Virginia Motor Sport Club Discussion Forums

General => Autos and Autosport => Topic started by: jloehlein on November 29, 2014, 03:20:13 PM



Title: Factory Five Cobra Build
Post by: jloehlein on November 29, 2014, 03:20:13 PM
My Dad's Cobra showed up on Wednesday.  I figured I'd try and keep a build thread on here with the progress.  He unloaded it with the driver on Wednesday.  We inventoried all the boxes of parts it comes with and then pulled the rear end out of the parts Mustang on Thanksgiving.  Today, Jeff came over and we made a body buck to hold the body while I work on everything else.  Next, I've gotta figure out how to take the body off the frame and get it onto the buck.

Here's the Mustang sans rear end sitting with some of the other parts cars we have.  Classy.
(https://farm8.staticflickr.com/7514/15722328189_f197ef3e2c_c.jpg)

The car sitting next to the body buck
(https://farm8.staticflickr.com/7575/15908380165_9d6d632ab2_c.jpg)

Another view of the body buck
(https://farm8.staticflickr.com/7484/15722327909_1848801649_c.jpg)

Front of the car
(https://farm8.staticflickr.com/7504/15907727582_9185fcd2d8_c.jpg)

Fancy powder coated frame
(https://farm8.staticflickr.com/7486/15908378725_ab9460aa2f_c.jpg)

Many boxes
(https://farm8.staticflickr.com/7563/15286117174_baa552699b_c.jpg)


Title: Re: Factory Five Cobra Build
Post by: catapultkid on November 29, 2014, 03:49:05 PM
Looks awesome! Going to be a good thread. Looks like it just will fit in a two car garage with all the parts.


Title: Re: Factory Five Cobra Build
Post by: wahoo5 on November 29, 2014, 05:27:06 PM
This should be fun to follow. Thanks. When do you move into the new shop?

David


Title: Re: Factory Five Cobra Build
Post by: jloehlein on November 30, 2014, 05:13:10 AM
Hoping to be in the new shop around New Year.  I'm in no rush, but it would certainly be nice to have the additional space.


Title: Re: Factory Five Cobra Build
Post by: mazda6guy on November 30, 2014, 06:12:44 AM
Nice!!!!!   You now have me thinking of a similar build to keep me busy this winter unless I get a 250cc shifter kart.  Please keep us posted on the build and the ultimate garage that you are building too?


Title: Re: Factory Five Cobra Build
Post by: rothaus on November 30, 2014, 06:37:40 AM
  I'm in no rush, but it would certainly be nice to have the additional space.

There is always RUSH to get more space, ask me why I know.

Great Project ! If I'm not would be so much into the P-cars, this would be.... Never Mind.

Cheers
Engelbert


Title: Re: Factory Five Cobra Build
Post by: jloehlein on November 30, 2014, 05:38:42 PM
Hah, yeah.  I can't wait for the new garage.  I'll have to have some kind of party once it's done.  For now, I'm happy with the "small" 22x22' garage.  It's easier to heat :)

So, I got the body buck finished up today.  Just put in some diagonal bracing and shelves down the side.  Then, Paul came over to take a look and he and Danielle helped remove the body.  It must only weigh about 100lbs.

Finished body buck
(https://farm8.staticflickr.com/7515/15731141047_ccfa75fd3b_c.jpg)

Body mounted on the buck, all the boxes fit underneath.  I can roll it out of the garage if I need more room to work.
(https://farm9.staticflickr.com/8565/15732317739_a762c9ddea_c.jpg)

From the back
(https://farm9.staticflickr.com/8680/15732317199_9b14c1b4a1_c.jpg)

Now I've gotta start cleaning up the rear end out of the Mustang.  I ordered some POR-15 paint and will order some 3.08 gears.  Since the car is so light and the motor will likely only rev to ~5500rpm, the 3.73s in it now are way too aggressive.  3.08s should cruise at ~1900rpm @ 70mph and be able to do 70mph in 2nd and 130mph in 4th, which seems pretty good for autocross and track day use.


Title: Re: Factory Five Cobra Build
Post by: GeneCooley on December 01, 2014, 07:22:43 AM
X/P or E/M?


Title: Re: Factory Five Cobra Build
Post by: jloehlein on December 01, 2014, 07:58:50 AM
X/P or E/M?

Can I add some ballast and run it in CAM? :P

Classing isn't really a concern.  I'm hoping that once it's sorted out, it'll be a contender for FTD.


Title: Re: Factory Five Cobra Build
Post by: ccann26 on December 01, 2014, 12:08:28 PM
Kit car !

You did it wrong get a Vega......


Title: Re: Factory Five Cobra Build
Post by: GeneCooley on December 01, 2014, 01:58:26 PM
X/P or E/M?

Can I add some ballast and run it in CAM? :P

Classing isn't really a concern.  I'm hoping that once it's sorted out, it'll be a contender for FTD.

Classing is important in that it can make a difference in how you build the car and what kind of safety equipment you need.  There's not too much difference in requirements for X/P and E/M, but if you wanted an X/P car the rules are stricter than E/M (less allowed and more weight).  If you run E/M you can build a lighter car--1850# with most Ford V-8s.

The problem with CAM is that (unless the rules have changed) you can't run R comps or slicks, and also, nobody want to have a 3000# Cobra.  But that was a joke, right???

It's all good though, if we have 5 or 6 cars running for FTD it should be a really interesting year. I'm going to go out and spend some more money on the Fiat...

Keep posting updates,
Gene Cooley 


Title: Re: Factory Five Cobra Build
Post by: jloehlein on December 02, 2014, 04:59:05 AM
Yeah, I was joking about CAM.  We'll run whatever class it fits in, it's not important.  Looks like using the ABS system from the Mustang may kick it out of XP.  The safety requirements seem pretty simple in any of them.


Title: Re: Factory Five Cobra Build
Post by: GeneCooley on December 02, 2014, 08:03:55 PM
ABS (and Traction Control) are a problem in E/M also, unless it is an unmodified system that came on the car.  You can't add either to a car.

There's a chance that the D and E/M ABS rules will be changed eventually.  I tried this year to get a rule change to allow ABS/TC but it was shot down.  Others are still working on it

Gene


Title: Re: Factory Five Cobra Build
Post by: jloehlein on December 03, 2014, 05:32:58 PM
Here's a video (https://www.youtube.com/watch?v=MVoDPDmzPks&feature=youtu.be) of the assembled motor on the dyno.  I haven't seen a dyno chart, but supposedly it's making 600hp and 624ft-lbs of torque.  Engine builder says the Factor Five headers are fairly restrictive and we'll lose a bunch of power.  Should still be north of 400whp, which is plenty.  It's a 408 (bored, stroked 351W) with some kind of fancy heads and cam.  Plus an EFI velocity stack intake...because that's the easiest to fit under the hood :grin:


Title: Re: Factory Five Cobra Build
Post by: catapultkid on December 03, 2014, 05:58:02 PM
OH.... MY.... LORD....


Title: Re: Factory Five Cobra Build
Post by: wahoo5 on December 04, 2014, 08:20:46 PM
WOW. Looks great and sounds better. You won't be sneaking up on anyone.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on December 07, 2014, 04:45:59 PM
Well, I got a little bit more done this weekend.  Front suspension is on and the rear end is torn apart.  I've gotta order some parts (differential rebuild kit, front hub nuts) before I go much farther.  Hopefully they come in this week.

I started by removing all of the aluminum panels.  I made sure I labeled them all and recorded the order in which I removed them so I can put them back on without too much thinking.

Before:
(https://farm8.staticflickr.com/7493/15969036101_6a94991e05_c.jpg)

After:
(https://farm8.staticflickr.com/7511/15783611828_d206117fc3_c.jpg)

(https://farm8.staticflickr.com/7574/15783705920_95e91d4969_c.jpg)

Pile of aluminum panels:
(https://farm8.staticflickr.com/7541/15351382993_1e8f984543_c.jpg)


Paul came over and gave me a hand with the front suspension.  We got that together for the most part.  The hub nuts were backordered from Factory Five so I've gotta get some from elsewhere before I can bolt up the hubs and brakes.  We're going to use the brakes off my Dad's '95 Mustang Cobra.

Front suspension:
(https://farm8.staticflickr.com/7514/15784985849_519af5b01b_c.jpg)


I also disassembled the rear end.  It's currently got 3.73 gears, which will get swapped out for some 3.08s.  I'll be rebuilding the Eaton Posi that's already there and painting the whole housing.

Here's the rear as it came out of the Mustang.  It's only slightly crusty:
(https://farm8.staticflickr.com/7574/15970342552_55432e28f3_c.jpg)

I ground off the quad shock mounts and hit the whole thing with a wire wheel and degreaser:
(https://farm8.staticflickr.com/7516/15785294947_ce09eb61da_c.jpg)

Here it is completely disassembled:
(https://farm9.staticflickr.com/8574/15970350102_8d8957ddb4_c.jpg)


If I have time this week after work, I'll start prepping and painting the rear end so I can hopefully mock it up in the car next weekend.  If I can get the steering rack and front brakes in, the front end will be good to go.  Then just finishing up the rear end and I should be able to roll it around.

In other news, the sheeting on my building is up.  They need to do the trim and gutters and I need to put the garage doors up.  Hopefully we can get the power run this month and everything hooked up in January.

(https://farm8.staticflickr.com/7556/15969006301_0ceb343744_c.jpg)

(https://farm8.staticflickr.com/7544/15969005601_bbc05300ba_c.jpg)


Title: Re: Factory Five Cobra Build
Post by: ccann26 on December 07, 2014, 07:19:33 PM

 That garage !


Title: Re: Factory Five Cobra Build
Post by: jamescarriv on December 09, 2014, 08:00:09 AM
That mud!


Title: Re: Factory Five Cobra Build
Post by: jloehlein on December 09, 2014, 05:54:28 PM
That mud!

