Frequently Asked Questions – AK40
Yes, we can supply our build manual on a usb stick with your chassis kit. You will also get a password once you have secured your chassis manufacture date with us to our members only area, which has the AK40 build manual with video clips with hints and tips on every stage of the build. We are available by phone or email should you require any technical advice throughout your build.
The body is made from glass fibre. We use the highest quality glass and resin, this ensures that our bodies achieve very smooth lines with no sags, bumps, or ripples. The bodies are as a standard finished in a mid-grey gel colour. You do have the option for a small additional cost at your initial body order stage to have a second gel coat colour, second coat gel is only advised if you do not wish to have the car painted at the end of the build. Gel coats are available in a vast range of RAL colours. Please note however that the body will require a good amount of prepping before being ready to use on the road finished. It will be supplied to you straight from the mould complete with flash lines that will need to be rubbed down sanded and polished.
The AK 40 Standard body in mid-grey
Full range of gel coat colour options
No, it is not a necessity that the body be painted. We offer the body at your initial order stage with an additional coat of gel finish in a vast array of colours for a small additional charge. This is commonly used for cars being built on a tight budget or that are going to be used on the track. The second gel coat colour will save you paying money for paint that is likely to acquire many chips if being used on the track. Please note however that the gel coat finish will never look as good as a paint finish and can only be offered in a solid colour, so no metallic or pearl finishes are available. Vinyl stripes, roundels and numbers can be added direct to the prepared gel coat body if you so desire.
AK40 chassis – Powdercoated black as standard
You will require the aluminium panel kit. Front & Rear Uprights, suspension, brakes, engine and gearbox, clutch, brake and fuel lines and components, a cooling system, steering system, exhaust system, body, windscreen, bulkhead screen & rear screen and brightwork, cockpit instruments, steering wheel and switches, lights, wiring loom, interior and wheels and tyres… many of these parts are available from AK.
Yes, we can build the car to any stage for you before delivery. For those not mechanically confident we can also offer a rolling chassis option. We can build the car to any stage of completion for you.
- Chassis
- Panel Kit c/w Panel fixing kit
- Front & Rear hubs including clevis pin & spinners
- Shock Absorbers (adjustable ride height and damping – Nitron) & Springs x 4
- Wishbones, tie bars, rose joints with fitting kit
- Front & Rear Anti Roll Bars
- Radiator
- Cooling Fans x 2
- Centre Tunnel Cooling Pipes
- Fuel Tanks x 2
- Wheels & Tyres x 4
- Steering Rack
- Brake Pipes & Fitting kit
- Clutch Pipes & Fitting kit
- Brakes Complete, to include callipers, rotors & handbrake callipers x 2
- Steering Column complete
- Steering wheels c/w quick release centre
Contact AK for prices for the above parts all assembled for you.
Yes, we produce 6 factory builds a year. The car can be built around your specification and there are many options on parts that can be discussed prior to you placing your order. Please contact the AK team to discuss the factory build package on 01733 267633.
Specification Coyote Engine/ ZF Quaife Gearbox – FEB 25
Chassis
- AK chassis with lowered floor pan, finished in satin black powder coating (Other colours available extra)
- Ali panel set fitted.
Body
- Complete MK1 GT40 Body shell complete. Hand laid gel with High temperature resin throughout. (Gurney bubbles available)
- Full heat protection on rear clam.
- All inner arches fitted.
- Twin Nostrils.
Axles
- Front & Rear aluminium uprights including top & bottom clevis pin assy, bearings, pin drive hubs, steering arms & spinner.
- Dual circuit AP Racing brakes front and rear.
- Brembo handbrake calipers.
- OBP bias adjustable pedal box.
- Drive by wire throttle.
Steering
- AK’s steering rack with twin U/J rack to column extension.
- AK collapsible steering column.
- Quick release steering wheel.
Wheels and Tyres
- Image BRM replica 15” wheels 8” front 10” rear.
- Period 15” Tyres 215/60/15, 275/50/15.
Engine
- 460 BHP Generation 3 Ford Coyote.
- Jenvey Throttle bodies.
- Canems ECU.
- AK Alloy radiator.
- 2 X 12” fans Thermo Switch with Dash override button.
- Alloy header tank.
- Silicone hoses throughout in Black.
- Air conditioning unit.
Brakes
- AP Racing 4 pot Brakes front and rear.
- Brembo handbrake calipers.
Clutch
- Ford Coyote Standard clutch.
- Hydraulic clutch release bearing.
Transaxle
- Quaife ZFQ 5 speed gearbox.
- Dog leg box.
Exhaust system
- Bundle of snakes 1 ¾” stainless.
- Exhausts wrapped in heat protection.
