Welcome to my blog. I hope that you find this interesting and useful, especially if you are embarking on the same journey that I am. My name is Jonathan Weiswasser, and I am a Vascular Surgeon living in Montclair, NJ. I have decided to build a Factory Five Roadster (see here) and chronicle the process on this site. I will do my best to provide as much information as I can so as to help others who are involved in the same endeavor.
The mission is to build a classic car for purposes of pleasure driving. I am not a race-car driver nor do I have any interest in becoming one.
Another philosophy of the mission here is that I plan on keeping it very, very simple. I am opting against power windows and brakes, hydraulic clutches, independent rear suspension, and sophisticated electronics, etc. in favor of a simple build. Maybe the next one will be more of an exploration of the aftermarket for some of the fancy mods. On the other hand, little conveniences that add to the aesthetic do appeal to me, like the hood lifting pistons, or side pockets, or turn signal switches that mount to the steering wheel. So, what you will see in the following pages is a synopsis of the construction of a standard, complete kit, Mark IV, Factory Five Roadster.
I am not quite a novice at this sort of thing; I completed construction of a Vans Aircraft RV-8 in 2004, after 2100h of construction over 2.5y (see here). Through that experience, I developed friendships with other builders and one of them, Mr. Mike Witte, came up with idea of building this car. We researched the company and the product throughly and flew in our RV’s to Wareham, MA in late September, 2010 to tour the factory. We ordered our kits during that visit.
As far as particulars, the Roadster is a 1965 Shelby Cobra Replica. The chassis is made of welded tube and the body is vinyl ester fiberglass. I plan on carburated or fuel injected (haven’t decided) Ford 302 350hp engine, using a pre-1973 block (due to NJ state requirements, emission standards are based on the block-year of the engine). I am currently pricing shops to build the engine. The kit comes with everything except the engine, transmission, and the rear end (which I purchased from the Factory as an option).
My previous experience with cars has been limited to changing tires. I am not well versed on the nuances of the automotive engine or systems, and hope to gain a better understanding as I plod through this. Please excuse any mistakes or mis-statements in advance.
- 10-18-13; Photo Shoot with RV
- 10-10-13; The Next Day
- 6-19-12; More Fire Analysis
- 5-23-12; Bad Press, Good Press?
- 5-20-12; Some final thoughts
- 5-19-12; Finished For Good.
- 4-30-12; DONE!
- 4-4-12; Paint Update IV
- 3-28-12; Paint Update III
- 3-2-12; Paint Update II
- 2-9-12; Paint Update
- 11-11-11; Driving to work, Formal alignment
- 11-4-11; NJ STATE LEGAL!
- 10-6-11; Engine Swapping
- 10-1-11; Major setback..
- 9-28-11; NJ DMV Paperwork
- 9-26-11; Wind Wings, Sun Visors, Front Bumper
- 9-24-11; Final Assembly, Exhaust Hangars, Edging, Mirrors
- 9-21-11; Heater and Footbox Vent Fixtures, Body Seams
- 9-17-11; Shifter plate, E-brake cover, Pedestal Install
- 9-16-11; Seats and Seatbelts
- 9-15-11; Carpeting the trunk
- 9-15-11; Carpeting
- 9-1-11; Interior work; Damplifier Pro & Luxury Liner
- 7-31-11; Roll Bars, Wipers, Wrap-Up Metal Work
- 7-21-11; Radiator Cowl, Splash Gaurds
- 7-11-11; Hood Scoop
- 7-11-11; Trunk
- 7-11-11; Doors
- 7-8-11; Windshield
- 7-7-11; Body On, Hood Installation
- 7-4-11; Front Lights
- 7-1-11; Engine & Oil Leak Diagnostics, Hood hinge
- 6-30-11; Footbox Access Panel, Engine Codes, Oil Leak
- 6-29-11;Wiper Motor, DS Footbox
- 6-27-11; Body On/Body Off; Metal Riveting
- 6-13-11; Roll Bars, Body Mount
- 6-12-11; Post Cart Punch List
- 6-6-11; GO – CART!