Yeah, we've still got to do final grading.  Putting a greater slope on the swale around the building so it drains out to the woods is on that list.  And covering everything with stone should help.  So much stone.  In the mean time, at least I get to test the 4wd capabilities of my truck on super-bald tires.


Title: Re: Factory Five Cobra Build
Post by: ccann26 on December 09, 2014, 06:21:54 PM

 I thought I saw doughnuts in the mud...


Title: Re: Factory Five Cobra Build
Post by: rothaus on December 09, 2014, 08:19:24 PM
It cannot be big enough, yes yes yes


Title: Re: Factory Five Cobra Build
Post by: pipefitter on December 11, 2014, 03:52:59 PM
How big is it? 30'x 60'? It looks great.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on December 11, 2014, 06:20:21 PM
How big is it? 30'x 60'? It looks great.

It's 32'x80'.  I was originally planning on a 50'x80' building, but the county didn't want that since it's bigger than my house.  Also, anything north of 3000sqft is considered commercial and I'd have needed to have two separate handicap-accessible restrooms (one men's, one women's) and a bunch of other BS.  This route was easier than trying to fight that and it really should be plenty large enough.  I just won't be able to drive a tractor trailer through it like I could have with the other one.


Title: Re: Factory Five Cobra Build
Post by: whiteryder on December 12, 2014, 06:44:51 AM

If you're looking for a decor/paint scheme, I just saw this guy's collection on an episode of Car Fix.
Found some pictures of it online for you. 

Scroll to page 4, "Shazam":
  http://tvraaca.org/voyager/Jun2012-JuneJubilee.pdf

Scroll to "Mystery Tour to Tommy Smalls Collection in Dade City 9/4/10"
  http://local.aaca.org/hillsborough/photos.htm



Title: Re: Factory Five Cobra Build
Post by: pipefitter on December 14, 2014, 03:08:32 PM
 Are you planning to run a business from it, or simply using it for your own projects? I do have an old SCCA race car that would fit in there really well................


Title: Re: Factory Five Cobra Build
Post by: jloehlein on December 16, 2014, 06:50:13 PM
Are you planning to run a business from it, or simply using it for your own projects? I do have an old SCCA race car that would fit in there really well................

Hah, just my own projects.

This past weekend, I didn't get a ton done.  I did manage to rebuild the Eaton Posi that was in the car, paint the rear end, and remove the power steering rack from the parts car.  I'm hoping this coming weekend I can re-assemble the rear end, put new tie rods in the steering rack and get them both in the car.  I've also got the next two weeks off of work and my Dad is coming down, so we should be able to make a bunch of progress.

Dirty carrier:
(https://farm9.staticflickr.com/8660/15853720797_f21e1d8455_c.jpg)

Stripped down and wiped off:
(https://c1.staticflickr.com/8/7537/15852204500_f0fddc9ddf_c.jpg)

I put it back together, but didn't take any pics.  It took about 20 minutes to get it shimmed properly (as far as I can tell), but it was fairly simple.  I've gotta remove the old bearings and press new ones on, then install the new ring gear.

I cleaned off the rear end and prepped it with some chemicals that are needed for POR 15.  I also cleaned and treated the rear calipers, brackets, and heat shields.
(https://farm8.staticflickr.com/7559/16038774952_18783180c9_c.jpg)

I painted the rear end with 3 coats of POR 15 and 2 coats of flat black Rustoleum.  The brackets and calipers have 1 or 2 coats of POR 15 and several coats of VHT caliper paint.  This picture is prior to putting the flat black on the rear end:
(https://farm8.staticflickr.com/7484/16039482435_1d67ce67de_c.jpg)

I'm looking forward to the next few weeks.  We'll see how far we can get.  Who knows, maybe the motor will even show up.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on December 23, 2014, 06:30:23 PM
Well, we finally got the rear end finished up.  Thanks to a bad pinion bearing, I lost about a day trying to figure out why the gear pattern looked horrible no matter how we set it up.  Once we replaced the bearing and got it shimmed up right, the pattern looked about perfect.

Here it is all buttoned up:
(https://farm8.staticflickr.com/7573/15904054158_f5a2181ef8_c.jpg)

And in the car with the 3-link setup:
(https://farm9.staticflickr.com/8624/16065693946_5f9c2f9dbe_c.jpg)

Also got the power steering rack in the car.  We had to shorten the inner tie rod ends about an inch, but it looks like it'll work out fine.
(https://farm9.staticflickr.com/8596/15905739087_e85ebaf038_c.jpg)


Title: Re: Factory Five Cobra Build
Post by: jloehlein on December 30, 2014, 07:20:40 PM
Well, got some more done in the last week.  My Dad was down for a while.  We spent a couple days in Delaware with Danielle's parents and a few days putting up garage doors, so only a few days working on the Cobra.

We did manage to get the steering system buttoned up, the pedal box and gas tank in, and started on the aluminum panels.

Here's the car as it sits now:
(https://farm9.staticflickr.com/8616/15966052019_d5f90399bf_c.jpg)

From the back:
(https://farm8.staticflickr.com/7571/16126336816_1f871d7bc1_c.jpg)

My Dad sitting in it:
(https://farm8.staticflickr.com/7504/15964816060_f9334f6db7_c.jpg)

Clecos are great for holding everything together, I hadn't ever used them before:
(https://farm9.staticflickr.com/8657/16150223071_8636ded91b_c.jpg)

There was some interference between the clutch pedal and a chassis tube.  Apparently, this is a common issue:
(https://farm8.staticflickr.com/7504/15964820570_d784923b6b_c.jpg)

Some people notch the tube, but we thought it would be smarter to notch the pedal:
(https://farm9.staticflickr.com/8601/16151371582_30f0d5d0f8_c.jpg)


Lastly, here's a couple shots of the garage as we put the doors up.  I bought some scaffolding with some of the money I saved by doing them myself.  Still have a couple days of work left to get rest of the horizontal tracks and the openers up.  Ricardo is working on the interior room and I've gotta get the rough grading and electric done next.  Hopefully I'll be in some time in February.

(https://farm8.staticflickr.com/7551/15966365687_4d4ffbbb47_c.jpg)

(https://farm8.staticflickr.com/7549/15966365037_0d41e7c99f_c.jpg)



Title: Re: Factory Five Cobra Build
Post by: wahoo5 on December 31, 2014, 05:08:55 PM
Did you end up hanging the doors yourself?

David


Title: Re: Factory Five Cobra Build
Post by: jloehlein on January 01, 2015, 06:12:50 AM
Did you end up hanging the doors yourself?

David

Yeah.  It's a fair bit of work to get the horizontal tracks hung because There is no ceiling, but it's not very complicated to do.


Title: Re: Factory Five Cobra Build
Post by: pipefitter on January 01, 2015, 07:43:28 AM
What are you going to grade it with?


Title: Re: Factory Five Cobra Build
Post by: jloehlein on January 01, 2015, 12:19:07 PM
What are you going to grade it with?

$$$.  Someone with the right equipment will be doing it.  My guess is they'll need to dig some ditches to drain the water and let it dry out a bit before coming in with a bulldozer or something.


Title: Re: Factory Five Cobra Build
Post by: pipefitter on January 01, 2015, 03:49:17 PM
Are you willing to fool with it? I have a small Kubota tractor with a backhoe, if that would do any good.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on January 01, 2015, 04:00:30 PM
Are you willing to fool with it? I have a small Kubota tractor with a backhoe, if that would do any good.

I appreciate the offer.  Let me see what my guy comes back with.  I've got so many projects that I won't mind having someone do this.  I've gotta have over 1/2 acre covered in stone too, so my guess is that it will be really easy with a large piece of equipment.


Title: Re: Factory Five Cobra Build
Post by: pipefitter on January 02, 2015, 07:34:26 AM
That's probably a little more than my tractor is up to.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on February 23, 2015, 06:25:26 PM
So, it's been a while.  It's been really cold out and I had a handful of small projects here and there to wrap up, like replacing the coils on my Insight after one died on my way to work.  That's no fun when you don't have garage space.  Thankfully this guy is coming along.  The electric stuff is currently being installed.  After that, I just need to get the final grading done and pour my aprons.  It should be good to go.

(https://farm9.staticflickr.com/8650/16443511689_6bfaab637d_c.jpg)

We finally got the motor for the Cobra in January, so my Dad made some plans and came down last weekend to get it into the car.  It fits, so now I can start mocking up where to mount all the stuff around it like the fuel pressure regulator, ABS pump, and figure out how I'm going to run the wiring.

The truck driver unloaded the motor onto my trailer in the street and I backed it down the driveway to drag into the garage:
(https://farm8.staticflickr.com/7418/16430610672_ea3ce71cf6_c.jpg)

Here it is on the crane:
(https://farm9.staticflickr.com/8678/16421940687_cfaee1dd69_c.jpg)

Then in the car:
(https://farm9.staticflickr.com/8597/16628569772_d1be2c6d77_c.jpg)
(https://farm9.staticflickr.com/8577/16629230655_d50655dfd2_c.jpg)

We test fitted the headers.  The aluminum part I've got my hand on is the driver's side footbox.  People say it gets really hot and I can see why.  We'll be heat wrapping the headers and I'll be making heat shields for the footboxes.
(https://farm9.staticflickr.com/8682/16628137261_2e1e832a8b_c.jpg)

I had to order some offset dowel pins to position the steel bellhousing correctly, so I'll have to wait for those before I can put the transmission in.  We're also going to use solid motor mounts which we don't have yet, so I'm sure I'll be pulling the motor at least a couple more times.  Thankfully, it's pretty easy when there's no body in the way.


Title: Re: Factory Five Cobra Build
Post by: catapultkid on February 23, 2015, 07:54:36 PM
I was hoping to see one of the "test fits" inside the lemons miata bay...

Motor looks nuts!


