{"id":2,"date":"2017-07-06T11:51:35","date_gmt":"2017-07-06T11:51:35","guid":{"rendered":"http:\/\/krissfamily.org\/buildmanual\/MK4\/?page_id=2"},"modified":"2026-06-26T20:10:57","modified_gmt":"2026-06-26T20:10:57","slug":"sample-page","status":"publish","type":"page","link":"https:\/\/krissmotors.com\/FFR\/","title":{"rendered":"Introduction"},"content":{"rendered":"

If you dream of building, owning, and driving an AC Cobra, you’ve come to the right place!<\/p>\n

\"\"<\/a>

FFR Roadster CAD drawing<\/p><\/div>\n

BUILD MANUAL<\/strong> details the construction of an all-new \u2014 that is,\u00a0non-donor<\/em>\u00a0\u2014\u00a0Factory Five Racing<\/a>\u00a0(FFR) Roadster, generally referred to as the\u00a0Mk3<\/em>\u00a0or\u00a0Mk4<\/em> <\/span>1<\/sup><\/a><\/span> as well as the 289 USRRC<\/em><\/a> period-correct version and the MK4 Challenge<\/em><\/a> racer.<\/p>\n

The FFR Roadster is a replica<\/em> of the AC Cobra: see also\u00a0Legacy of the FFR Roadster<\/a>. <\/p>\n

0<\/span>1<\/span>2<\/span>3<\/span>4<\/span>5<\/span>6<\/span>7<\/span>8<\/span>9<\/span>10<\/span>11<\/span>12<\/span><\/div>
\n

BUILD MANUAL content preview<\/h1>\n

BUILD MANUAL<\/strong> covers 12 major topics in clearly written how-to sections illustrated with over 650 photos, drawings, and diagrams. Click on the 12 tabs above for a overview of our detailed instructions and technical assistance. Full access requires a membership pass<\/a>.
\n<\/div>\n

\n

Getting Started<\/h1>\n

Initial decisions<\/h3>\n

\u2714\ufe0e Understand the AC Cobra legacy (development history, race results, vintage car photos)
\n\u2714\ufe0e Is this the dream car you really want?
\n\u2714\ufe0e What is a replica?
\n\u2714\ufe0e Build one or buy one?
\n\u2714\ufe0e Kit car manufacturer comparison: picking the right primary vendor
\n\u2714\ufe0e Build the FFR Mk3, Mk4, 289 USRRC, or Challenge kit?<\/p>\n

Project planning<\/h3>\n

\u2714\ufe0e Articulate a build objective
\n\u2714\ufe0e Understand rear suspension alternatives
\n\u2714\ufe0e Define specifications and explore customizations
\n\u2714\ufe0e Review state registration requirements
\n\u2714\ufe0e What about insurance coverage?
\n\u2714\ufe0e Establish a realistic build budget
\n\u2714\ufe0e Select wheels and tires
\n\u2714\ufe0e Consider customizations and special parts
\n\u2714\ufe0e Select vendors and place orders
\n\u2714\ufe0e Record keeping: orders and inventory
\n\u2714\ufe0e Learn technical terminology<\/p>\n

Work area setup<\/h3>\n

\u2714\ufe0e How to prepare your workspace
\n\u2714\ufe0e Comprehensive part labeling
\n\u2714\ufe0e Procure tools and supplies
\n\u2714\ufe0e Attend a FFR-oriented build school
\n\u2714\ufe0e Construct engine block holder and body buck
\n<\/div>\n

\n

Basic preparation<\/h1>\n

Kit staging<\/h3>\n

\u2714\ufe0e Receive FFR kits, wheels and tires, and other parts
\n\u2714\ufe0e Unpack, inventory and validate vehicle ID
\n\u2714\ufe0e Inspect and remove body
\n\u2714\ufe0e Chassis weep holes
\n\u2714\ufe0e Crate engine setup<\/p>\n

Aluminum fabrication<\/h3>\n

\u2714\ufe0e Remove emergency brake bracket and fill cutout
\n\u2714\ufe0e Fabricate custom transmission side tunnel fresh air vents
\n\u2714\ufe0e Position custom fuel pump and sending unit access covers in trunk area
\n\u2714\ufe0e Breeze radiator shroud
\n\u2714\ufe0e Test fit Breeze battery box in engine bay
\n\u2714\ufe0e Foot box removable cover
\n\u2714\ufe0e Panel preparation
\n\u2714\ufe0e Screw holes for seat belt bezels
\n\u2714\ufe0e Anodize or powder coat all aluminum<\/p>\n

