. Use a 1 / 16 ” drill bit and slowly (so the bit doesn’t walk off the tube) drill through the body into the tube at the mirror hole locations. Follow this with a 1 / 8 ” drill bit int...

  • Page 470

    469 www.Factoryfive.Com 508-291-3443 put the plastic spacers between the dash tube and the body so the screws can go through them. Put the mirror screws through the mirror, body and spacers and screw them into the dash tube..

  • Page 471

    470 www.Factoryfive.Com 508-291-3443 side mirror philips head screwdriver, drill, 3 / 32 ”, 3 / 16 ” drill bits, marker, ⅜” wrench. Rearview mirrors/fasteners. Only a driver side mirror is included with the kit. A passenger side one is available if desired. Unpack the side mirror assembly..

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    471 www.Factoryfive.Com 508-291-3443 disassemble the mirror, removing the large base from the stand. The large base is replaced by the smaller insert and gasket..

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    472 www.Factoryfive.Com 508-291-3443 temporarily bolt the mirror back together with the small insert. Sit in the seat to find a good location you can see it from and see clearly over the rear fender..

  • Page 474

    473 www.Factoryfive.Com 508-291-3443 mark the location and use the gasket to locate and drill the mounting holes. Disassemble the mirror and bolt the mounting insert with mounting bolt and the gasket to the body..

  • Page 475

    474 www.Factoryfive.Com 508-291-3443 slide the stand-off and upper gasket down the bolt and onto the mounting bracket. Bolt the main body of the mirror to the mounting stand-off..

  • Page 476

    475 www.Factoryfive.Com 508-291-3443 screw the mirror into the body and adjust it before tightening. Light wiring wire strippers, wire crimpers, chassis harness instructions headlight components, amber front turn signal lights, rear lights, license plate light, electrical system completion component...

  • Page 477

    476 www.Factoryfive.Com 508-291-3443 wire in the headlights to the chassis harness. On the headlight, there are three wires, black is ground, white is high beam and the red is low beam. Wire the turn signals up to the chassis harness. On the light, the red wire is the dim light and the green wire is...

  • Page 478

    477 www.Factoryfive.Com 508-291-3443 unpack the door check-straps. Rivet the check-strap to the door hinge using a 3 / 16 ” rivet. Open a door wide but not enough so that the door hits the body. The straps will stretch slightly over time so allow enough room for this by closing the door slightly fro...

  • Page 479

    478 www.Factoryfive.Com 508-291-3443 while holding the door open, pull the check strap tight and mark the location of the mount holes on the inside face of the 2”x 2” tube. Drill 3 / 16 ” holes at the marked locations and rivet the mount to the chassis..

  • Page 480

    479 www.Factoryfive.Com 508-291-3443 under door aluminum drill, 1 / 8 ” drill bit, rivet tool, silicone, caulking gun, spray glue, tin snips. Packaged aluminum, interior trim/carpet, secondary body fasteners unpack the under door aluminum panels. They are shaped to fit around the bottom of the door ...

  • Page 481

    480 www.Factoryfive.Com 508-291-3443 test fit and then glue in the remaining carpet sections under the doors. Cut a section of the large c channel weatherstrip to fit from the bottom of the door hinge to the door latch and push it in place over the body, aluminum and carpet to finish the edges off. ...

  • Page 482

    481 www.Factoryfive.Com 508-291-3443 steering wheel/hardware, factory five badge unwrap the steering wheel center section and push it into the steering wheel and boss, a little wd40 on the o- ring helps if it is tight. Peel the backing off the badge and stick it in the center section making sure you...

  • Page 483

    482 www.Factoryfive.Com 508-291-3443 with the steering wheel in the position that is most comfortable for you tighten the set screws on the collar of the upper steering bearing. Side exhaust 3 / 16 ”, 5 / 16 ” hex key, ⅜”, ½”, 9 / 16 ” socket, ratchet, 9 / 16 ” wrench, drill, 3 / 16 ”, 5 / 16 ” dril...

