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**************************************************************** Roadster Build BlogExciting New ProjectPosted on February 24, 2008 ------------------------------------------------------------ S & H Motors will soon be building our next project. We’ve acquired a Factory Five MK III roadster 5.0 HO, and are currently prepping the donor car. We will be posting a (mostly daily) diary of this build so stop back often!
John
Phase 1: Donor CarPosted on February 28, 2008 ------------------------------------------------------------ Well, so far we’ve spent a lot of time cleaning and restoring many of the parts — power steering rack, brackets, wiring, front spindles, etc. After cleaning and painting the 8.8 four link rear axle, we installed the SSB rear disc brake kit and installed a Roush rear support cover.
What started out as a 5.0L HO Mustang engine with 224 hp will now be a 5.8L 400+ hp engine. The engine is being built by Jeff Guyette of Messena and will be delivered this Sunday. Jeff’s been building race car engines for about 20 years and comes highly recommended. It will also come with new engine roller lifters, roller rocker arms, stroker kit, aluminum heads and a Moroso oil pan.
The donor car is 1988 Mustang GT that we bought on eBay and has a T5 five-speed manual transmission.
Minor SetbackPosted on March 5, 2008 ------------------------------------------------------------ We were supposed receive the engine this past Sunday, but Jeff ran into a slight problem. The roller rocker arms are taller than the standard arms so the rocker cover has to have special spacers to raise the cover up. We’re hoping to have the engine delivered this coming Sunday.
As soon as we install the transmission and bell housing on the engine, we’ll post a picture or two.
Stay tuned!
Good News!Posted on March 5, 2008 ------------------------------------------------------------ We heard yesterday that the roadster kit will be shipped around March 22. The car is shipped with the body mounted to the frame. All the other parts are boxed separately, sequentially numbered.
We should have everything by April 2.
Let It Snow!Posted on March 10, 2008 ------------------------------------------------------------ We had quite a bit of snow over the weekend so we weren’t able to get the engine. Weather permitting, we should have it here this coming Sunday.
If any of you out there have any questions or comments, please drop us a line or comment here.
Finally!Posted on March 17, 2008 ------------------------------------------------------------
After a few delays the engine finally arrived and it looks beautiful! Jeff did a great job! We’ll install the clutch and all the accessories this week. Time to get our hands dirty!
It’s a Roadster!Posted on March 23, 2008 ---------------------------------------------------------------------
Good news! We received the roadster kit from Factory Five yesterday. Everything arrived safe and sound and very organized. They provide a list of what’s on backorder and sequentially number every box.
They sent along a new, updated manual and instructions for all the add-ons (heater, wipers, convertible top, etc.).
Tomorrow we will begin by unwrapping and checking everything off the lists. We will then build a body buck and remove the body from the chassis.
Starting The BuildupPosted on March 29, 2008 --------------------------------------------------------------------
Yesterday we built a body buck and moved the body from the frame to the buck. We then started the buildup of the coil-over shocks for the front suspension. We also began marking the aluminum panels in preparation for the drilling and riveting.
Everything is going quite smoothly so far and we are very impressed with the quality of the parts.
SuspensionPosted on April 13, 2008 ------------------------------------------------------------
We installed the front suspension and steering assemblies, as well as the rear suspension and fuel tank. We installed the driver’s foot box with silicone and rivets and will be installing the passenger foot box this afternoon.
Spring Has Sprung!Posted on May 2, 2008 ----------------------------------------------------------------------- Well, Jerry and I accomplished quite a bit these past couple of weeks. After installing the passenger foot box, we put the battery and battery box in the trunk and ran the positive battery cable to the front of the engine compartment. We then hooked up the hydraulic brake system and bled the lines.
This past Sunday, we took advantage of the nice spring weather and installed the engine and transmission assembly. This took quite a bit of maneuvering, but with help from Shane, DJ, and Debbie, we had it done in a quick twenty minutes.
Earlier this week we connected the drive shaft and installed and connected the clutch cable. We installed the radiator and hooked the hoses up to the engine yesterday.
We began work on the wiring harnesses this morning. Early next week we hope to begin work on the exhaust system (including the side pipes), hook up all the wiring and put gas in the gas tank, all leading up to the big day when we get to start the engine for the first time!
