Introduction
- Membership account
- About Build Manual
- Terms of Use
Initial decisions
- What is a replica?
- Legacy of the FFR Roadster
- Do you really want one?
- Build or buy?
- AC Cobra replica manufacturers
- Which FFR model kit?
Project planning
- Build objective
- Rear suspension alternatives
- Wheel and tire options
- Build budget
- Replica car insurance
- Vehicle registration and title
Work area setup
- Body buck
- Engine block holder
Kit staging
- Unpack and take inventory
- Body alignment and removal
- Chassis preparation
- Verify vehicle ID
Aluminum fabrication
- Panel procedure
- Fresh air vents
- Radiator shroud
- Battery box
- Sheetmetal modifications
Crate engine readiness
- Crate engine setup
- Flywheel dowel pins
- Oil pan swap
- Engine mounts
- Intake Manifold
- Thermostat
- Clutch
- Transmission
Front suspension
- Lower control arm
- Upper control arm
- Spindle, hub, and brake assembly
- Steering rack
- Preliminary alignment
- Koni front shocks
Rear suspension
- Differential
- Rear axle and CV Joints
- IRS control arms, spindle, rotor and shocks
- Driveshaft safety loop
Pedals
- Front footbox panel
- Pedal box
- Accelerator pedal
- Pedal upgrade
Steering
Brakes
- Brake master cylinders
- Brake fluid reservoirs
- Brake lines
- Emergency brake cables
- Handbrake
- Bleed and adjust brakes
Automotive electricity
- Concepts and components
- Switches, relays, fuses and diodes
- Wire specifications
- Dash layout
- Wiring layout
Mounted components
- Ron Francis fuse box
- Solenoid
- Battery switch
- Firewall attachments
- Breeze Battery box
Dash fabrication
- Panel construction
- Dash wiring
- Gauge wiring
- Russ Thompson turn signal
- EFI and EEC electronics
- Gauge calibration patch panel
Wiring integration
- Electrical grounds
- Weather Pack connectors
- Integrate Ron Francis and MassFlo EFI harnesses
- Fuse box modifications
- Switch connections
- Sending units
- Harness connections
Component diagrams
- Horns
- Radiator fan
- Fuel pump
- Wipers
Fuel delivery
- Fuel tank
- Fuel lines and filter
- EFI plumbing
Electronic fuel injection
- EFI system components
- Distributor
- EFI harness connections
Engine installation
- Engine bay panels
- Engine drop-in
Engine bay components
- Alternator
- Starter
- Wiper motor
Cooling system
- Radiator mount
- Coolant fill port and hoses
Exhaust system
- Exhaust header
- Side pipes and shields
Cockpit construction
- Clutch cable
- Transmission tunnel
- Seats
Go cart stage
- Fire extinguisher
- License plate light wiring
- Roll bars
- Seat belts
Engine start and test drive
- First engine start
- Distributor timing
- Run diagnostics
- Go cart test drive
- Professional alignment
Gel coat prerequisites
- Hood hinge
- Radiator cowling
- Trunk hinge
- Guard panels
- Fills and seals
- Gel coat wiring
Body-on components
- Gel coat shell
- Fittings and fitment
- Windshield
- Lucas wipers
- Calibrate instruments
- Gel coat testing
Shell preparation
- Paint plan
- Fiberglass preparation
- Paint process
Trim and fixtures
- Lock box
- Shifter and handbrake boots
- Safety harness
Carpet and insulation
- Insulation
- Carpet overview
- Footbox finish
- Cockpit finish
- Trunk finish
Exterior trim
- Mount painted shell
- Body badges
- Wind wings and mirrors
- Bumpers and spats
- Headlamp adjustment
Driving
- First time wash and wax
- Project completion photos
- Driving shoes and ear protection
- Road handling adjustments and driving technique
- Maintenance checklist and oil analysis
Library
- Specifications
- Definitions
- Tools and supplies
- Tool inventory
- Supply inventory
- Parts inventory
- Order history
- Vendors