  • Page 484

    483 www.Factoryfive.Com 508-291-3443 unpack the hardware for mounting the side exhaust. Bolt the mounting bracket to the pipe on the forward side of the bracket..

  • Page 485

    484 www.Factoryfive.Com 508-291-3443 bolt the pipe and gasket to the header or j-pipe flange with using the shorter ⅜” bolts and mechanical locknuts. Drill a 3 / 16 ” hole in the 2”x 2” outrigger tube directly above the middle hole in the mounting bracket. You want this hole as high as you can get i...

  • Page 486

    485 www.Factoryfive.Com 508-291-3443 screw the rubber hanger onto the chassis with the sheet metal mounting screw using one of the washers between the rubber and the head of the screw. Bolt the bottom section of the hanger to the side exhaust mounting bracket using the middle length 5 / 16 ” button ...

  • Page 487

    486 www.Factoryfive.Com 508-291-3443 using the inner hole of the bracket as a guide, drill the 2”x 2” outrigger all the way through both of the tube walls and into the footbox area with a 5 / 16 ” bit. Insert the rubber standoff between the bracket and outrigger and put the nut on finger tight then ...

  • Page 488

    487 www.Factoryfive.Com 508-291-3443 tighten the whole assembly together. Aluminum splash guards 1 / 8 ”, 3 / 16 ” drill bit, drill, rivet gun, silicone, caulking gun, ¾” socket, ratchet, extension, marker secondary body fasteners, packaged aluminum, front wheel and tire.

  • Page 489

    488 www.Factoryfive.Com 508-291-3443 front wheel put some of the press-on bulb seal around the outside edge of the aluminum front splash guards (they look like large elephant ears)where they will contact the body. Hold the splashguards up against the rear bent lip of the engine bay “f” aluminum. Ove...

  • Page 490

    489 www.Factoryfive.Com 508-291-3443 fit the splash guards in position. If needed, trim them to fit around the outside edge, the weatherstrip will cover the trimming. Put a wheel and tire on the car and check for aluminum clearance. If necessary push the aluminum in and mark the inside of the body a...

  • Page 491

    490 www.Factoryfive.Com 508-291-3443 silicone and rivet the panels in place down the length of the flange. Use one of the 3 / 16 ” rivets to attach to the bottom of the fender just forward of the exhaust cut-out..

  • Page 492

    491 www.Factoryfive.Com 508-291-3443 rear wheel push a piece of the bulb seal weather stripping around both rear splash guards where they will contact the body. Fit the panels in place and trim the outside perimeter if needed. The small tab on the bottom faces towards the rear of the car and is on t...

  • Page 493

    492 www.Factoryfive.Com 508-291-3443 silicone and rivet the panels in place. Bend the lower tab by hand to fit up flush with the body..

  • Page 494

    493 www.Factoryfive.Com 508-291-3443 use a long 1 / 8 ” rivet as low as possible to attach the tab to the lower fender. Finishing touches review the race car checklist in the appendix..

  • Page 495

    494 www.Factoryfive.Com 508-291-3443 headlight alignment masking tape, marker, tape measure make sure that the car is at the correct ride height before the alignment procedure is done. Ride height should be 4½” at the front and 4½” at the back measured to the bottom of the 4” round tube with the nor...

  • Page 496

    495 www.Factoryfive.Com 508-291-3443 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 distance of measurement b from the vehicle ce...

  • Page 497

    496 www.Factoryfive.Com 508-291-3443 total toe: 1 / 16 ” for a car using power steering car use the following specifications: caster: 7 camber: -0.5 total toe: 1 / 16 ” 2015 irs only camber: -0.5 to -0.75° total toe: 1/8” toe in adjusting the upper control arm use the diagram below for reference. Sl...

  • Page 498

    497 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. Optional parts check out www.Factoryfiveparts.Com for the latest op...

  • Page 499: Technical Support

    498 www.Factoryfive.Com 508-291-3443 performance reference material and technical support chapter 6.

