Mk4 Engine Kit: What's Included?

Unpacking the Mk4 Complete Kit: A Comprehensive Guide

Embarking on the journey of building your own car is an exciting endeavour, and the Mk4 Complete Kit aims to simplify this process by providing a vast array of meticulously curated components. This kit is designed to be a one-stop solution, offering almost everything you'll need, leaving you to source only the engine, transmission, rear end, wheels, tires, and the final coat of paint. The term 'everything' is used with good reason, as the kit extends to include even the finer details such as hood hinges and a complete custom chassis wiring harness. Furthermore, it's engineered for flexibility, allowing you to integrate your preferred engine with a variety of available headers and engine/transmission mount assemblies. Let's delve into the specifics of what makes the Mk4 Complete Kit such a comprehensive package.

Frame and Chassis: The Foundation of Your Build

The Mk4 kit provides a robust foundation with its complete jig-welded original style 4” round tube frame. This frame is pre-equipped with all necessary mounts, ready to accept small block Ford and 1987-2004 Mustang running gear. For those with different engine or suspension preferences, the kit can be ordered to accommodate a wide range of options. The frame comes standard with a powdercoated black 3-point roll bar, and crucially, includes mounts for a passenger-side roll bar. Chassis powdercoating is also an available option to enhance both aesthetics and durability.

Body and Exterior Components: Crafting the Iconic Look

The distinctive silhouette of the Mk4 is brought to life with a hand-laid 3/16” laminate composite body and panels. These are crafted using vinylester resin for a strong yet lightweight structure. The kit includes detailed components such as driver and passenger doors complete with molded door liners and integral steel door frames. The hood features a molded hood liner and a separate hood scoop, while the trunk boasts a molded trunk liner and an improved mount face for the license plate light. To ensure a professional finish and proper sealing, the kit is generously supplied with secondary body fasteners, adhesive-backed and foam weatherstrip, C-channel door edge trim, plastic end caps, trunk and engine bay seals (push-on rubber bulb seal), and rubber hood and trunk bumpers. For precise alignment and smooth operation, multi-adjustable door hinges with bronze bushings, an adjustable hidden trunk hinge kit, and a hood hinge kit with hydraulic piston supports are all included. Rounding off the exterior are original quick-jack comp bumpers with stainless steel sleeves.

Chassis Aluminium Panels: Precision Fit and Finish

To complement the composite body, the Mk4 kit provides over 40 laser-cut, pre-formed 6061-T6 aluminum panels. These are designed for the cockpit, trunk, and engine bay, ensuring a precise fit and a clean appearance. The kit includes a substantial quantity of 1,200 pre-packaged rivets (1/8” and 3/16” short and long) for their secure installation. You’ll find complete MK4 cockpit aluminum, with optional block-off plates and covers for a customized look, as well as a comprehensive engine bay aluminum assembly incorporating aluminum nose sections and splash guards.

Suspension Systems: Engineered for Performance

The Mk4 kit offers choices for its suspension, catering to different preferences and driving styles.

Front Suspension:

The standard front suspension features unequal length A-arm control arms with a coil-over shock setup. This comes complete with all necessary components and fasteners. It includes KONI brand high-performance mono-tube, rod-end shock absorbers, a coil-over kit for these dampers (including spring hat, threaded seat, and 500 lb. black powdercoated springs), adjustable upper control arms with ball joints, and lower tubular control arms with ball joints.

Rear Suspension Options:

You have two primary options for the rear suspension:

• 3-Link Rear Suspension: This option includes rear axle brackets, fasteners, and axle straps specifically designed to mount a Mustang 8.8” rear solid axle and brakes. It comes complete with all hardware for installation, including the FFR Deluxe 3-Link suspension kit with rear-end brackets, upper link kit, panhard bar kit with rod-ends, and grade 8 fasteners. It also features KONI brand high-performance mono-tube, rod-end shock absorbers, a coil-over kit for KONI dampers (with 350 lb. black powdercoated springs), and Factory Five tubular rear lower control arms with polyurethane bushings.
• 2015 Mustang Independent Rear Suspension (IRS): For those seeking modern IRS performance, this option includes a welded tubular steel IRS frame, upper and lower control arms with bushings, grease fittings, and fasteners (powdercoated black). It also features left and right IRS toe adjustment arms with rod ends and fasteners, KONI coil-over shocks with their respective kits and springs, right and left CV axles, rear wheel studs, an IRS e-brake cable adapter, differential mounting components, and a driveshaft adapter for manual cast iron center sections.

Brake System: Confidence in Stopping Power

Safety and control are paramount, and the Mk4 kit addresses this with a comprehensive brake system. It includes SN 95 style spindles with integral upper ball joint mounts and fasteners, front hubs with dust covers, and front brakes featuring Ford Mustang GT 11” front rotors with twin-piston PBR aluminum calipers and brake pads. The kit also incorporates master cylinders (detailed in the pedal box assembly), stainless braided brake lines for the front with mount clips, banjo bolts, and brake line mounting fasteners. Pre-flared 3/16” brake line and T-adapters are provided, along with a complete emergency brake handle assembly with a leather boot.

Steering System: Precise Control and Vintage Feel

The Mk4 kit offers a complete steering system designed for a 15:1 manual rack. This includes everything from tie rod ends to a vintage steering wheel, all with a collapsible design for safety. Specific components include the 15:1 manual steering rack with inner and outer tie rod ends, polyurethane steering rack bushings, a rack shaft adapter, a nickel-plated lower steering shaft with fully welded U-joints, and a collapsible upper steering shaft with friction washers. A 14” vintage wood and aluminum steering wheel with a boss and FFR center section, along with steering bearings and hardware, are also included, ensuring a tactile and authentic driving experience.