Electrical & Dashboard
- Period dashboard layout.
- Savage dash switches.
- Start button.
Flight LED white period instruments includes: - Speedo.
- Rev counter.
- 2 x fuel gauges.
- Oil pressure.
- Water temperature.
- Volts.
Exterior & Brightwork
- Tinted laminated heated front screen.
- Laminated bulkhead screen.
- Laminated rear clam glass.
- Perspex side windows with hatch.
- Single wiper with washer jet.
- Zeus fixings for front clam, rear clam and nostril.
- Period headlights.
- Front and side indicators.
- Period rear lights.
- Period number plate lights.
- GT40 style Filler caps.
- Body painted by AK’s Painters – Standard car colour of your choice (vinyl stripes and decals extra)
Interior
- Period seats with ringlets, Black.
- Jaguar quality black carpet.
- Three-point Willans black seat belts.
- Dash in Alcantara and black leather.
- Instruments – All Smith’s flight LED White.
- Switches – To be illuminated round brushed aluminum Savage range and consisting of:
- Hazard
- Heater
- Rear fog
- Side lights
- Head lights
- Heated screen
- Horn
- Main beam
- Air conditioning
- Air con fan
- Radiator fans
- Fuel pump crossover switch
- Wiper switch
- Screen wash button
- USB socket
- Alloy gear lever knob
- Period correct right hand side gear shifter.
- Mountney leather steering wheel
- Quick release boss.
- Immobilizer fitted.
- Interior mirror
- Driver and passenger mirrors, body mounted.
ALSO AVAILABLE AS LEFT-HAND DRIVE OPTION
Vehicle will be put through the UK’s Vehicle Inspectorate Low Volume Scheme, registered and taxed for 6 months.
The average build will take around 800 hours. This is from start of build to on the road.
No. Every item on the AK40 is new, except for, the Ford 302 engine if you are opting to go old school!!
The decision ultimately is yours! You can use Ford 302 V8. Or if you want a brand-new crate engine then the 5 Litre Ford Coyote. Some clients are now breaking the norm and fitting other V8 engine options including the Chevy 6.2 Litre LS3 engine with over 430 BHP. Jenvey throttle bodies which change the look of the engine to more of an old school look and increase the bhp by around 30 bhp. For factory build car’s, we as manufacturers are restricted to using the Ford Coyote engines or Chevy LS3 engines to comply with current UK emissions. This does not apply to amateur builds, so if you are doing a self-build then your emissions test will be based on the year of your used engine block. All old block engines will be required to be verified with evidence of the engines age.
FORD 302
FORD COYOTE
Chevy LS3 WITH JENVEY THROTTLE BODIES
You can use a New or reconditioned Renault transaxle. We recommend the new Quaife gearbox. Automatic gearboxes can also be used, please contact us for more information on these.
We made some design changes at the end of 2024 and now have several clients at 6’3” who are comfortable in the driver’s seat. We have alternative options available to taller clients including an extended foot pedal and the use of different seats to further offer that little bit extra on leg space.
No, other than what you can fit in the passenger side and door compartments.
The average lead time for a chassis kit is around 10 weeks. Body slots are around 3 – 4 months and factory build cars are normally in the region of a 9 – 12 month lead time.
A £1000 deposit secures your chassis manufacture date / collection date and the final balance payment for a chassis package or rolling chassis is due on or before the agreed collection/delivery date. Factory build costs are split over 3 staged payment dates throughout the build after the initial £1000 deposit is paid, the final payment on completion of the car.
We always recommend a factory visit where you will be welcomed to have a full factory tour and weather dependant, a passenger ride in one of our company demonstrator cars. We can then discuss with you the different body and chassis options and offer you a chassis manufacture date to suit your build start date. If a factory visit is not a possibility, we would be happy to talk you through the list of options shown on our AK40 kit order form to ensure your body and chassis are manufactured exactly to your wishes.
We have both Distributors and Build Agents in various countries worldwide. Contact us and we will put you in touch with local to you AK agents.
If you are based in the USA or Canada and looking for a fully built car, then please contact us and we will arrange for our distributors to contact you directly to discuss your AK40 project.
PLEASE DOWNLOAD OUR ORDER FORM (PDF)
Yes, so long as you adhere to the parts that we recommend and fit them as advised then your finished car will pass the test. AK offer a service to carry out a full IVA pre-test and can prepare and present your car for the IVA test procedure for you. Please contact the AK team for details on 01733 267633.
No, a moderate tool kit will be adequate for the car build.
The ride quality is suitable for everyday use, long distance touring and track events. With fully adjustable shock absorbers the ride quality can be altered by changing the damper settings in a matter of minutes from comfortable road settings to track day settings.