Crate engine readiness<\/h3>\n

\u2714\ufe0e Crate engine delivery and setup
\n\u2714\ufe0e Flywheel dowel pins
\n\u2714\ufe0e Swap oil pan
\n\u2714\ufe0e Engine mounts
\n\u2714\ufe0e Intake manifold
\n\u2714\ufe0e Thermostat including heater bypass
\n\u2714\ufe0e Clutch including clutch fork and release bearing
\n\u2714\ufe0e Transmission
\n<\/div>\n

\n

Suspensions<\/h1>\n

Front suspension<\/h3>\n

\u2714\ufe0e IFS overview
\n\u2714\ufe0e Lower control arm (LCA)
\n\u2714\ufe0e Upper control arm (UCA)
\n\u2714\ufe0e Spindle and bracket
\n\u2714\ufe0e Hub and brakes
\n\u2714\ufe0e Steering rack
\n\u2714\ufe0e Preliminary front alignment
\n\u2714\ufe0e Koni front shocks<\/p>\n

Rear suspension<\/h3>\n

\u2714\ufe0e Understand rear suspension alternatives \u2757 240-258
\n\u2714\ufe0e Differential
\n\u2714\ufe0e Rear axle and CV joints
\n\u2714\ufe0e Control arms, spindle, and rotor
\n\u2714\ufe0e Koni rear shocks
\n\u2714\ufe0e Fabricate and install driveshaft safety loop
\n\u2714\ufe0e Preliminary rear alignment
\n<\/div>\n

\n

Mechanical controls<\/h1>\n

Pedals<\/h3>\n

\u2714\ufe0e Install driver side (DS) front foot box aluminum panel
\n\u2714\ufe0e Foot box panel assembly
\n\u2714\ufe0e Pedal box
\n\u2714\ufe0e Install firewall aluminum panel
\n\u2714\ufe0e Accelerator pedal
\n\u2714\ufe0e Upgrading pedals
\n\u2714\ufe0e Upgrading brake pads<\/p>\n

Steering<\/h3>\n

\u2714\ufe0e Steering system including steering shaft and steering wheel
\n\u2714\ufe0e Modify DS foo tbox side panel for hose and harness access<\/p>\n

Brakes<\/h3>\n

\u2714\ufe0e Brake master cylinders
\n\u2714\ufe0e Wilwood Balance Bar
\n\u2714\ufe0e Remote brake fluid reservoirs
\n\u2714\ufe0e Brake lines
\n\u2714\ufe0e Emergency brake cables
\n\u2714\ufe0e Emergency handbrake
\n\u2714\ufe0e Bleed brakes
\n<\/div>\n

\n

Electrical system<\/h1>\n

Automotive electricity<\/h3>\n

\u2714\ufe0e Understanding switches, relays, fuses and diodes
\n\u2714\ufe0e Wire specifications
\n\u2714\ufe0e Dash overview
\n\u2714\ufe0e Wiring overview
\n\u2714\ufe0e Wiring connections<\/p>\n

Mounted components<\/h3>\n

\u2714\ufe0e Ron Francis\/FFR fuse box
\n\u2714\ufe0e Solenoid
\n\u2714\ufe0e Battery switch
\n\u2714\ufe0e Firewall attachments
\n\u2714\ufe0e Breeze battery box installation with chassis grounds<\/p>\n

Dash fabrication<\/h3>\n

\u2714\ufe0e Dash construction
\n\u2714\ufe0e Dash wiring
\n\u2714\ufe0e Gauge wiring
\n\u2714\ufe0e Russ Thompson turn signal
\n\u2714\ufe0e EFI computer, underdash filler panel, and related components
\n\u2714\ufe0e Gauge calibration patch panel<\/p>\n

Wiring integration<\/h3>\n

\u2714\ufe0e Multiple electrical grounds
\n\u2714\ufe0e Terminal blocks
\n\u2714\ufe0e WeatherPack connectors
\n\u2714\ufe0e Integrate harnesses (Ron Francis and MassFlo EFI)
\n\u2714\ufe0e FFR fuse box modifications
\n\u2714\ufe0e FFR and EFI fuse box wiring
\n\u2714\ufe0e Headlight switch connections
\n\u2714\ufe0e Ignition switch connections
\n\u2714\ufe0e Neutral safety switch
\n\u2714\ufe0e Sending units
\n\u2714\ufe0e EFI 9-pin connections
\n\u2714\ufe0e Rear harness
\n\u2714\ufe0e Front harness
\n\u2714\ufe0e EFI harness
\n\u2714\ufe0e Alternator wiring
\n\u2714\ufe0e Sending units<\/p>\n