Title: Re: Factory Five Cobra Build
Post by: DamnYankee on February 27, 2015, 06:08:24 AM
Sweet project. Where you located ?
Ron


Title: Re: Factory Five Cobra Build
Post by: jloehlein on February 27, 2015, 06:00:39 PM
Sweet project. Where you located ?
Ron

I'm out in Powhatan.  You?  I'm actually looking for a point of reference to figure out if I can mount my fuel filter on the firewall.  I think it will depend on how much the body overhangs it, which will determine if the element can be removed from the top when the car is assembled.


Title: Re: Factory Five Cobra Build
Post by: DamnYankee on March 04, 2015, 11:19:12 AM
I used an in-line filter near the tank.


Title: Re: Factory Five Cobra Build
Post by: DamnYankee on March 05, 2015, 07:23:03 AM
And I'm in Mechanicsville, about 10 miles east of RIC airport. I'd be happy to drive the car over there if it ever dries out :-)


Title: Re: Factory Five Cobra Build
Post by: jloehlein on March 08, 2015, 02:52:02 PM
And I'm in Mechanicsville, about 10 miles east of RIC airport. I'd be happy to drive the car over there if it ever dries out :-)

Nice, I'll shoot you an email.  Would be good to take a look at your car before I start drilling holes in my Dad's :)

Over the past couple weekends, I tackled a couple other projects.  I did manage to run some mig wire along where I'm planning to run the fuel lines.  I tried a couple routes: 1) on the outside of the passenger frame rail and 2) inside the trans tunnel (as recommended by the engine builder!?!?).  I'm definitely going to run the lines on the frame rail, it seems a bunch safer and is not any more complicated.

(https://farm8.staticflickr.com/7287/16757639025_4c0b94b570_c.jpg)

(https://farm9.staticflickr.com/8685/16731753556_8ebca6df1d_c.jpg)

(https://farm8.staticflickr.com/7592/16550380807_449a6636d1_c.jpg)


Once I got that laid out, I pulled the motor back out to put the the steel bellhousing on and attached the transmission, which was way more of a hassle than it should have been because I didn't notice that the clutch alignment tool had a smaller diameter pilot surface than the transmission.  Once I realized why it wasn't lining up, I just used the transmission to line up the clutch.  I also cut some mounting points off the rear of the transmission that interfere with the frame.

(https://farm8.staticflickr.com/7602/16570066368_d43137c963_c.jpg)

(https://farm9.staticflickr.com/8658/16571515299_42b390713d_c.jpg)

(https://farm8.staticflickr.com/7628/16550375797_fb50da8a5b_c.jpg)


Title: Re: Factory Five Cobra Build
Post by: jloehlein on March 29, 2015, 05:21:28 PM
Made some more progress.  I pulled the rear end out to get it narrowed 1.5" so that we can keep the ABS.  I also got the motor back in, made the fuel lines, and mounted up a power steering cooler.

PS cooler mounted to some 1" square tube.

(https://farm8.staticflickr.com/7628/16959651285_01ff251c12_c.jpg)


The FFR kit comes with an in-tank fuel pickup for an external fuel pump.  I wanted to run an in-tank pump, so I picked up a 320lph pump that came in a pickup with AN fittings welded on.

(https://farm8.staticflickr.com/7646/16958707021_e9c48d9143_c.jpg)


The fuel supply line is 1/2" and the return is 3/8".  I'm using stainless steel hardline which comes in coils, so I had to straighten them out.

(https://farm8.staticflickr.com/7644/16958309562_75ab682548_c.jpg)


Tube straighteners are ~$300 and basically just some wheels in an adjustable frame.  Folks online have made them, and I had some scrap angle iron laying around, so I ordered some concave wheels and got to work.

(https://farm8.staticflickr.com/7600/16339562223_6671abb135_c.jpg)

(https://farm9.staticflickr.com/8702/16337286424_cecb6b068a_c.jpg)

(https://farm9.staticflickr.com/8749/16771962768_0ae325b763_c.jpg)


The finished product in action.  It works pretty well.  The final result isn't perfectly straight, but I can work with this.

(https://farm8.staticflickr.com/7628/16958697511_14eb3c944f_c.jpg)

(https://farm8.staticflickr.com/7587/16933707376_6d6475c52f_c.jpg)


I spent probably a whole day measuring, bending, test-fitting, measuring, removing, bending, test-fitting, etc. over and over again.  I must have removed and installed the lines about 50 times.  I got the 1/2" line finished up first since the 3/8" is a bit easier to work with in case I needed to tweak it to fit next to the 1/2" line.  The end result looks pretty good to me.  I still need to make a few braided hoses to connect the lines to the fuel pump and the pressure regulator, but that should be pretty quick.

The hard lines start at the back of the car.  AN hose will connect them to the fuel pump, running under the panhard rod mount.  I was originally going to run the hard line under the panhard rod mount, but realized that I needed to be able to remove it to get the rear end out.

(https://farm8.staticflickr.com/7287/16970747832_8949463ab1_c.jpg)

I used some fancy-pants aluminum clamps to mount the lines to frame.

(https://farm9.staticflickr.com/8741/16349710624_0c2032086c_c.jpg)

(https://farm8.staticflickr.com/7626/16351981533_cf96058037_c.jpg)

The lines come through the engine bay on the passenger side footwell.  I mounted the filter there, where it seems like it will be easy to access.  I wish the filter opened up from the other end because then it would have been easier to mount at the rear of the car near the fuel tank where there is plenty of room.

(https://farm9.staticflickr.com/8716/16349709474_7d3484cb68_c.jpg)


I'll probably wrap up the power steering system next.  Then onto the brakes, which I'll use my tube straightener and bender for again.


Title: Re: Factory Five Cobra Build
Post by: wahoo5 on March 29, 2015, 06:23:38 PM
Pretty slick.

David


Title: Re: Factory Five Cobra Build
Post by: jloehlein on April 26, 2015, 05:23:48 PM
So, I had the last week off of work and my Dad came down to help out on the garage and the car.

We wrapped up the power steering cooler
(https://farm8.staticflickr.com/7674/16662799293_4fd2e2c650_c.jpg)


We also started on the wiring
(https://farm8.staticflickr.com/7661/17095255938_609f5641c0_c.jpg)


There is a ton of extra wire that I'll have to clean up
(https://farm8.staticflickr.com/7724/17281207862_f38937fba7_c.jpg)


I bent up some pipe to get water to the heater core
(https://farm9.staticflickr.com/8800/17281209592_494c92474a_c.jpg)


It's coming along!
(https://farm8.staticflickr.com/7686/17283029935_8db0f8875e_c.jpg)


We also put up plywood panels in the workshop portion of the garage and the electrician was able to wrap up his work.  We started moving some stuff down there for storage.  Hopefully this week the aprons get poured and then we can finish spreading stone around the building.
(https://farm8.staticflickr.com/7693/17075587487_70e6c51ec6_c.jpg)


Jeff came over Saturday and gave me a hand welding up this awesome workbench/toolbox using some parts bins that I picked up from a Radio Shack that was closing.  I'm happy with the way that it came out and am making a couple more.
(https://farm9.staticflickr.com/8705/17283021085_b6e3af0781_c.jpg)


Title: Re: Factory Five Cobra Build
Post by: rothaus on April 26, 2015, 05:44:19 PM
Power steering, Water cooling, Heat core, what do you need all that stuff for ? LOL.

Looks great ! Glad to see that you moved to the new space, and the plywood is up. Like the monster drawer cabinet. Soon that engine will make some sound.

Cheers
Engelbert


Title: Re: Factory Five Cobra Build
Post by: jloehlein on July 23, 2015, 06:26:19 PM
Well, it's been a busy few months, so I haven't made a ton of progress on the Cobra.  My Dad and I did manage to roll it down to the big garage a few weeks ago and I just started work on the brakes.

Here it is sitting in the new garage
(https://farm1.staticflickr.com/532/19955616705_4a605dac49_c.jpg)

(https://farm1.staticflickr.com/483/19929382876_662bf66d8f_c.jpg)


I'm installing the ABS from the Mustang into the Cobra, which is going to complicate things quite a bit, but hopefully be worth it.

Here is the pump, I need to find a place to mount it
(https://farm1.staticflickr.com/330/19767552518_c114c02ea8_c.jpg)

The factory mount isolates the unit from vibration.  I want to use as much of it as possible
(https://farm1.staticflickr.com/330/19960776421_66416076a9_c.jpg)

(https://farm1.staticflickr.com/506/19332949384_587454057d_c.jpg)

I cut off the horizontal mounting points and welded on a tab to get three bolt holes on roughly the same plane
(https://farm1.staticflickr.com/436/19929389816_ec7cb469d1_c.jpg)

(https://farm1.staticflickr.com/527/19767571948_2029aa4c34_c.jpg)

I decided to mount the unit in the front passenger side of the engine bay.  I made a brace to bolt the mount to.  I will paint the brace and mount gloss black to match the chassis
(https://farm4.staticflickr.com/3753/19768931269_1205083497_c.jpg)

(https://farm1.staticflickr.com/437/19332933264_8ca8f60834_c.jpg)

(https://farm1.staticflickr.com/457/19334640303_8ce8524d12_c.jpg)


Title: Re: Factory Five Cobra Build
Post by: MikeDe on July 26, 2015, 04:57:41 PM
Justin,
     I just gotta say that this is freaking awesome, what an experience for you and your Dad to literally build a car from the ground up! I love reading up on the post.



Title: Re: Factory Five Cobra Build
Post by: jloehlein on July 27, 2015, 08:04:00 PM
Justin,
     I just gotta say that this is freaking awesome, what an experience for you and your Dad to literally build a car from the ground up! I love reading up on the post.

Thanks!  We're having a lot of fun.  Hopefully now that that garage is together and the car and all my tools are down there I'll be able to make some quicker progress.  Would love to have it running (sans body) by the end of the season and then tackle the bodywork over the winter/spring.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on August 10, 2015, 03:45:30 AM
Well, I made some more progress in the last couple weeks.  Paul and I had been talking about wanting to be able to roll cars around our garages, so we built a couple sets of wheel dollies.  I can move the car around the garage alone without having to make a lot of turns, which is nice.

