Daniel's Cobra Roadster Project

Photo dump

2010-12-12T09:10:00.001-06:00

I've struggled to get photos published on the blog in a timely manner, so here is a dump of them all.

Intake porting

2010-12-11T21:04:00.002-06:00

Santa came early and dropped off a set of GT40X Aluminum heads!! So I've started porting the Cobra Intake to match the head ports as they are MUCH bigger. Found a great article on porting 5.0 intakes here. This guy is very well respected for his work and I followed his process. Ports 1-4 are done on the intake for the most part. I want to do a little more work on port 1, but they are essentially done.

An Update, Finally!!!!

2010-10-18T20:05:00.007-05:00

Well, it has been several months since my last update, time to get back to work!!! Found out I had several more broken pieces on the 911 engine than I originally thought. In addition to the cam adjustment gear, I also broke 3 rocker arms. So I pulled the motor out of the car so I can replace the rockers and inspect for any other damage. Once the motor was out, I moved the body up to my parents place to make more room in the garage.

Forward Progress....

I picked up working on the rear brakes lines. I originally followed the stock routing with the center flex line dropping down to hardlines running down the axle. I decided I didn't like that and ran hard lines to each rear wheel with a flex line down the caliper. I then decided I didn't like that. Back to the original routing I went. I have new flex lines on order for the frame to axle, and the 2 axle to caliper lines. Should be in later this week. Here is a picture of the rear wheel mock-up for 2nd attempt at routing brake lines:

Also finished up the pedal box:

I used the Russ Thompson gas pedal and the stock Mustang pedal box. The kit from Breeze Automotive includes pedal covers for the brake and clutch. Came out very nice I think. I've bent the pedals so there is enough clearance around the gas pedal and the brake pedal so each can be depressed without impacting the other.

Also this weekend, completed bench bleeding the master cylinder and re-installed it after finishing the pedal box. Lastly, on the car, painted the floor panels of the passenger compartment with Lizard Skin.

Lastly, my lil' Angel and I went to Dallas Mustang's annual car show on Saturday. Here are some pics from it:

2010-05-24T19:34:00.003-05:00

Well, I haven't got any new updates because I haven't been working on the Cobra. My 911SC has been sharing the garage since Christmas as I tried to troubleshoot why it ran so badly. Well, I finally found the culprit. A broken cam adjuster on the left bank allowed the cam to shift out out of phase with the crank. New ones are on order and I hope to have by the end of this week to fix over the 3 day weekend.

FFR Black Friday Sale

2009-12-01T12:45:00.001-06:00

I got an awesome deal on wheels, windwings, and sun visors from Factory Five's Black Friday Sale. Now, I just got to get over this head cold so I can get back in the garage...

Thoughts and next on the list - 10/04/2009

2009-10-04T21:13:00.003-05:00

Bending and flaring the brake lines was much easier than I expected. I was really dreading this part of the build, probably more than anything else. Rented a brake line bender and flare tool from Autozone. Napa hooked me up on the custom adapters needed to hook everything up. Brake parts list:
1986 SVO 4 disk master cylinder
73mm Single piston calipers from 1991 Lincoln
5 lug front rotors from 1991 Lincoln
Stainless Steel Flex lines from Maximummotorsports

Next to tackle is rear brake line and fuel lines.
Then fabricate a battery box.

Completed front brake lines

2009-10-04T21:09:00.003-05:00

Installed Breeze Automotive Fuel Filter mount

2009-10-04T21:07:00.003-05:00

Finshed passenger footbox

2009-10-04T21:06:00.002-05:00

What's next....

2009-09-27T22:05:00.003-05:00

Got quite abit done on the 3 weeks off with the new baby.... :)
Next on the agenda is:
Finish installing the driver's and passenger's footpanels.
Paint and install the passenger compartment panels.
Run brake and fuel lines.

Gas Tank installed!!!

2009-09-27T21:59:00.002-05:00

Rear Axle installed this weekend

2009-09-27T21:58:00.006-05:00

Includes the following modifications:

Rear disc brake conversion from North Racecars using fox length, 5lug axles.
Optional 3 link rear suspension w/Panhard Rod.

Koni adjustable coilovers.

3.73 rear gears with rebuilt Traction-Lok differential.

Coilover Konis have major cool factor

2009-09-27T21:58:00.002-05:00

Stated Installing drivers foot panels

2009-09-27T21:56:00.002-05:00

Rear axle Rebuild

2009-09-20T11:58:00.003-05:00

After completely stripping down the rear axle, Tara and I primered and painted the axle yesterday. Also cleaned and prepped the gas tank and tank cover. Found out the tank has a 255lph fuel pump in it. That was a nice surprise.
Also rebuilt the tractionlok with new carbon fiber clutch disks from a 2003 Cobra. A friend from church helped get the carrier bearings removed and new ones pressed on. Next on the list will be to top coat the axle and re-assemble. Also work on prepping and installing the gas tank.