Fuel and Cooling Systems: Essential Fluids Management

The fuel system is designed around an OEM-style fuel tank, providing everything from the gas cap to the lines, and is adaptable for both carbureted and fuel-injected setups. This includes mounting straps, hardware, vents, gaskets, a pick-up, and a fuel level sending unit. Fuel lines, connectors, and a filler neck are also supplied, along with pre-flared fuel lines and high-pressure flex lines. A distinctive Aston LeMans style polished aluminum fuel cap with an integral pressure cap is a stylish and functional addition. The cooling system is equally well-equipped, featuring an electric cooling fan with mounting hardware, radiator hoses, and fasteners. An aluminum radiator with a cap and in-line filler neck, a radiator mount kit, and a stainless steel radiator hose kit are provided. An overflow tank, thermostat switch, and all necessary wiring complete this essential system.

Engine Accessories and Exhaust: Powering Your Mk4

The Mk4 base kit is engineered to accommodate a range of engines, including big block Fords, small block Ford Windsors, and modular 4.6L and 5.0L Coyote engines. It comes with an alternate drive pulley assembly, an oil filter relocate kit, and an exhaust assembly designed to adapt Mustang engines and headers to vintage side-exit exhausts. This includes a 4-into-1 side exhaust (J-Pipe only) with rubber hanger brackets and gaskets. The kit also includes an oil filter relocate kit with fittings and hoses, and an accelerator cable assembly. Optional full-length tubular headers for various Ford engines and catalytic converters are available to further customize your powertrain.

Driveshaft: Transmitting Power

A crucial link in the drivetrain, the Mk4 kit allows you to select from three available driveshafts, complete with fasteners, to match your specific engine and transmission combination.

Gauges, Dash, and Electrical Assembly: The Nerve Centre

Eliminate wiring harness complexities with the Mk4's integrated harness and electronic gauges. You can choose between vintage/replica or modern/performance gauges to complement the authentic street-style dash. The assembly includes a covered aluminum dash, dash buttons, toggles, indicator lights, switches, and horns. A custom-fit chassis wiring harness, ignition and headlight switches, a turn signal switch, starter solenoid, and horns are all part of this extensive package. Various mounting kits, clips, ties, and grommets ensure a tidy and professional electrical installation. A choice between seven Autometer electronic gauges (including a programmable speedometer and tachometer) or seven vintage FFR replica electronic gauges (including a GPS speedometer) allows for personalized instrumentation.

Interior Accessories: Comfort and Style

The interior of your Mk4 will be period-correct and comfortable, thanks to the inclusion of authentic style roadster metal-framed seats in black vinyl, 5-point Simpson brand harnesses, a complete cockpit carpet set, an emergency brake boot, and an authentic interior rear-view mirror. Original style door latches, leather check straps, and an authentic stainless shifter handle with a polished ring and boot contribute to the vintage aesthetic. The authentic 14” wood and aluminum steering wheel is also part of this comprehensive interior package.

Exterior Accessories and Lighting: The Finishing Touches

The exterior is equally well-appointed. The kit features an authentic chrome-on-brass vintage windscreen with tinted safety glass and side bars. A three-lock set, including T-trunk and L-shaped hood handles with matching keys, ensures security. An authentic license plate light and bracket, a stylish 3.5” Aston roller gas cap, competition hood pins, and high-quality laser-cut aluminum side louvers add to the car’s distinctive look. Ceramic FFR badging adorns the nose and tail. Lighting is handled by original style headlamp assemblies with halogen bulbs and authentic style front amber turn signals and red rear tail-lights, all DOT-approved. An authentic bullet-style sideview mirror completes the exterior.

Pedal Box and Components: Control at Your Feet

Moving away from the Mustang pedal box, the Mk4 kit utilizes the proven Wilwood brand pedal box. This includes adjustable pedals, mounting hardware, master cylinders, a clutch quadrant, clutch cable, and a threaded firewall adjuster. The accelerator pedal, cable, return spring, and ball stud retainer are also included, along with brake line adapters and T-fittings.

Fasteners: The Unsung Heroes

A testament to the kit's completeness, it includes over 1,500 top-quality zinc-plated, chrome, and stainless steel USS and SAE fasteners. These are meticulously numbered and packed individually by assembly, ensuring you have the right fastener for every step of the build.

Assembly Manual: Your Guide to Success

To facilitate the building process, the Mk4 Roadster Complete Kit comes with a digital (PDF) assembly manual. This comprehensive guide is packed with pictures, diagrams, and CAD drawings, serving as an invaluable resource throughout your project.

Frequently Asked Questions:

• What engine and transmission can I use with the Mk4 Complete Kit? The kit is designed to accept small block Ford and 1987-2004 Mustang running gear, but can be ordered to accept a wide variety of engines and transmissions. Optional headers and mount assemblies are available to suit different engine choices.
• Does the kit include wheels and tires? No, the Mk4 Complete Kit requires you to source your own wheels and tires.
• What type of brakes are included? The kit includes SN 95 style spindles, Ford Mustang GT 11” front rotors with twin-piston PBR aluminum calipers, and a complete emergency brake system.
• Can I choose my gauges? Yes, you can select between vintage/replica or modern/performance electronic gauges, with specific options for Autometer or FFR replica sets.
• What is the material of the body panels? The body panels are made from a hand-laid 3/16” laminate composite using vinylester resin.

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