(https://farm1.staticflickr.com/481/20199623222_3ccc61c958_c.jpg)

(https://farm1.staticflickr.com/517/20019792368_ebd4961f8b_c.jpg)


Looking at the factory position of the rear brake calipers, I didn't like the options I had for running the brake lines, so I decided to swap the calipers to the front side of the axle, which required pulling the rear end apart for like the third time.

(https://farm1.staticflickr.com/495/20207830535_fb0695bcb8_c.jpg)

I had to grind a notch into the opposite end of the mounting flange on the axle to accommodate the ABS sensors.

(https://farm1.staticflickr.com/504/20250520030_a7e24fda76_c.jpg)

I mounted the passenger caliper on the driver side and vice-versa so the bleeders are in the correct position.

(https://farm1.staticflickr.com/495/20251953999_840d3a39ac_c.jpg)


Lastly, I spent yesterday starting to run the hard brake lines.  The lines from the master cylinders the to ABS pump are at least parallel to each other, though I need to figure out how to brace them.

(https://farm1.staticflickr.com/285/20251967439_120e7d5fcb_c.jpg)

(https://farm1.staticflickr.com/347/20250526600_043fdfa5c1_c.jpg)


I need to run a hard brake line to the rear of the car, install the soft lines and mount the fluid reservoir.  Once that's in place, the brakes should work, though I'll need to wire up the ABS.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on August 16, 2015, 04:28:35 PM
Well, it was a productive weekend, though most of the progress was on the garage rather than the car.  Since I moved all my tools down, many have been taking up space on my workbenches while I figured out where to put them.  Since nothing had a real "home", I kept putting stuff down wherever I last used it, which meant I kept losing things and spending 5 minutes just finding them again.

I decided that I wanted most of my hand tools up on the wall where I could see them clearly, so I ordered a bunch of Ernst socket rails and wrench organizers that I could hang.  In addition to those, I made some wooden holders for my ratchets and extensions.

I laid out a pattern in a piece of scrap wood and drilled a bunch of holes

(https://farm1.staticflickr.com/676/20449007330_2b28bc70ec_c.jpg)

Holds my extensions well

(https://farm1.staticflickr.com/760/20016077423_6da8437ac8_c.jpg)

I drilled some more holes in a piece of scrap to hold my ratchets

(https://farm1.staticflickr.com/782/20016075163_e5b2959cba_c.jpg)

Mounted them on the wall with metric sockets on the left, SAE on the right

(https://farm6.staticflickr.com/5691/20014438284_4260c8f15a_c.jpg)

And then mounted the rest of my tools.  Having all of this wall space is nice.

(https://farm1.staticflickr.com/706/20448998700_f74a305b76_c.jpg)

I also made a shelf to hold my screwdrivers and managed to re-use a piece of scrap 3/8" fuel line to make a rack for my pliers

(https://farm6.staticflickr.com/5749/20450297459_f876b42e4e_c.jpg)


On the car, I got the braided stainless lines in, so I made some brackets out of 2" aluminum bar so I could mount them to the chassis.  Paul came over and gave me a hand running the hard brake line to the rear.  It's all bent into shape now, but I need to mount it to the frame and flare the ends still.  It was so much easier working with two people - the line is 12' long and has to be maneuvered around all the various frame tubes to get into place.  I'll have to take some pictures when I do some more work next weekend.  The only one I have right now is one of the rear braided line and mount.

(https://farm6.staticflickr.com/5765/20450082419_51b7919406_c.jpg)


Title: Re: Factory Five Cobra Build
Post by: rothaus on August 16, 2015, 05:00:43 PM
Cool, Looks like a candy store to me, Yummm.

Cheers
Engelbert


Title: Re: Factory Five Cobra Build
Post by: wahoo5 on August 17, 2015, 07:34:10 AM
Nicely done. That time spent will save lots of time down the road.

Here is what you really need.

https://www.facebook.com/COP4x4/photos/a.10151536338887198.1073741840.181467227197/10153071121477198/?type=1&theater (https://www.facebook.com/COP4x4/photos/a.10151536338887198.1073741840.181467227197/10153071121477198/?type=1&theater)

David


Title: Re: Factory Five Cobra Build
Post by: GeneCooley on August 17, 2015, 02:28:07 PM
Bernard and I could build an entire car out of just one drawer of that thing.
Gene Cooley


Title: Re: Factory Five Cobra Build
Post by: jloehlein on September 07, 2015, 03:38:25 PM
Well, I made some progress on the Cobra this weekend.  Got a bunch of small stuff done to finish up the brake lines and mounted the radiator.  The radiator sits at a 51 degree angle and the Factory Five-recommended radiator mounting method is to just bolt the top of the radiator to a 3/4" square tube and leave the bottom unsupported.  That's pretty sketchy, so we bought a kit someone sells to support the bottom.  Now to take it all apart and paint it, then figure out how to route the hoses.  Paul and Jeff were over, so I've got some ideas.

(https://farm6.staticflickr.com/5813/21040422218_fa44c25a8c_c.jpg)

We also made progress on Jeff's F500 car this weekend, though as we were rebuilding one of the carbs we found that the pilot jet was clogged AND stuck so we couldn't get it out.  Even after heating the thing with MAPP gas and soaking it in Kroil, it was stuck.  We ended up breaking the tip of a screwdriver off in it trying to get it out.  Time for new carbs.

We also used some time to move some cars out of the yard and back to the garage.  Now we've just got two left in the backyard.  One Miata missing a front-end and the donor Mustang missing the rear end.  Will have to figure out a good way to move them.

(https://farm1.staticflickr.com/602/20605652404_5f437a126e_c.jpg)

(https://farm6.staticflickr.com/5702/21217919242_23dd5f0033_c.jpg)


Title: Re: Factory Five Cobra Build
Post by: rothaus on September 10, 2015, 06:15:01 PM
Is that blind car the dead 911 Cab ?


Title: Re: Factory Five Cobra Build
Post by: jloehlein on September 11, 2015, 02:59:16 AM
Yup - still not sure what to do with it.  I'll likely just part it out after selling the Boxster.


Title: Re: Factory Five Cobra Build
Post by: rothaus on September 11, 2015, 05:08:37 AM
... after selling the Boxster.

I posted a link here back in May. I was hoping that there is may some interest.

http://www.dorkiphus.net/porsche/showthread.php?t=34538 (http://www.dorkiphus.net/porsche/showthread.php?t=34538)


Title: Re: Factory Five Cobra Build
Post by: jloehlein on September 26, 2015, 02:51:21 PM
Well, it's time for another update.  I've made some progress on plumbing the cooling system.  Unfortunately, I hit a deer in the Miata last weekend, so the Cobra will have to wait until I fix that car.  Here's where it's at now though.

After painting the radiator mounting brackets, I laid everything out on my workbench.  Instead of using the corrugated flexible pipe that Factory Five supplies for the radiator hoses, I got some 1.5" aluminum tube, mandrel bends, and some radiator hoses with a bunch of bends in them that I could hack up.

(https://farm1.staticflickr.com/750/21550874368_e47cb8dbe9_c.jpg)


Jeff came over to give me a hand and we started mocking stuff up.  The upper radiator hose/tube was basically perfect just using two 45 degree bends.  I didn't even have to cut them.

(https://farm1.staticflickr.com/740/21550728560_f4cf185cc2_c.jpg)


The lower is more complicated, we cut a 180 degree bend in half to get a 90, then a section of straight pipe, then another 45.  Taped it together and then took it out of the car for Paul to weld.  Note that the blue masking tape leaves much less residue than the regular.  Should have used that on the lower, too.

(https://farm1.staticflickr.com/763/21117693003_39ed41d8a9_c.jpg)

(https://farm6.staticflickr.com/5694/21738720915_5973297ec6_c.jpg)


Paul welded everything up and I bought a real coolant expansion tank rather than the one Factory Five provides with the kit, which some people claim is too small and results in air being sucked into the cooling system on a regular basis.  Now I just needed some way to bead the ends of the tubes, that's what the Vise Grips are for.

(https://farm6.staticflickr.com/5641/21551862849_de312c37bb_c.jpg)


I don't have the best picture, but I copied some other folks on the internet and welded a washer onto one jaw of the Vise Grips and ground a notch in the other jaw.  Running around the soft aluminum tube, it's pretty easy to create a raised bead so the hose doesn't slip off once clamped on.

(https://farm1.staticflickr.com/608/21738717755_403d3ea560_c.jpg)

(https://farm1.staticflickr.com/616/21116025264_29a46aba46_c.jpg)

(https://farm1.staticflickr.com/722/21738735835_1a16c95e54_c.jpg)


The plumbing looks good in the car.  I may have to lower the radiator cap fitting some, we'll find out when I put the body on.

(https://farm6.staticflickr.com/5634/21712656886_0aa3e2f838_c.jpg)

(https://farm6.staticflickr.com/5832/21117704933_9dc2f70212_c.jpg)


Title: Re: Factory Five Cobra Build
Post by: jloehlein on February 14, 2016, 07:00:13 PM
Alright, I'm back at it after getting the Miata mostly squared away.  There are a few things left that I need to take care of before I can run and drive the car:

Brakes
- install master cylinder reservoir
- bleed brake system

Cooling System
- install overflow tank
- install lower radiator tube, ensure fit
- install heater hoses and heater valve
- fill, bleed system

Fuel System
- remake fuel rail crossover hose (engine builder did poorly)
- add missing brace to fuel rail (engine builder only installed 3 of 4)

Misc
- re-make PS return line
- oil, transmission fluids
- clutch line
- throttle cable
- install headers, exhaust

Wiring
- all of it :(

I started knocking out some of the easier stuff this weekend.  Of course the brake and coolant reservoirs Factory Five supplies are garbage.  The brake fluid reservoir may hold 4oz of fluid...and it's not vented.  People report issues sucking the reservoirs dry or creating a vacuum because they are not vented.  Great.  So, I ordered some nice reservoirs, but now I need to find a place to mount them.  It looks like the driver's side frame tube at the top of the engine bay will be the best spot, but the hard brake lines I made are in the way.  Jeff helped me start to remake them so that they snug up under the tube.