Component diagrams<\/h3>\n

\u2714\ufe0e Horns
\n\u2714\ufe0e Radiator fan
\n\u2714\ufe0e Fuel pump
\n\u2714\ufe0e Wipers<\/p>\n<\/div>\n

\n

Fuel system<\/h1>\n

Fuel delivery<\/h3>\n

\u2714\ufe0e Install gas tank
\n\u2714\ufe0e Install fuel lines and filter
\n\u2714\ufe0e Breeze EFI bypass regulator<\/p>\n

Electronic fuel injection<\/h3>\n

\u2714\ufe0e Mass-Flo fuel components
\n\u2714\ufe0e Distributor
\n\u2714\ufe0e EFI fuel lines
\n\u2714\ufe0e EFI harness
\n<\/div>\n

\n

Engine bay<\/h1>\n

Engine installation<\/h3>\n

\u2714\ufe0e Install engine bay panels prior to engine installation
\n\u2714\ufe0e Engine drop-in
\n\u2714\ufe0e Drive shaft
\n\u2714\ufe0e Attach chassis grounds to engine block and cylinder head<\/p>\n

Engine bay components<\/h3>\n

\u2714\ufe0e Alternator
\n\u2714\ufe0e Starter
\n\u2714\ufe0e Wiper motor<\/p>\n

Cooling system<\/h3>\n

\u2714\ufe0e Assemble radiator-shroud-fan unit
\n\u2714\ufe0e Mount radiator
\n\u2714\ufe0e Pressurized coolant fill port
\n\u2714\ufe0e Connect radiator hoses<\/p>\n

Exhaust system<\/h3>\n

\u2714\ufe0e Exhaust headers and oxygen sensors
\n\u2714\ufe0e Exhaust side pipes, see also engine mount adjustment
\n\u2714\ufe0e Heat shields
\n<\/div>\n

\n

First engine start & test drive<\/h1>\n

Cockpit construction<\/h3>\n

\u2714\ufe0e Cockpit overview
\n\u2714\ufe0e Clutch cable
\n\u2714\ufe0e Transmission tunnel
\n\u2714\ufe0e Install transmission tunnel vents and cockpit floor panels
\n\u2714\ufe0e Modify tunnel cover for emergency brake and shifter assembly
\n\u2714\ufe0e Trial fit seats<\/p>\n

Go cart stage<\/h3>\n

\u2714\ufe0e Install remaining trunk panels
\n\u2714\ufe0e Install fire extinguisher
\n\u2714\ufe0e Install remaining cockpit panels
\n\u2714\ufe0e Trunk license plate wiring
\n\u2714\ufe0e Drill roll bars
\n\u2714\ufe0e Preliminary seat belt installation<\/p>\n

Engine start and test drive<\/h3>\n

\u2714\ufe0e First engine start
\n\u2714\ufe0e Distributor timing
\n\u2714\ufe0e Run diagnostic codes
\n\u2714\ufe0e Professional alignment
\n\u2714\ufe0e Go cart test drive<\/p>\n<\/div>\n

\n

Body completion<\/h1>\n

Gel coat prerequisites<\/h3>\n

\u2714\ufe0e Hood hinge preparation
\n\u2714\ufe0e Radiator cowling
\n\u2714\ufe0e Trunk hinge preparation
\n\u2714\ufe0e Foot box gap fills
\n\u2714\ufe0e Prepare rear and front splash guards (elephant ears)
\n\u2714\ufe0e Foam tape and rubber seals on chassis, aluminum panels
\n\u2714\ufe0e Exterior front and rear light wiring
\n\u2714\ufe0e Mount gel coat body<\/p>\n

Body-on components<\/h3>\n

\u2714\ufe0e Check gauge and dash fitment
\n\u2714\ufe0e Connect fuel filler neck
\n\u2714\ufe0e Windshield install
\n\u2714\ufe0e Adjust roll bar cutouts and install
\n\u2714\ufe0e Lucas wipers
\n\u2714\ufe0e Pre-fit doors and bottom trim
\n\u2714\ufe0e Prepare trunk lid
\n\u2714\ufe0e Pre-fit hood
\n\u2714\ufe0e Exhaust side pipes
\n\u2714\ufe0e Exhaust heat shields
\n\u2714\ufe0e Gauge calibration
\n\u2714\ufe0e Gel coat test drive<\/p>\n

Shell preparation<\/h3>\n

\u2714\ufe0e Paint plan, including options, schedule and budget
\n\u2714\ufe0e Fiberglass shaping
\n\u2714\ufe0e Hood scoop
\n\u2714\ufe0e Paint selection
\n\u2714\ufe0e Paint process
\n\u2714\ufe0e Clear coating<\/p>\n<\/div>\n