- 6-4-11; First Engine Start
- 6-3-11; Attempt at engine start
- 6-2-11; Air Cleaner, E-brake
- 6-1-11; Heater Core Plumbing and Radiator Chin Strap
- 5-30-11; Exhaust Headers and Clutch Cable Final Installation
- 5-27-11; Coolant and Fuel Rail Plumbing
- 5-26-11; Radiator Installation
- 5-24-11; Pinion Angle and Driveshaft
- 5-23-11; Fuel Regulator, Transmission Seal Replacement
- 5-20-11; Powering the Dash
- 5-19-11; Sender Wiring, Starter and Alternator, Grounds
- 5-18-11; Pedestal and Accessory Wiring
- 5-11-11; accelerator cable, clutch cable
- 5-9-11; Finishing wiring: dash and steering installation, tranny wiring.
- 5-4-11; Integrating wiring harnesses
- 5-1-11; ENGINE INSTALLATION
- 3-30-9; 250A Fuse, Trunk Nutplates
- 3-28-11; Radio, Speakers, Cigarette Adaptor Initial Install
- 3-19-11; Cubby Door, Fuel Line Fix
- 3-14-11; Coarse Wheel Alignment
- 3-11-11; Cabin Lights, Trunk Cubby
- 3-9-11; Ground Bus, Heater Motor
- 3-7-11; Battery Wiring, Underdash Filler
- 3-2-11; Headlight Switch, Footbox Vent Wiring, Battery and Cutoff Switch
- 2-25-11; Dash Harness Part II, Footbox Vents
- 2-24-11; Dash Wiring and Harnessing
- 2-17-11; Dash and Gauges
- 2-16-11; Starting the Dash Panel
- 2-15-11; More Dash Wiring; Relays and Terminal Blocks
- 2-14-11; Dash Guts Wiring, Trimmed Inner Tie Rod
- 2-9-11; E Brake, Beginning Dash
- 2-8-10; Brake line leak repair, starting E-brake
- 1-31-11; Pedestal Panel and More Battery Installation
- 1-27-11; Bleedin’ Brakes
- 1-21-11; Wiring Harness Installation
- 1-10-11; Fuel Pump and Planning
- 1-6-11; Clamping Brake Lines, Battery Box
- 1-3-11; Trunk Panels
- 1-2-11; More Brake Lines
- 1-1-11; Brake Lines
- 12-31-10; Plumbing Fuel
- 12-30-10; More Plumbing and retracing some steps
- 12-28-10; Plumbing
- 12-24-10; Brake Reservoirs
- 12-17-10; Fuel Lines and Ordering Stuff
- 12-15-10; Backtracking a little..
- 12-12-10; Everything You Need To Know From Build School
- 12-9-10; Ordered Engine and Preparing for Build School
- 12-4 to 12-6-10; Cockpit Aluminum
- 12-3-10; Tank Install and Cockpit Panels
- 12-2-10; Steering Assembly and Fuel Tank
- 12-1-10 Wilwood Pedal Assembly
- 11-29-10; Panhard Bar and Firewall
- 11-24-10 Mounting the Rear Axle
- 11-21-10 Finish IFS and Rear Axle Prep
- 11-19-10 Front Suspension
- 11-18-10 Rear End Delivery
- Nov-10-10 – Landlocked – brakes and shocks
- 11-6-10 Onto the Buck
- 11-5-10 Delivery!!!!
- 11-3-10 Body Buck
- 10-31-10 Preparing the Garage
- Welcome and About Me
March 16, 2012 at 8:45 pm |
I noticed in your build that you used the supplied wilwood master cylinder reservoir. Have you had any problem with these? I’m struggling with a leaker.
March 17, 2012 at 10:17 am |
No problems for the most part.. I did have to give the whole assembly some extra attention for some leaking. Be careful that the metal, circular, worm-type clamp straddles the O-ring washer that sits between the body and the base of the reservoir. Some have advocated using heat to help create a more robust seal – check out the forums on that..
HTH
Jon
June 12, 2015 at 7:04 pm |
Thank you very much for this amazing documentary! A fanstatic write up of the build, and I’m sure I will be referring to it lots after I start my own build.