5th time is a charm

2009-06-22T22:31:00.003-05:00

Well, worked the last 2 nights on getting the pedal cluster mounted. After installing it and taking it off 5 times, I finally got it installed correctly. I kept finding parts I forgot... I had the brake pedal shortened for use with manual brakes and I am using a master cylinder from a 1986 SVO which came from the factory with 4 wheel disk brakes.
I jacked with the factory gas pedal and I couldn't find a position I liked. The instructions say to cut 2 inches off of it and remount the pedal. Most comments on ffcobra.com say this turns it into an on/off switch since it is so short. I've been trying to bend it in different directions to get the same effect while maintaining the length. It is also too far over to the right. I may just break down and spend the 80 bucks to get a Russ Thompson Gas pedal...

Next on the agenda will be the Rear axle rebuild... Oh boy!!! Yes, Will I will try and get some pictures posted...

Good progress this weekend

2009-03-23T08:06:00.003-06:00

Completed mounting and drilling the driver's side footwell. Started on the passenger side as well. Broke all my drill bits, so had to stop... Also picked up the bearings for the front end so I can mount the front brakes. Had to go to 3 stores and 2 trips to get 4 bearings.... arghhh.

Took the brake pedal to a machine shop over the weekend to get it shortened to work with the manual brakes. Will pick it up today. Also the clutch quadrant kit should arrive today as well. With the brake pedal and clutch quadrant kit, I should be able to reassemble the pedal box together and install.

Box 1A is empty!!!

2009-03-20T14:52:00.003-06:00

Well, I've finished the first box of parts!!! The front suspension is done and the steering column has been mocked up. I've taken the steering back apart so I can remove the driver's engine panel to paint it. Next items to work on:
drill all rivet holes for the engine bay panels
paint the panels - I'm using a ceramic insulating paint from LizardSkin.
rebuild the rear axle - I purchased the 3.73 rear gears today. That is the last thing I needed to rebuild the rearend.
Install the pedal cluster - brake pedal is being shortened to use without brake booster. Also ordered a new clutch quadrant/cable/adjuster from Steeda.

Making Progress on Front Suspension

2009-03-09T14:33:00.004-06:00

Completed assembly of the front passenger and part of the driver suspension. Waiting on strut bolts from Breeze Automotive to come in for final assembly. Will move on to mounting steering rack. The 2 body panels mounted behind the suspension were painted with POR-15. Came out pretty good, considering I had to do them twice....

Valentine Weekend update

2009-02-15T21:17:00.000-06:00

Got all the aluminum panels removed this weekend. Also, modified the new control arms Kim got me for Valentine's Day. Hope to paint them and the F panels this week so I can start installing the front suspension.

Body Removed!!!

2009-02-11T20:04:00.000-06:00

Built a body buck this weekend and a raise shelf to go over the car. Removed the body and placed it on the buck. Makes for plenty of work room in the garage.

Turned the first nut

2009-02-01T23:28:00.000-06:00

Well,
Actually put a wrench to the Cobra today and removed the doors. Will get the wood this week to build a body buck to set the body on. Next step is body removal.

F5R6814 arrived today!!!!

2008-11-13T17:05:00.000-06:00

Well, F5R6814 arrived this evening about 6pm. This was the third drop off for the driver that day. It took about an hour from when he arrived to get everything into the garage. Thanks to all the helpers. As you can see from the pictures below, the wife did a great job keeping everyone fed and entertained.
Started inventory on the 15 boxes. Got through the first 2 this morning. Man, it takes a bunch of parts to build a car... :)

My wife's work. The fabulous planner!!!!

All the boxes that come with the kit.

Unloading. The GTM was going to Oklahoma

We unloaded in the middle of the street that feeds into our neighborhood. That got a little interesting after dark.

Lining the body/frame up on the dolly I built to move it around. From here we rolled it down the street and into the neighborhood. Several folks stopped to come check it out.

Admiring our handy work...

The move in crew. I'm on the left. Cousin next to me. Friend in red. Dad on the right.

'Gift' curtesy of my Aunt.

My daughter and friends kid taking her for a spin.

Did the obglitory sit in the seat and go vroom-vroom. If we can trim the video down, I'll post it.

Now back to parts inventory tonight. Plan to clean up donor parts tomorrow and build the body buck.

On its way!!!

2008-11-08T20:22:00.000-06:00

Stewart Transport called on Friday and kit should be delivered on Wednesday night or Thursday morning.

Making a Home

2008-11-05T21:42:00.000-06:00

Kim and I with the help of my Aunt and Cousin painted the garage this week. We used the Rustoleum 2 part concrete epoxy. It came out great.

Here are some pics of her new home:

Here is my workspace:

Here is the celebration material for each milestone: (Delivery, first panel fitted, a screw installed, a bolt tightened, etc.)

The Plan

2008-11-01T21:18:00.000-06:00

Factory Five Mark 3.1 Base Roadster
Options:
Driver and Passenger Chrome Rollbar
3 link rear suspension
Powder coated frame

Donor build using a 1991 Mustang

Plans:
302ci Small Block with Factory EFI
Rest of engine build TBD...
T-5 wide ratio 5 speed
8.8" live axle with 3.55 gears
5 lug fox length rear axle with 98 GT rear rotors
11" front disc brakes w/5lug conversion
15" Halibrand style wheels

Kit ordered on 10/20/2008. Born on date: 11/01/2008
Expected delivery 1st week of November.

Can't wait!!!!!!!!!!!