  • Page 500

    499 www.Factoryfive.Com 508-291-3443 maintenance check the items on the race car check sheet in the appendix on a yearly basis or before track days depending on how hard the car is driven. Wheels only 7”-9” wheels are recommended for the front. If using a wheel wider than 7”, ffr front lower control...

  • Page 501

    500 www.Factoryfive.Com 508-291-3443 17”x 9” and 17”x 10.5” fr style wheels. For a more vintage look, take a look at our halibrand style wheels. Our online parts catalog: www.Factoryfiveparts.Com has more views of these wheels on cars. Left: 15” ffr halibrand style. Right 17” ffr halibrand style 199...

  • Page 502

    501 www.Factoryfive.Com 508-291-3443 1999-2003 rear end because of the width of this rear end, custom wheels are needed if 10” or wider wheels are wanted. Use two (2) 9” wide, 5.95” backspace wheels in the front. See the table above for different width wheel backspacing. Performance modifications th...

  • Page 503

    502 www.Factoryfive.Com 508-291-3443 efi engines there are three things an engine needs; air, fuel and spark. If you allow more of each of these into the engine, it will make more power. Throttle body stock 87-93 mustang size: 58mm a 65mm throttle body work well up to 350hp. Ford racing, bbk, jegs, ...

  • Page 504

    503 www.Factoryfive.Com 508-291-3443 we’ve found that the mustang factory headers work well for the stock engine. If you want to go to an aftermarket set, the 1⅝” mac shorty unequal length headers or ford racing 1⅝” unequal length headers fit as bolt on parts. They will reward you with an approximat...

  • Page 505

    504 www.Factoryfive.Com 508-291-3443 below has been selected to optimize the capabilities of the system. If an attempt is made to utilize some of the specified components, but not all of them in correct combination, then braking abilities may not be satisfactory. Some of the setups may not clear som...

  • Page 506

    505 www.Factoryfive.Com 508-291-3443 helpful reference material must reads www.Thefactoryfiveforum.Com the largest discussion forum for factory five racing kits. Also has many vendor links. Helpful 5.0l ford dyno tests. By richard holdener. Www.Cartechbooks.Com building 4.6/5.4l ford horsepower. By ...

  • Page 507

    506 www.Factoryfive.Com 508-291-3443 if you are considering buying a completed vehicle from a third party (we do not and will not perform any vehicle assembly work for customers), keep the following in mind: factory five racing does not build or sell completed or partially completed vehicles. We are...

  • Page 508: Appendix A – Templates

    507 www.Factoryfive.Com 508-291-3443 appendix a – templates.

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

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

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

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

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

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

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

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

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

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

  • Page 519

    518 www.Factoryfive.Com 508-291-3443 appendix b – race car check sheet.

  • Page 520

    519 www.Factoryfive.Com 508-291-3443 car_______________________________________ date___________ steering steering wheel tight ___ universal joint set screws tight ___ rack mount bolts tight ___ tie rod ends tight ___ tie rod to spindle bolts tight ___ steering free lock to lock ___ front suspension ...

  • Page 521

    520 www.Factoryfive.Com 508-291-3443 battery mount and connections secure ___ brake lights functioning ___ all wires free and clear of moving or hot parts ___ rear suspension ride height ___ shock mounting bolts tight ___ spring collars tight/taped ___ wheel bearings tight (irs) ___ tire pressure se...

  • Page 522

    521 www.Factoryfive.Com 508-291-3443 appendix c – torque specifications general bolt torque specifications* 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 -18 100 ⅝ -11 100 ⅝ -14...

  • Page 523

    522 www.Factoryfive.Com 508-291-3443 appendix d – fluid specifications engine oil type capacity 302 10w-30 5.0 qts. 4.6l 5w-30 8.0 qts w/ffr pan transmission oil type t-5 t-45 3650 tko t-56 mercon/dexron iii trans. Fluid 2.8 qts. 3.25 qts. 4.0 qts. 2.64 qts. 4.0 qts 8.8 solid rear axle oil type capa...