At the same time, I need to make some brackets to mount the lines and the reservoirs.  I got a 3D printer last month, so I decided to mess around and print some test brackets for the brake lines and the brake reservoir.  The brake line clamp is simple, it spaces the lines about an inch out from an existing mount and has two holes for the lines.  I printed these out of cheap HIPS plastic, which I bought in red.  I'll remake them out of black ABS or maybe some polycarbonate, if needed.

(https://farm2.staticflickr.com/1493/24915828772_a95c22aaa1_c.jpg)

(https://farm2.staticflickr.com/1555/24940597641_d1f7a10f27_c.jpg)

(https://farm2.staticflickr.com/1468/24403268784_59ea58d906_c.jpg)


I printed the block 80% hollow, with a 1mm shell.  I wanted to see how strong it was, so I decided to try and jack up the Miata with it.

(https://farm2.staticflickr.com/1521/24737603260_219a3da1b9_c.jpg)

That's the back wheel off the ground.

(https://farm2.staticflickr.com/1444/24402529634_e83cb56377_c.jpg)

The block survived fine, you can see where it made an impression in the wood.

(https://farm2.staticflickr.com/1637/24406302363_882ea006f7_c.jpg)

Here, I cut the block open.  You can see how it's supported internally.  Seems to be plenty strong.

(https://farm2.staticflickr.com/1603/25006789866_f7cd3a3a19_c.jpg)


Jeff helped me mock up the brake reservoir bracket.  I need to make some adjustments to the size, but that's easy to do since it only takes like 5 minutes in SketchUp, then I can re-print overnight.

(https://farm2.staticflickr.com/1490/24407036683_534d47b40f_c.jpg)

(https://farm2.staticflickr.com/1603/24403254154_7892a66ec5_c.jpg)

(https://farm2.staticflickr.com/1455/24666239749_c7fe4f2d5d_c.jpg)

(https://farm2.staticflickr.com/1571/24915100012_df6b3f5e00_c.jpg)


I'll start knocking stuff off the list and hopefully have this thing running in a couple months.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on March 13, 2016, 03:28:56 PM
Got a couple small items done this weekend.  I don't have pictures of everything.  I re-made the fuel line that connects the two fuel rails.  The engine builder cut it too short and also only installed it half way onto the fittings.  He also only installed 3 of the 4 fuel rail mounts, so I ordered and installed another.  Not a big deal, but disappointing.

I made a couple of tweaks to the 3d printed master cylinder reservoir bracket and re-printed it in black

(https://farm2.staticflickr.com/1583/25766959745_b59370a678_c.jpg)


I also re-bent the power steering return line and mounted the lower radiator tube Paul welded up.  I raised the cooler up to make more clearance for the radiator hose.  If you compare the shot of the lower radiator hose to the one a couple posts up, it is much better.

(https://farm2.staticflickr.com/1614/25766165075_acef0edd0a_c.jpg)

(https://farm2.staticflickr.com/1602/25139581623_4742555196_c.jpg)


Jeff also helped me frame a 42"x56" poster of the LeMons car that I had made like a year ago.  I made the frame out of a 2x4 and box jointed the ends.  Now I need to figure out where to hang it.

(https://farm2.staticflickr.com/1660/25034370605_881d3d406f_c.jpg)

(https://farm2.staticflickr.com/1701/25135877434_b13fb0be41_c.jpg)


Title: Re: Factory Five Cobra Build
Post by: jloehlein on March 19, 2016, 04:07:52 PM
Well, I finally buttoned up the brake hydraulics.  I got to use the 3d printer to print out a grommet where the soft brake lines, hard brake lines, and wiring harness come through the firewall.  I printed it in two pieces to sandwich the firewall.  I also left opposite-facing slots in it where the wiring harness comes through so that I could slip it over the harness, instead of trying to pull the harness through.

Here is the hole in the firewall that I've gotta put the 4 brake lines and wiring harness through

(https://farm2.staticflickr.com/1595/25916636345_c6d9b0c389_c.jpg)


And the grommet

(https://farm2.staticflickr.com/1592/25283937734_5f844e8a8b_c.jpg)


I installed it around the wiring harness and then pulled the soft brake lines from the reservoirs to the master cylinders

(https://farm2.staticflickr.com/1601/25890745606_aa0f51e621_c.jpg)


Once that was in, I pushed the hardline through, bent up and flared the portion inside the car that connects to the master cylinders

(https://farm2.staticflickr.com/1612/25287923043_e8ee569ce0_c.jpg)

(https://farm2.staticflickr.com/1467/25616072720_60e0f528af_c.jpg)


I filled the master cylinders and pressure bled the system.  I found some leaks, but thankfully after tightening the fittings down some more, everything seems to be fine.  The stainless steel lines need a lot of torque.  I think I'm gonna try and button up the cooling system next.


Title: Re: Factory Five Cobra Build
Post by: rothaus on March 19, 2016, 06:21:43 PM
This is cool stuff.

I like the frame you made for the Woody Mobil.

So you do 3D printing. That makes me thinking.

Cheers
Engelbert


Title: Re: Factory Five Cobra Build
Post by: jloehlein on March 20, 2016, 03:16:46 AM
Thanks, Engelbert.  The 3D printing is pretty interesting.  I've wanted one for a few years and this seemed like a good excuse to buy one.  If you need anything done, let me know.  It's really good for small parts and brackets.


Title: Re: Factory Five Cobra Build
Post by: MikeDe on March 27, 2016, 11:47:56 AM
What color is it going to be? Gotta love a Cobra!


Title: Re: Factory Five Cobra Build
Post by: jloehlein on March 27, 2016, 03:54:53 PM
We're trying to find a nice shade of maroon.  Maybe something like this, with no stripes.

(http://www.ffcars.com/photopost/data/500/medium/picture_of_the_month_2010_012.jpg)


Title: Re: Factory Five Cobra Build
Post by: MikeDe on March 27, 2016, 04:14:41 PM
Ahhh yeah sweet....the helmet...all makes sense now.  I like the maroon.  My best friend's dad has one that is maroon. 


Title: Re: Factory Five Cobra Build
Post by: jloehlein on April 24, 2016, 06:08:03 PM
Well, I've been doing a bunch of piddly things over the past few weeks, so I don't have a ton of pics.  I do keep finding things that the "professional" engine builder did wrong.  Makes me worry about the rest of the motor.  Anyways, I think I've got the cooling system and power steering almost buttoned up.

I mounted the coolant overflow next to the brake reservoirs.

(https://farm2.staticflickr.com/1705/26153316241_edddff43dd_c.jpg)


I was worried I might have to lower the height of the radiator cap, but after laying the hood on, we've got plenty of room.

(https://farm2.staticflickr.com/1591/25614859814_0a7f8e6a83_c.jpg)

(https://farm2.staticflickr.com/1585/26193695356_9c9a29e34c_c.jpg)


So, with everything buttoned up, I pulled a vacuum on the cooling system to see if it had any leaks.  There was a leak somewhere - large enough that you could hear air being sucked in from somewhere around the upper radiator hose and thermostat housing.  I checked the hose clamps on the hoses and checked the heater hose fitting in the intake manifold - no leaks.  I poked around a bit and found that the thermostat housing was leaking.  Not normally a big deal, but the reason why it was leaking certainly is - it's the wrong housing!

You can see here the blue lines outline where the bypass hose is on the housing.  That tube should be ~5mm further inside of the mating surface on the intake manifold.  I'm sticking a pick in the back of it and I could get the tip of the pick inside the housing.

(https://farm2.staticflickr.com/1580/26353617990_3cb7942692_c.jpg)

Here you can see there is ~82mm between the outside of the bypass hole on the manifold and the lower mounting bolt.  On the housing that was installed, there is ~88mm.  Thankfully, we had the stock housing off my dad's old 302, which fits correctly.

(https://farm2.staticflickr.com/1680/26626661515_986a23ab18_c.jpg)

(https://farm2.staticflickr.com/1514/26626668825_ef676b3235_c.jpg)

Anyways, we threw it back together.  There are some extremely slow leaks (loses 1psi of vacuum after about 15 seconds) that I pinpointed to the paper gaskets on the thermostat housing and water pump.  I think it's just because they're dry.  Once there is water in the system, it should be fine.  Before I do that, I think I'm going to pull the valve covers though and see if I see anything else "off" about the motor.  I'm debating whether or not to pull the whole motor apart.  On the one hand, it would probably mean an extra month before getting the car running - and if it blew up, it would be my fault.  On the other hand, I'm fairly skeptical about the quality based on the number of small issues we've seen.  I've got some time to think about it while we try to get Paul's car ready for Hyperfest.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on June 04, 2016, 03:55:39 PM
Well, after getting Paul's VW running for Hyperfest, I'm back to working on the Cobra.  I told myself I was going to just hack the wiring together quick and dirty to get the car running, and then clean it up over the winter, but I can't help myself.  I pulled apart the harness that came with the motor and have started to re-route it and clean it up.

There was a bunch of extra wiring because the engine harness is generic.  There was an extra 10 feet of wiring on the fuel pressure sensor!  You can see it curled up on the ground in this pic.  The engine harness is the one with the grommet and all the loom on it.

(https://c1.staticflickr.com/8/7387/26777722984_f7ee384a69_c.jpg)


Loom pulled off and everything spread out

(https://c5.staticflickr.com/8/7133/27429263396_d96e4c691e_c.jpg)


One thing I didn't like was that there were adapter connectors between the harness and some components - MAP sensor, IAC valve, TPS (not shown).  That makes it difficult to bundle everything up, so I cut the adapter connectors out and re-terminated the ends.

(https://c7.staticflickr.com/8/7292/26854371574_2f6029547e_c.jpg)

(https://c3.staticflickr.com/8/7432/26854370594_5169e53816_c.jpg)


Then I started bundling things together, looming the individual connectors, and looming the bundles.  It looks real clean.

