Build Plan Guide for Classic Cars

      Welcome to the RRS build plan guide. So you are thinking of restomoding Falcon, Fairlane, LTD, Mustang, Maverick, etc, draw up a plan, put together a timeline, make up a budget. Now remember the saying "The best-laid plans of mice and men often go awry" , things will change, things will take longer , things will cost more, but there will be great moments, the first time you fire the engine, the first splash of colour, the first drive.

      This page is for the rookie or the amateur car builder, we welcome comments, questions and suggestions just email using the button at the top of the page.

Find your dream car

Map out your vision


Assess the extent of rust and structural work required

Step 1

a. Wheels and tyres (determines body mods and suspension requirements)

"When you build a race car, you start with tyres & wheels and build up from there, the same applies to a full restomod, always start with wheels and tyres.

Flaring guards, mini-tubbing and legal ride height are not problems you want to face after paint"

"Remember overall tyre width and tread width are different and vary from brand to brand"

"VSB 14 states that going 1" over track will require engineers report on axle loading"

b. Engine specification, trans, cooling system, rear axle assembly exhaust

"The Motor determines the engine bay requirements, likewise the inter-cooler size"

"The transmission determines the trans tunnel requirements"

"The horse power determines rear axle setup"

c. Body mod’s associated with above

"Customizing the trans tunnel will affect how much customisation you need to do to the interior"

"Room around your motor is important if your shock are to close to motor you will cause the rear half the motor to cook"

"The motor height will determine if you need to customize the bonnet"

Great planning will help, so will an endless supply of money and mates willing to help.

e. Front suspension, if its a Ford» RRS

f. Rear suspension, if its a Ford» RRS

g. Power steer, no power steer, steering column, if its a Ford» RRS

h. Brake front and rear

The choice of rims will determine the brake options you can pick. Most ford stock rims were 14" to 15" this will limit both your brake and tyre options.

Balance with the front brake package is everything

i. Electrical (lighting, relays, wiring switches, accessories, battery instruments)

So many decisions are interrelated engine bay size motor choice, battery location. A common practice to free up space in the engine bay is relocate the battery into the boot (trunk).

Classic cars can have the electrics update to just about any level. From led lights to keyless entry you need to source and cost your design.

j. Air conditioner Heater Demister Re-plumbing the dash to fit AC

Air conditioning is a creature comfort that most people want, for those of us old enough to remember the trips on the old vinyl seats soaking with sweat.

"Cars are to be driven and enjoyed, suffering for historical accuracy is not part of any build plan I have ever done" 

k. Interior; Dash, centre consul, hood lining, seats, doors, instrument panel internal lighting.

Changing seats has registration, insurance & engineering certification in some states)

l. Glass & rubbers, window mechanisms.

Most ground up restoration require rust repairs that require removal of the front and or rear window.

m. Body parts, paint & body repair materials, nuts & bolts and other fasteners including glues and solvents

n. Labour spreadsheet

"Road" "Race" "Science"

You have the car, you have the vision.

You have assessed the car, it can be saved.

Now you are ready to begin to bring your vision to life.


RRS has put this build plan page together to share our CEO and founder's knowledge acquired over nearly 40 years of car building and modifying .

"The most common error in building a modified car is the lack of a detailed plan with associated budget, time table and activity process."


Step 1: List all components that need restoring, replacing or modifying

Step 2: Write wish list of components

Step 3  Cost of labour and parts

Step 4 Vision of the vehicle’s performance and intended usage


d. Legal requirements eg. Emission and safety

Every jurisdiction has different rules, please check with your local authority.

Example Western Australia requires approval for a change of colour.

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