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Author Topic: Factory Five Cobra Build  (Read 47438 times)
pipefitter
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« Reply #25 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................
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« Reply #26 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:


Stripped down and wiped off:


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.


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:


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.
« Last Edit: February 10, 2017, 09:43:21 AM by jloehlein » Logged

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« Reply #27 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:


And in the car with the 3-link setup:


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.
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« Reply #28 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:


From the back:


My Dad sitting in it:


Clecos are great for holding everything together, I hadn't ever used them before:


There was some interference between the clutch pedal and a chassis tube.  Apparently, this is a common issue:


Some people notch the tube, but we thought it would be smarter to notch the pedal:



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.





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« Reply #29 on: December 31, 2014, 05:08:55 PM »

Did you end up hanging the doors yourself?

David
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« Reply #30 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.
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« Reply #31 on: January 01, 2015, 07:43:28 AM »

What are you going to grade it with?
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« Reply #32 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.
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« Reply #33 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.
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« Reply #34 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.
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« Reply #35 on: January 02, 2015, 07:34:26 AM »

That's probably a little more than my tractor is up to.
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« Reply #36 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.



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:


Here it is on the crane:


Then in the car:



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.


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.
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« Reply #37 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!
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« Reply #38 on: February 27, 2015, 06:08:24 AM »

Sweet project. Where you located ?
Ron
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« Reply #39 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.
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« Reply #40 on: March 04, 2015, 11:19:12 AM »

I used an in-line filter near the tank.
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« Reply #41 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 :-)
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« Reply #42 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 Smiley

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.








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.





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« Reply #43 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.




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.




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.




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.








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






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.



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





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.




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.
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« Reply #44 on: March 29, 2015, 06:23:38 PM »

Pretty slick.

David
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« Reply #45 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



We also started on the wiring



There is a ton of extra wire that I'll have to clean up



I bent up some pipe to get water to the heater core



It's coming along!



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.



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.
« Last Edit: April 26, 2015, 05:27:20 PM by jloehlein » Logged

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« Reply #46 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
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« Reply #47 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





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


The factory mount isolates the unit from vibration.  I want to use as much of it as possible




I cut off the horizontal mounting points and welded on a tab to get three bolt holes on roughly the same plane




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




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« Reply #48 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.

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« Reply #49 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.
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2000 Honda Insight - Daily Driver
1995 Honda Civic CX - Street Mod/HPDE beater
1994 Chevy Caprice wagon w/6 speed - tow vehicle
1991 Mazda Miata (plus parts cars) - LeMons racecar
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