(https://c4.staticflickr.com/8/7410/27385104275_3c1cf51f0a_c.jpg)

(https://c8.staticflickr.com/8/7006/27391982911_590878ce31_c.jpg)

(https://c3.staticflickr.com/8/7062/26854367594_c7617425bd_c.jpg)

(https://c7.staticflickr.com/8/7063/26854366694_74c9da40f4_c.jpg)


Unfortunately, I forgot to run a few wires for the gauge senders, so I'm pulling everything back apart to run them.  Also, I noticed the connector on the distributor pickup was messed up.  Here is a picture of an assembled connector.

(https://c2.staticflickr.com/8/7604/26856231953_98766a5271_c.jpg)

One of the terminals on the pickup connector was pushed in.  If anyone knows where I can get one of these terminals, let me know.  It's the one on the top in the picture below.  Compared to the Weather Pack terminal on the bottom, it's almost the same size - the length of the tip to the retaining tangs is only 10mm vs the Weather Pack's 15mm though.

(https://c3.staticflickr.com/8/7458/26854363554_521d11c647_c.jpg)


Title: Re: Factory Five Cobra Build
Post by: jloehlein on June 05, 2016, 05:18:28 PM
Well, I'm pretty sure I found the terminals for the distributor online.  Hopefully they come in this week.  I took the day to add the wires I forgot to run for the gauges and loomed it all the way to the firewall.

(https://c1.staticflickr.com/8/7433/27210450880_d9d8838540_c.jpg)


They will go through the firewall where the oval hole is, but I don't want to have to pull the dash to disconnect the ECU or remove all of the connectors from the engine in order to remove it.  I've got some flanged wiring connectors that I can use.

(https://c1.staticflickr.com/8/7097/27388365592_42216e28fc_c.jpg)

(https://c5.staticflickr.com/8/7061/27388364932_20619b2889_c.jpg)


In order to leave room for body wiring and expansion in the future, I decided to use the two rectangular connectors and put a big grommet above them.  Rather than trying to cut a large circular hole, two rectangular holes, and drill a bunch of holes for the mounting bolts, I laid out a plate that I'll 3D print and use to mount all the wiring to.  Now I just need to enlarge the existing hole in the aluminum so everything runs through it.

(https://c7.staticflickr.com/8/7407/27210445310_50e1144881_c.jpg)


I also drilled a hole in the thermostat housing and ordered a tap so I can mount the water temp sender.  Hopefully I can button that up plus the engine wiring next weekend and move onto wiring the rest of the car.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on June 12, 2016, 06:46:46 PM
Well, I think I'm done with the engine bay wiring harness, and I have diagrammed out the rest of the harness in the car.  I need to pick a spot to mount the ECU and ignition so that I can make the rest of the harness.

I mounted the plate that I 3D printed and installed the flange-mount connectors.

(https://c2.staticflickr.com/8/7189/27026077073_228ef86cd5_c.jpg)

(https://c1.staticflickr.com/8/7418/27025030384_f7e6fb7601_c.jpg)


I cut the extra wire from the harness and terminated them each into two connectors.  I'm going to wait to shrink the heat shrink until I know I didn't forget anything.

(https://c7.staticflickr.com/8/7693/27601611046_39568a4cb0_c.jpg)

(https://c3.staticflickr.com/8/7530/27025027114_e8a958ce98_c.jpg)


In addition to those, I separated out the wiring for the magnetic pickup and ran it in some shielded loom to prevent any electrical interference.  I put a separate firewall connector closer to the center of the car so it didn't need to travel along the battery cables.

(https://c5.staticflickr.com/8/7435/27025023204_40b8eda51d_c.jpg)


Hopefully just a few more weekends and I can fire the car up.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on June 19, 2016, 02:27:10 PM
Well, made some good progress this weekend.  I have a few sensors left to mount, including the oxygen sensor, so Paul came over to give me a hand mounting the body and exhaust so we could mark where the sensor will go and make sure it doesn't hit anything.

(https://c2.staticflickr.com/8/7312/27167871193_92be806bf2_c.jpg)


With that done, I got back to wiring.  I needed to wire the ECU and ignition.  I decided to focus on the ignition first.  I was originally planning on mounting them both inside the car, but have read that the FAST ECUs are really sensitive to electrical interference - which the ignition creates a lot of.  Paul and I decided it would be better to mount the ignition box at the front of the engine compartment.  I designed a mount, 3D printed it and mounted everything up on Sunday.

(https://c3.staticflickr.com/8/7299/27167019274_783053ea80_c.jpg)

(https://c6.staticflickr.com/8/7311/27167833373_8112e490a9_c.jpg)

(https://c3.staticflickr.com/8/7336/27500777770_1295c67fab_c.jpg)

(https://c1.staticflickr.com/8/7713/27500775360_cb5b1849bc_c.jpg)

I spent Sunday running the ignition wires.  This included cutting open the chassis harness so I could run the power wires back to the battery with the existing harness.  Kind of a pain, but it's coming out well.  I still need to mount the coil and supply a 12V switched source, but that's it.  Next weekend, I'm going to try to mount the ECU and finish wiring it.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on July 09, 2016, 06:09:35 PM
So the last few weekends were pretty productive.  Jeff helped me mount the coil next to the power steering pump.  It's on a simple bracket made out of a piece of steel plate.

(https://c3.staticflickr.com/8/7734/27640180130_1fdd298820_c.jpg)


I mounted the ECU and cleaned up the wiring.  All of the stuff hanging off to the right side is extra.  I'll remove it once I know it's working.

(https://c6.staticflickr.com/9/8571/28126413141_cc7bc2bb40_c.jpg)


I also wired up the dash so that we could keep an eye on things.

(https://c7.staticflickr.com/8/7436/27921347502_135a638a71_c.jpg)

(https://c8.staticflickr.com/8/7371/27409845943_390c703421_c.jpg)


After getting a replacement set of headers because the flange from the driver's side header to the sidepipe wasn't welded, I found that we had to grind the flange to the head a bit in order to access the spark plugs.

(https://c3.staticflickr.com/8/7726/27761525010_ca715be1bd_c.jpg)


Once we got the headers mounted up again, we were able to fire it up (click the image for a video).

(https://c7.staticflickr.com/8/7305/27810997550_3d5447b5c9_c.jpg) (https://flic.kr/p/JnyCDL)CobraStart (https://flic.kr/p/JnyCDL)


And here is one of the shakedown runs at the practice autocross (https://www.youtube.com/watch?v=pMErOTfM6C4).  Camera could have been aimed better...oh well.

So as of now, the car runs and drives.  The ECU is a FAST EZ EFI 2.0 that came with the motor.  It's self-learning, and only self-learning...which means I can't manually tune it.  Looking online, I don't think there is an aftermarket ECU that gets worse reviews.  The car runs rich and I can't manually tune it.  The self-learning is also very finicky - it doesn't self-learn below 2% throttle, and 2% throttle is quite a lot for the car.  You can hear the car breaking up towards the finish in the video.  I believe it's because of how rich it was running.  I tricked the ECU into pulling out fuel by telling it the motor was 351ci (supposedly, it's 408) and it had 65lb injectors (it has 50lb injectors).  That got rid of the hesitation, but it's still rich.  I'm going to pull the plugs out of it and make sure they look even.  Will also put a separate wideband into the other exhaust bank so that I can keep an eye on it.  I'm also going to buy an ECU I can actually tune.  FAST sells one that uses the same wiring harness, so I won't have to re-do everything.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on August 20, 2016, 01:54:38 PM
Alright, I got the FAST Sportsman XFI ECU in the car today.  I can tune it!  I got the ECU because it uses the same wiring harness as the EZ EFI - and I had already spent all that time making sure the wiring was neat.  I bolted it in, fired the car up and drove it around the block.  It took me ~10 minutes of driving and tuning to get it running well.  The AFR is right and there is no more hesitation.  At least through the portion of the map that I was able to hit driving around the neighborhood :)

(https://c7.staticflickr.com/9/8547/29009129382_2c74d15148_c.jpg)

Now to finish cleaning up the wiring, then on to bodywork.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on August 28, 2016, 03:08:24 PM
More progress.  I spent a little bit of time and removed all the unnecessary wires from the ECU connector.  The pins slip into the back of the connector and lock into place.  You're supposed to be able to use a tool that slides around the wire to release the lock, but I didn't have much luck with those tools, I just kept breaking them.  I decided to just get a new connector and break apart the old one to get to all the pins.

Here is all the extra wiring.

(https://c7.staticflickr.com/9/8280/28644419334_6c45507e0d_c.jpg)


I cut open the existing connector to access the pins and after removing the seal on the back, used the tool to get out the ones that I could and then just cut the plastic away from the rest of them.

(https://c1.staticflickr.com/9/8203/29159378232_ae178eda22_c.jpg)


Here's the pile of unused wiring, the cut up old connector, and the broken tools.  The plastic tools actually worked better than the metal one, but I still broke 4 of them.

(https://c4.staticflickr.com/9/8492/29190764131_49a10e9aed_c.jpg)


All the loose wiring, labeled so I don't mess anything up.

(https://c1.staticflickr.com/9/8415/29161176712_f91fb231cf_c.jpg)


And the new connector plugged into the ECU.  I've got one more wire to run and then I can loom all of this up.

(https://c7.staticflickr.com/9/8322/28667591454_0a6a8803d7_c.jpg)


Title: Re: Factory Five Cobra Build
Post by: jloehlein on September 25, 2016, 12:25:49 PM
Alright, well I'm back to working on the Cobra after a couple weeks of vacation and also starting to rebuild my mower.  Went to London, Barcelona and Germany on vacation.  Went back to the Nurburgring (we went 5yrs ago on our honeymoon).  Rented a Toyota GT86 and did 6 laps (video (https://www.youtube.com/watch?v=bER_7q7ZU1k)).  Also went to the Goodwood Revival.  Watched a few races, including a bunch of Cobras, XKEs and Ferraris sliding through the corners.  It was fun.