Yes, based on your exact specification for your car. You will find the costs for those parts on our AK price list. We recommend you purchase small range of standard nuts and bolts in various sizes.
We recommend using our tried and tested UK supplier Power Torque Engineering Ltd for your Coyote engine. Contact AK Sportscars for your Quaife gearbox. www.powertorque.co.uk / Tel: 02476 635757
Yes, the AK has adequate ground clearance for road calming devices and ferry loading ramps. A diagonal approach is recommended for particularly steep driveways or speed humps. If in doubt take the diagonal option!
The costs of course will depend mainly on your engine and gearbox option you choose to build the car. An average customer will spend in the region of £80,000 – £100,000 on their build. Budget builds can be achieved for as little as in the early 70’s whilst budget blowers can spend into the late 120’s on their builds.
We would expect the following averages…. Ford 302 16-18 mpg, Ford Coyote – 25 mpg and the Chevy LS3 – 25 mpg.
Once you have mastered the technique then you should have no problems. We expect you will have this conquered by attempt number 3. The art is in holding your body weight on your arms to get your bottom onto the side sill OR alternatively if you have clean shoes, standing on the seat.
Yes, we a few clients who use the AK40 as their daily drive. You have a heater for the winter months. Air conditioning can also be fitted for summer and for cars travelling to hotter climates.
Yes, you do not have to use the AK supplied seats, but you will need to ensure the alternative seats comply for passing the IVA testing.
Yes, this is no problem, we can adapt the AK chassis to accommodate an automatic gearbox. We have a local company that can fit a hand control system to the car, we also allow for a few modifications for purposes of access and carriage of a wheelchair.
AK427 WITH HAND CONTROLS FITTED- similar can be fitted to the AK40
Yes, you do not have to use the AK recommended BRM wheels, but you will need to ensure that you have the correct offsets to pass the IVA testing requirements.
Overall Length
Front and rear clips open 4,375 mm
Front and rear clips closed 4,225 mm
Overall Width
Doors open 3,715 mm
Doors closed 1,850 mm
Height 1,000 mm
Wheelbase 2,415 mm
Track
Front 1,460 mm
Rear 1,535 mm
Toe in
Front 4mm or 1°
Rear 0mm or 0°
Camber
Front – 1°
Rear 0 to -1°
Caster
Front +4 to +5°
Rear +7 to +11°
AK 40 DESIGN WEIGHTS
AXLE 1 638 kg
AXLE 2 780 kg
GROSS 1400 kg
Once you have placed your chassis order and have a date to aim for, the following is the AK40 build stages:
1. Set chassis on stands
2. Fix panels to the chassis
3. Loosely fit pedal box
4. Cut and fit panel 6
5. Attach support mesh to inner sills (optional)
6. Fit front wishbones and uprights
7. Fit rear wishbones, tie bars and uprights
8. Set measurements of wishbones
9. Fit front and rear shock absorbers and springs
10. Fit steering rack and track rod ends
11. Fit front and rear anti roll bars
12. Fit discs and calipers
13. Fit edge protection around front upper sill holes
14. Fit brake lines
15. Fit clutch line
16. Attach brake and clutch lines to pedal box
17. Fit master cylinders
18. Fit loom loosely in position
19. Consider a drop down tray for fuses and relays (optional)
20. Fit floor
21. Fit lowered floor pans (optional)
22. Fit aircon unit, drier and trinary switch
23. Fit coolant pipes through tunnel
24. Fit radiator, coolant pipes and thermostat
25. Seal between radiator and body
26. Fit rack to mounts and track rod ends
27. Fit radiator bleed pipe.
28. Fit expansion tank and oil catch tank.
29. Fit overflow pipe from expansion tank
30. Fit cooling fans
31. Fit aircon condenser
32. Decide on air con pipe run and install
33. Decide on position of battery and install fixings
34. Fit battery cable positive
35. Fit battery earth
36. Fit screen wash bottle
37. Fit wiper motor
38. Fit horn
39. Fit radiator fan relays
40. Fit steering column, u/j’s, boss and steering wheel
41. Fit gear stick, casing and rods
42. Fit handbrake lever
43. Fit loom securely including earths x4
44. Decide on position of then fit fuel solenoids, pumps and swirl pot
45. Fit fuel hose.
46. Fit engine and gearbox mounting brackets
47. Trial fit engine
48. Make suitable hole in rear panel to accommodate rear gear linkage
49. Attach gear linkage
50. Attach coolant hoses to engine
51. Attach fuel hose to engine
52. Attach loom to engine
53. Attach battery cable to engine
54. Attach earth strap(s) to engine
55. Attach exhaust system
56. Attach handbrake compensator to calliper
57. Fit body