\n

Interior and exterior finish<\/h1>\n

Trim and fixtures<\/h3>\n

\u2714\ufe0e Emergency brake boot
\n\u2714\ufe0e Shifter knob, rubber boot, and bezel
\n\u2714\ufe0e Safety harness
\n\u2714\ufe0e Seats<\/p>\n

Carpet and insulation<\/h3>\n

\u2714\ufe0e Heat and vibration protection
\n\u2714\ufe0e Carpet overview
\n\u2714\ufe0e Driver foot box finish
\n\u2714\ufe0e Passenger foot box finish
\n\u2714\ufe0e Passenger side lock box
\n\u2714\ufe0e Transmission tunnel finish
\n\u2714\ufe0e Rear cockpit wall finish
\n\u2714\ufe0e Trunk floor gap<\/p>\n

Exterior trim<\/h3>\n

\u2714\ufe0e Painted body mount
\n\u2714\ufe0e Trunk lid mount
\n\u2714\ufe0e Side louvers
\n\u2714\ufe0e Body badges
\n\u2714\ufe0e Fuel neck and gas cap
\n\u2714\ufe0e Wind wings
\n\u2714\ufe0e Final hood and latch
\n\u2714\ufe0e Side and rear view mirrors
\n\u2714\ufe0e Headlight assembly
\n\u2714\ufe0e Over-rider bumpers
\n\u2714\ufe0e Wiper arms and blades
\n\u2714\ufe0e Fender spats
\n<\/div>\n

\n

Graduation<\/h1>\n

Driving<\/h3>\n

\u2714\ufe0e Headlamp adjustment
\n\u2714\ufe0e First time wash and wax
\n\u2714\ufe0e Ear protection
\n\u2714\ufe0e Driving shoes
\n\u2714\ufe0e Road handling adjustments
\n\u2714\ufe0e Maintenance checklist
\n\u2714\ufe0e Engine oil analysis
\n\u2714\ufe0e Driving technique<\/p>\n<\/div>\n

\n

Library<\/h1>\n

\u2714\ufe0e PDF documents, FFR supplemental instructions
\n\u2714\ufe0e Common automotive abbreviations
\n\u2714\ufe0e Vendors, parts, tools, and more<\/p>\n<\/div><\/div><\/div>\n

INSTANT FULL ACCESS<\/h1>\n

For immediate access to all BUILD MANUAL<\/strong> content, purchase a one-year ($25) Premium Content membership pass. If you already have a membership pass, just LOG IN<\/strong><\/a> now. <\/p>\n

If your pass has expired, please re-register and purchase a new one. For more information, read our Terms of Use<\/a> and Build Manual<\/a> overview. This site is pubished by Kriss Motors<\/a>.<\/p>\n

NO MEMBERSHIP?<\/div>
New visitor? It’s easy to purchase a Premium Content membership pass for your Factory Five project. Just click HERE<\/strong><\/a>.<\/div><\/div>\n","protected":false},"excerpt":{"rendered":"

If you dream of building, owning, and driving an AC Cobra, you’ve come to the right place! BUILD MANUAL details the construction of an all-new \u2014 that is,\u00a0non-donor\u00a0\u2014\u00a0Factory Five Racing\u00a0(FFR) Roadster, generally referred to as the\u00a0Mk3\u00a0or\u00a0Mk4 as well as the 289 USRRC period-correct version and the MK4 Challenge racer. The FFR Roadster is a replica\u2026 Read More: Introduction »<\/a><\/span><\/p>\n","protected":false},"author":1,"featured_media":7,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"open","template":"","meta":{"pmpro_default_level":"","footnotes":""},"class_list":["post-2","page","type-page","status-publish","has-post-thumbnail","hentry","pmpro-has-access"],"_links":{"self":[{"href":"https:\/\/krissmotors.com\/FFR\/index.php?rest_route=\/wp\/v2\/pages\/2","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/krissmotors.com\/FFR\/index.php?rest_route=\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/krissmotors.com\/FFR\/index.php?rest_route=\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/krissmotors.com\/FFR\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/krissmotors.com\/FFR\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=2"}],"version-history":[{"count":10,"href":"https:\/\/krissmotors.com\/FFR\/index.php?rest_route=\/wp\/v2\/pages\/2\/revisions"}],"predecessor-version":[{"id":3102,"href":"https:\/\/krissmotors.com\/FFR\/index.php?rest_route=\/wp\/v2\/pages\/2\/revisions\/3102"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/krissmotors.com\/FFR\/index.php?rest_route=\/wp\/v2\/media\/7"}],"wp:attachment":[{"href":"https:\/\/krissmotors.com\/FFR\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=2"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}