Anyways, I think I've finished up all of the major wiring on the Cobra!  I'll still need to wire up the 12v power outlet, heater, a couple minor switches, and eventually the ABS computer, but those aren't necessary right now.

Here is all the wiring I ended up cutting out of the engine harness.

(https://c4.staticflickr.com/9/8143/29841052171_a91239ab08_c.jpg)

And the ECU plugged in and wiring loomed to the fuse box.

(https://c8.staticflickr.com/9/8542/29298270143_948fe98d4d_c.jpg)

We also installed the passenger seat.  Next Saturday we'll mount the dash and the car should be ready for the practice autocross at that point.  Hopefully we can get some more tuning done.

Then I've gotta finish putting my mower back together...

(https://c7.staticflickr.com/9/8103/29810350262_13144e184c_c.jpg)


Title: Re: Factory Five Cobra Build
Post by: jloehlein on October 02, 2016, 04:46:16 PM
Alright, just got done cutting the grass with my newly-engine swapped mower :)  Got a chance to upload a couple videos from today's practice, which went really well.  I had only been able to tune the car for a few minutes while driving it around the block at very low RPM.  I took some guesses to get the rest of the VE table setup and was amazingly close.  No more breaking up from being way rich like at RIR.  The first run, AFRs stayed above 11.0.  I pulled some fuel out and got it pretty close by the end of the day.  Not sure there is too much more I can do right now.

Here is a video of my last run. (https://www.youtube.com/watch?v=gIlwwj9cVqI)

The car is well-balanced, but super sketchy on the 245/45/17 street tires.  I only went above 40% throttle once according to the data logs, and I know I was blowing the tires off the car.  We've got another set of wheels that will get 275s up front and 315s out back next year.  Should be a lot more stable.

Now I can start all the bodywork...


Title: Re: Factory Five Cobra Build
Post by: jloehlein on December 19, 2016, 07:54:33 PM
Well, it's been a while...been doing bodywork.  Not many pictures, but we're making progress.  Dealing with things like this panel gap

(https://c4.staticflickr.com/6/5502/30934471115_3d69035fda_z.jpg)


The body can be adjusted forward, backward, up, down, left, right.  And the door can be adjusted forward, backward, up, down, in, out, and tilted.  And you need to sand the gaps to fit.  That's a lot of adjustment to deal with.  Every time you move one thing (e.g. the driver's door), we'd have to move something else (e.g. the body), and then something else (e.g. the passenger door).  Anyways, we got all the panel gaps lined up finally.

We even test-fitted the windshield and hardtop

(https://c6.staticflickr.com/6/5726/30934478525_9f4245c057_z.jpg)


This past weekend, we started sanding down the gel coat, especially the seams where the mold is bolted together.

(https://c8.staticflickr.com/6/5621/31605723031_1cab664aa1_z.jpg)


You find things like this - mold wax trapped under a thin layer of gel coat.

(https://c2.staticflickr.com/1/345/31605715841_425b1f4f29_z.jpg)


The first layer of filler is on, covering the seams.

(https://c5.staticflickr.com/1/438/31585217892_98feb0ccd6_z.jpg)


We'll continue sanding and filling low spots over the Christmas break and hopefully get the body ready for primer before I go back to work.  It's exciting, we're getting close.


Title: Re: Factory Five Cobra Build
Post by: wahoo5 on December 24, 2016, 05:56:50 PM
Looking great.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on February 04, 2017, 09:20:28 PM
Alright, we're getting closer.  The body is fully sanded and off the car, almost ready for primer.

(https://c1.staticflickr.com/1/624/32473740051_43c1f4e653_c.jpg)

My Dad has been working on the hardtop.  You can see with it test fit, there was quite a gap at the rear.

(https://c1.staticflickr.com/1/310/31109986423_11d15bf5e9_c.jpg)

(https://c1.staticflickr.com/6/5632/31802780551_e0da38fdcf_c.jpg)

If we set the rear completely down, the front wouldn't sit on the windshield.  It looks like the top might be designed for an older version of the car, where the windshield sat at a more vertical angle.  We figured the easiest way to deal with it was to cut a slit along the back and add more fiberglass.  We added a layer of fiberglass on the inside, filled the gap with stranded filler and then finished it with regular filler.  It fits much better now.

(https://c1.staticflickr.com/1/564/31079270834_55970872ac_c.jpg)

(https://c1.staticflickr.com/1/586/31992095016_537b19be72_c.jpg)

(https://c1.staticflickr.com/1/394/31992098366_6371f13784_c.jpg)

(https://c1.staticflickr.com/1/588/32105943765_cc7405f637_c.jpg)

(https://c1.staticflickr.com/1/630/32473739131_c5a39c4521_c.jpg)

While my Dad has been working on that, I've been tackling some more wiring and finishing work before the body goes back on and buries everything.  Here's a bunch of the wiring left to do...it's mostly for all the dash switches, turn signals, horn, indicator lights, etc...

(https://c1.staticflickr.com/1/284/31784561043_e56ed8d979_c.jpg)

I'm also adding another fuse panel and cigarette lighter/USB outlets.  I mounted them on a brace I made to connect the lower part of the dash to the car.  I also needed to add a distribution block to get more +12V wiring options, so I 3D printed a box to put it in.

(https://c1.staticflickr.com/1/638/32441436912_eac39b9610_c.jpg)

(https://c1.staticflickr.com/1/311/31784550243_0de17f6d83_c.jpg)

(https://c1.staticflickr.com/1/466/32707742715_8762ef48a4_c.jpg)

Jeff also helped me cut and bend up a 2nd layer for the firewall.  The supplied firewall is 0.040" aluminum and fairly flimsy.  People also complain about heat in the cockpit.  The thin layer of aluminum separating the engine bay doesn't do enough.  The 2nd layer I added is 18 gauge stainless.  It really helped stiffen up the firewall and should help with heat.  I also have started covering the engine bay side of the aluminum panels in heat reflecting material.

(https://c1.staticflickr.com/1/430/31896602833_c64a443c30_c.jpg)

(https://c1.staticflickr.com/1/377/32671246816_6b6dce0ba0_c.jpg)

I'm looking forward to wrapping up all the wiring and getting the body in primer.  Should only be a few more months until it's on the road.


Title: Re: Factory Five Cobra Build
Post by: rothaus on February 05, 2017, 06:00:31 AM
Wow that hardtop need some fitting. What were they thinking, just put some caulking, LOL. More fiberglass work. Looks like you are making nice progress.

Cheers
Engelbert


Title: Re: Factory Five Cobra Build
Post by: jloehlein on March 05, 2017, 07:32:11 PM
Well, we're making more progress.  I got the dash and auxiliary fuse panel buttoned up.

(https://c1.staticflickr.com/4/3785/32867279051_da75a2a515_c.jpg)

(https://c1.staticflickr.com/3/2781/32951358626_b46f331c53_c.jpg)

Now it's on to bodywork.  I got the Cobra in a coat of sprayable filler (Slicksand) and then moved on to Mindy's M3 for some practice.

(https://c1.staticflickr.com/3/2260/32023524734_565cbe5dc6_c.jpg)

(https://c1.staticflickr.com/1/631/31918151353_cbf79aca2a_c.jpg)

(https://c1.staticflickr.com/3/2731/33008065551_4ce6f68901_c.jpg)

Mindy's car is pretty much done now.  Still getting a lot of orange peel - I'm going to try some different techniques and try to paint when it's a bit warmer before painting the Cobra.  I'll put some more Slicksand on the Cobra and let my Dad sand it flat before spraying sealer, then base, pearl, and clear coats.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on April 09, 2017, 06:09:45 PM
Alright, we're getting close.  We've spent the last few weekends buttoning up loose ends before mounting the body, hopefully for the last time.

We made some heat shields to protect the fuel filter, and most importantly, our feet!  The aluminum doesn't do a great job keeping the heat out, so we made some cardboard templates, cut them out of stainless steel, polished them, and bent them up.  They're spaced off the aluminum panels ~3/4" to create a good air gap.

Here's the passenger side one covering the fuel filter

(https://c1.staticflickr.com/4/3782/33252727061_2fcee4aa3f_z.jpg)

And the driver side one protecting the wiring to the wideband O2 sensor

(https://c1.staticflickr.com/4/3706/33152507020_4f5e13c4d7_z.jpg)


I also cut open the rear wiring loom to run a single wire back for the reverse light.  Once I re-loomed the whole thing and clamped it up to the frame tubes, my Dad installed the aluminum panels in the trunk.

(https://c1.staticflickr.com/4/3751/33784055281_cc0d203cf7_z.jpg)

(https://c1.staticflickr.com/3/2848/33890003646_c0c1931fe5_z.jpg)


Then we spent most of the day today masking things off and mounting the body.  He's got a bunch more masking and cleaning to do, but if all goes well we should be able to paint it this coming weekend.  There's a chance we have it together by the end of the month!

(https://c1.staticflickr.com/4/3853/33895719046_31bf9d9a9e_z.jpg)

(https://c1.staticflickr.com/4/3760/33551988910_cf6045936f_z.jpg)

(https://c1.staticflickr.com/1/762/33895903936_ba3f9374c6_z.jpg)

(https://c1.staticflickr.com/3/2821/33896554196_0e5d1f9b27_z.jpg)


Title: Re: Factory Five Cobra Build
Post by: jloehlein on April 16, 2017, 03:18:14 PM
Scheduling, weather, and a bunch of other stuff came together this weekend and the car is painted!  My Dad did a bunch of prep during the week to get the car ready and I was able to take Friday afternoon off because work was slow.  I needed ~2.5 consecutive days to paint.