All Caught UpPosted on May 26, 2008 ------------------------------------------------------------ Jerry and I have been very busy over the last three weeks. Shortly after dropping the engine in, we slipped the yoke of the driveshaft into the extension housing of the transmission. We then bolted it to the flange on the rear axle and torqued each bolt at 80 psi.
We then installed the emergency brake handle and connected the cables and moved on to the gearshift.
We also began preliminary work on the wiring harnesses and spent a few days sorting everything out.
Since then, we’ve completed about 75% of the wiring. We began with the engine harness by locating the plugs to plug into the dash wiring, connecting the rear wiring harness to the dash harness and routing it along the transmission tunnel to the rear of the car. We then hooked up the rear harness to the fuel tank, fuel gauge and fuel pump. The rollover/impact switch was then installed in the trunk.
The instruments and padding on the dash panel were assembled and the wiring was connected.
We installed the oil pressure-sending unit and connected it to the oil pressure gauge, installed the engine temperature sensor and ran the wiring to the temperature gauge. We then hooked up the speedometer, the tachometer, the voltmeter and the fuel gauge. Next, we installed the headlight switch, 4-way flasher switch and the turn signal switch. We hooked battery charger up to the cables and then tested the instruments, turn signals, head and taillights and 4-way flashers with perfect results.
Back To WorkPosted on July 5, 2008 ------------------------------------------------------------ Well, after a few personal health-related setbacks we are back working on the roadster. We’ve completed most of the wiring and are currently working on repairing a fuel leak. We’ve ordered a part we hope will finally be the answer. Stay tuned…
Better Late Than Never!Posted on August 23, 2008 ------------------------------------------------------------ I know, I know! It’s been awhile since I’ve posted. Sorry about that!
We’ve accomplished quite a bit over the past few weeks. We’ve corrected the fuel leak and some wiring issues. We’ve also found a body man to paint our soon-to-be Black Beauty. I promise to be back with pictures this week of the rest of our progress. Thanks for sticking with us!
Whew! We’re Exhausted!Posted on September 27, 2008 ------------------------------------------------------------ We’ve installed the exhaust system as well as fit the body to the frame. We found a leak at the intake manifold so we have yet to run the engine for any length of time.
She’ll be released to the body man tomorrow and will be away for two long months. When we get her back, she’ll have a nice shiny black coat with a ghost stripe. We’ll have plenty to do while the body is away and as soon as we get the engine running, we’ll post a video so you can hear how it sounds.
We’ll post more updates as time goes on and we’ll post pictures as soon as she makes it back safe and sound! Thanks for sticking around and supporting our website and blog!
John and Jerry
Body UpdatePosted on January 4, 2009 ------------------------------------------------------------ The body has been primed and it looks like we should have it back in early February. In the mean time, we have installed the carpeting, seats, seat belts and stereo system, which we have neatly tucked inside the glove box. Due to the position of the heater, it was necessary to install the glove box in the rear firewall between the two seats (see photo below). The stereo will be operational via remote control. We also installed a Ford Racing wiring loom to tidy up all the wiring. We will post pictures of the body as soon as we get it back.
Body PhotosPosted on January 13, 2009 ------------------------------------------------------------ Our body guy, Jeff Dishaw emailed some photos of the painted body. He still needs to wet sand and buff it. After that, it’s all ours! From what we can see in the photos, Jeff has done a wonderful job – I’m sure pictures don’t do it justice!
The main color is Mercedes Black and the ghost stripe is a metallic black.
Kudos, Jeff!
Final DetailsPosted on March 3, 2009 ------------------------------------------------------------ Well, with the help of some friends, we finally got the body on. I supervised and made adjustments while Debbie (in the yellow shirt, below), Jason (guiding the front end, below), Catherine, Cassandra, Jerry and DJ carefully lowered it on to the frame. Everyone did a great job!
Over the past few weeks since the body went on, Jerry and I put all the finishing touches on. We hooked up all the exterior lights, attached the bumpers, the roll bars, front bumper oval, the side fins, brake vent grilles, wipers & washers, the mirrors, the side pipes and the door panels. Jeff, who did a great job with the body and paint, will be out to give it a final buffing. Other than that, the roadster is officially finished! We will upload photos of the final product as soon as the weather clears and we are able to take photos outdoors.
Jerry and I would like to thank everyone for their support and help with this project.
We look forward to the next one!
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