Friday afternoon we rolled the car into the paint room, finished cleaning and masking, and then set up a few sawhorses with all the other parts (doors, hood, trunk, top, etc).  Once we cleaned everything like 3 more times, I shot it all in a coat of dark grey sealer.  I then shot the insides of the doors, hood, trunk, and scoop in 2 coats of base, 2 coats of pearl, and 3 coats of clear.  We used PPG Omni for the base and pearl, which is "only" $300/gal.  The clear is PPG Deltron Urethane.

(https://c1.staticflickr.com/3/2823/33657406260_c1bf304a25_c.jpg)

(https://c1.staticflickr.com/3/2815/33657408500_b47f2651e2_c.jpg)

(https://c1.staticflickr.com/3/2914/34001550586_f8df8d389f_z.jpg)

The Omni paint looked good, but not nearly as nice as the test panel we shot using all PPG Deltron products.  The Deltron base and pearl is ~$700/gal.

Omni:
(https://c1.staticflickr.com/3/2849/34001551806_886c4627a2_z.jpg)

Deltron:
(https://c1.staticflickr.com/4/3935/34042376825_34b1fc304e_z.jpg)


Saturday morning, my Dad went to the paint shop to buy some Deltron base and pearl and we got ready to spray the rest of the car.  I masked off everything I had just sprayed and we mounted the doors, hood and trunk on the car.  Spraying it all together will help make sure everything matches.

(https://c1.staticflickr.com/3/2805/34054330875_675c478b7d_c.jpg)

(https://c1.staticflickr.com/4/3955/34054320015_582f5e54a8_z.jpg)

The hood and trunk were mounted so there was a gap around the whole thing, which would let me open/remove them, spray the jambs, then close them without touching the paint I had just sprayed.

(https://c1.staticflickr.com/3/2823/34054333995_df35c67fd8_z.jpg)

(https://c1.staticflickr.com/3/2937/33902753152_f7e6e440ea_z.jpg)

(https://c1.staticflickr.com/3/2879/33902752322_676b5a54d6_z.jpg)

(https://c1.staticflickr.com/3/2920/33216906824_560acb9141_c.jpg)

You can see all the overspray around the edges of the room.  I've got a massive intake fan pressurizing the room and two small box fans for exhaust, blowing through four 14"x24"x2" pleated HVAC filters with some paint filters in front of them.  The intake fan flows way too much air, but it is really effective at clearing the room out and keeping dust out of the room.  The overspray tends to settle in the dead areas of the room (the edges).  As long as the room is clean to begin with and you don't bring any dust in with you, the setup seems to work okay.  The overspray on the floor stays put...I actually am not sure I'll be able to clean the floor.


Sunday, all I had left to do was spray the clear.  I unmounted the hood, trunk, and doors so I could spray everything without having to open and close the doors and trunk and remove the hood repeatedly.  I sprayed the loose body parts first - 3 coats, then uncovered the body and sprayed it.  This way, I could keep my timing between coats in the optimal window and not worry about getting overspray on the body as I was clearing the other parts.  There's a bunch of overspray on the loose parts, but it'll come off easily when we sand and buff.

BTW, this is what the room looks like when you don't run the intake fan.

(https://c1.staticflickr.com/3/2831/33228994574_a38cc3c16f_c.jpg)

(https://c1.staticflickr.com/4/3947/33228996294_a8f0759713_z.jpg)

Safety first...

(https://c1.staticflickr.com/4/3736/33944214031_0fc566c20b_z.jpg)

And here is the fully painted car.  The pearl looks really cool in different lighting.

(https://c1.staticflickr.com/3/2847/33946658871_a7909ecb78_z.jpg)

(https://c1.staticflickr.com/4/3727/33946689761_aa8207a6cc_z.jpg)

(https://c1.staticflickr.com/3/2932/33264926473_0e5e5e7d00_z.jpg)

(https://c1.staticflickr.com/3/2868/33264903043_48e2b09e35_c.jpg)


I got a few runs in the clear, but overall it went on really nicely.  I was also very worried about striping the pearl, but thankfully didn't have any issues.  Once the clear dries for a couple days, my Dad wet sand the car, then I'll buff it.  It should look awesome.  Once that's done, we're pretty much onto final assembly!


Title: Re: Factory Five Cobra Build
Post by: catapultkid on April 17, 2017, 10:12:27 AM
Congrates! Looks awesome!


Title: Re: Factory Five Cobra Build
Post by: wahoo5 on April 17, 2017, 01:26:17 PM
Very, very nice. I can't wait to the finished product.

David


Title: Re: Factory Five Cobra Build
Post by: gunny on April 18, 2017, 03:06:30 AM
Yea, that paint looks great!

Gunny


Title: Re: Factory Five Cobra Build
Post by: jloehlein on April 19, 2017, 04:49:08 PM
Thanks, guys!  Looking forward to having it all together.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on April 22, 2017, 05:55:16 PM
Got some polishing done today.  My Dad wet sanded the car during the week down to 2000 grit.  I started polishing with Meguiars M100 and a wool cutting pad, then a foam cutting pad.  After that, I switched to M205 and a foam polishing pad, followed by Menzerna SF3800 and a foam finishing pad.

Here are the loose panels all sanded

(https://c1.staticflickr.com/3/2900/34127774436_01287d6035_z.jpg)

And the body

(https://c1.staticflickr.com/3/2869/34158392646_180f9c7ae9_z.jpg)


Here is the hood as I'm beginning to polish

(https://c1.staticflickr.com/3/2924/34207079445_9a51c4bde9_z.jpg)

I think this is after the 2nd step was completed - it is glossy again, but you can still see scratches around the reflection of the lights

(https://c1.staticflickr.com/3/2870/33396505683_da417246df_z.jpg)

After the 4th step

(https://c1.staticflickr.com/3/2885/34207079695_db689caf43_z.jpg)


Here is the full hood

(https://c1.staticflickr.com/3/2826/34041985032_500196e062_z.jpg)

Here is the reflection off the rear deck

(https://c1.staticflickr.com/3/2930/34073839761_d15e64e0cd_z.jpg)

And the car as it sits now

(https://c1.staticflickr.com/5/4189/34073834161_eacbd70c06_z.jpg)


I've still got a lot of polishing to do - tops of the other 3 fenders, all vertical surfaces, doors, trunk, top, etc.


Title: Re: Factory Five Cobra Build
Post by: jloehlein on May 21, 2017, 05:34:05 PM
Alright, we're definitely in the home stretch.  This weekend is the first time it's looking like a complete car.  Over the past few weeks we've gotten a lot of the finishing touches done.

We got some LED lights from Engelbert and mounted them up.  They are nice and bright.

(https://c1.staticflickr.com/5/4186/34645766882_cc3a614961_z.jpg)

The kit comes with a ton of cheap, plastic insulated butt connectors for the wiring.  I ditched those and added some real connectors.  I also had to separate the whole front light harness and shorten/modify it to get it to run cleanly across the front end of the car.

(https://c1.staticflickr.com/5/4190/34372092812_c3843cc666_z.jpg)

I wired the taillights in a similar manner.  You can also see that my Dad has re-painted the inside of the body black.

(https://c1.staticflickr.com/5/4169/33998676983_e33487d96d_z.jpg)

I also wrapped up a bunch of other stuff under the car, including the e-brake and driveshaft safety loop.

(https://c1.staticflickr.com/5/4251/34422314570_c6d5e11d71_z.jpg)


On the top side, we installed the defrost vents and seats.  Engelbert powder coated a ton of stuff on the car, including the seat brackets.  It all came out great.

(https://c1.staticflickr.com/5/4160/34422306010_70ab57734b_z.jpg)

(https://c1.staticflickr.com/5/4222/33998681823_b1fe1c2517_z.jpg)


We fired the car up for the first time since last summer - it started right up.  Unfortunately, the cheap heater core that it comes with is leaking.  I've bypassed it for now, but we'll have to take it out and fix/replace it soon.  There are also a bunch of other small things that need to be done (seat belts, carpet, covering misc holes/filling gaps, more polishing, center caps on the wheels, etc).  It's looking like a real car though!  We drove it around the neighborhood a few times.  Now to get it registered.

(https://c1.staticflickr.com/5/4198/34422316180_0aa8d15860_z.jpg)

(https://c1.staticflickr.com/5/4272/34808464835_2f51c02549_z.jpg)


Title: Re: Factory Five Cobra Build
Post by: wahoo5 on June 06, 2017, 02:26:18 PM
Just gorgeous. Wow. Need to bring it to Cars & Coffee at Regency. The next one is 6/17.

David


Title: Re: Factory Five Cobra Build
Post by: johndej on June 06, 2017, 04:08:57 PM
Looks great! Just sent this to a co-worker who was wondering what all went into building a cobra. Hope you get to start driving it soon!


Title: Re: Factory Five Cobra Build
Post by: jloehlein on June 06, 2017, 06:47:37 PM
Thanks, guys.  Might make it out to Cars and Coffee at some point.  Now we're getting Jeff and my car ready for track duty.  Good news is that it is finally running somewhat okay after I spent some time tuning it.  And it's inspected!  The windscreen is the perfect size for the inspection sticker.

(https://c1.staticflickr.com/5/4246/34301016504_6350f1d1d1_z.jpg)

Also - light weight!

(https://c1.staticflickr.com/5/4210/35097463125_cef134a936_z.jpg)


Title: Re: Factory Five Cobra Build
Post by: jloehlein on October 08, 2017, 03:32:54 PM
We finally got the car down the Peter to finish tuning it.  I had gotten the fuel tables close enough while street tuning it that we didn't need to make any changes - it was running ~12.0-12.5:1 AFR at WOT, so we just messed around with the timing.  I had the motor timed at ~16 degrees base timing.  We tried going to 18 and it lost a some power.  We found peak power at only ~12 degrees of timing.  The difference was pretty astounding - like an additional 40hp compared to 18 degrees.  Here is a video of one of the runs (https://www.youtube.com/watch?v=-7tMYVNZzFs).  Sounds good.

(https://farm5.staticflickr.com/4506/36910433733_d3f4cce35e_c.jpg)

(https://farm5.staticflickr.com/4481/37580309861_750a170227_c.jpg)