Fasterpatricks Custom Cobra Replica
 

This is the story of my build, This starts over three years ago, I will try to get this story up to date as fast as possible;


Well, most of the stuff to get the build started is here. Now let the lunacy transpire. This frame promises not to be original style but more of a hybred of sorts. Read way to many chassis books and head still spinning for details now.
http://www.clubcobra.com/photopost/d...0/IM000690.JPG
http://www.clubcobra.com/photopost/d...0/IM000684.JPG
http://www.clubcobra.com/photopost/d...0/IM000697.JPG

Patrick

Hey everyone,
Look what happened, while everyones out driving around I'm in the shop working. Just a few photos of what I've been up to.
http://www.clubcobra.com/photopost/d...0/IM000709.JPG
http://www.clubcobra.com/photopost/d...0/IM000708.JPG
http://www.clubcobra.com/photopost/d...0/IM000707.JPG
Patrick

Hey sever crash wont stop us, reposted pics from Saturday. Have been cutting parts Sunday and Mon. eve. Yes the framework sticks back far but it will all come out in the wash, you'll see. She's going to fuel 289 style with the tank sitting on that framework.
http://www.clubcobra.com/photopost/d...713_Small_.JPG
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http://www.clubcobra.com/photopost/d...0/IM000711.JPG
http://www.clubcobra.com/photopost/d...0/IM000710.JPG
see we're right back where we were. Patrick

We all know that scratch building requiers dedicaton or a whole lot of money. I'm cheap so this is every bracket/tab to hold my rear suspension together. It took me a week of evenings in 90deg. heat to cut, drill, and finish the lot. But satisfaction rate is very high. Now to cut and bend the tubing and I could get it on the car this week, in the same heat.
Patrick
http://www.clubcobra.com/photopost/d...715_Small_.JPG

Huge piece of the puzzle was accomplished. Five days off from work and lots of time in the shop and victory was mine. Just some minor lose ends to finish up and it should be done.
The Accomplishment
http://www.clubcobra.com/photopost/d...721_Small_.JPG
The Aftermath
http://www.clubcobra.com/photopost/d...724_Small_.JPG
I'm not even going to clean-up tonight just shove every thing out of the way, and do that tomarrow.
Patrick

Well spent a little time measuring and making adjustments to the mess. Found a few bugs, the center section was 5/32s out of center, fixed that, axles bound at full droop,needed new upper shock mounts to rectify that now they bind at full compress, not a problem once bumpstops are installed:cool:. Now the numbers, droop from ride height 4" total wheel travel till axels bind is 8 3/8" but doubt all that will be needed will make bumpstop addjustment with the body installed. No need to do that twice, will stop travel just before the wheels hit the body.
Full Droop
http://www.clubcobra.com/photopost/d...727_Small_.JPG
Full Compress(or at least to where the axels bind)
http://www.clubcobra.com/photopost/d...728_Small_.JPG
trying to stay cool: Patrick

Well, busy people have limited time. And kids don't help either, enough said. I have some stuff to show you. Take a look tell me what you think. These are pre debuging so there are some small things left to fix.
http://www.clubcobra.com/photopost/d...729_Small_.JPG
http://www.clubcobra.com/photopost/d...730_Small_.JPG
http://www.clubcobra.com/photopost/d...733_Small_.JPG
OH Yea! there is always one flaming hoop to jump through.
http://www.clubcobra.com/photopost/d...732_Small_.JPG
Now I should go, try to clean up, fix stuff, make umteen gussetts, and get ready to weld this all solid.
Patrick

What?
metal will distort when welded, really.(just kidding) Ya took care to do just that, not the first time I've stumbled down that trail. Wouldn't want to micro measure it now, heard some realy big bangs from tacks breaking loose but all looks to have came out well.
http://www.clubcobra.com/photopost/d...746_Small_.JPG
http://www.clubcobra.com/photopost/d...744_Small_.JPG
http://www.clubcobra.com/photopost/d...741_Small_.JPG
http://www.clubcobra.com/photopost/d...742_Small_.JPG
The welding took well over seven hours, welder was acting finicky, but I won. Cleanup took another four. I'm putting it all together right know.
Patrick

Well, I've got it all together and she did move around a bit, but nothing that shimming at final four wheel alinement can't cure, I'm realy happy with what I've got. There is one issue to deal with but I'm not talking.
http://www.clubcobra.com/photopost/d...752_Small_.JPG
http://www.clubcobra.com/photopost/d...750_Small_.JPG
http://www.clubcobra.com/photopost/d...748_Small_.JPG
Now to drop the body on and start headscratchin, look for a block and tranny for mockup and general stuff like that. Well I've got to get some sleep, kids start school tomarrow.
Patrick

Here mick, Some body on photos. Had to make struts so the suspension would be at ride height, then drape the body at the proper height.
http://www.clubcobra.com/photopost/d...755_Small_.JPG
http://www.clubcobra.com/photopost/d...757_Small_.JPG
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http://www.clubcobra.com/photopost/d...760_Small_.JPG
http://www.clubcobra.com/photopost/d...761_Small_.JPG
Sorry there will never be the VROOM-VROOM photo I'll wait till there is a seat in the car for that.
Patrick

Well we have power in the shop, Mod power. One lincoln mark VIII twin cam 4.6L. I have a big mess to cleanup in the shop and then I can start to mount this cool engine.
http://www.clubcobra.com/photopost/d...768_Small_.JPG
http://www.clubcobra.com/photopost/d...767_Small_.JPG
Patrick

Well we have engine mounted in frame. Position looks good, thanks to some new friends on the ffr site. They got me the dimension for the mounts for the 4.6L from front axle centerline, and then I moved them 1" forward, for maybe a little more space in the footbox. The Lincoln mounts made for an easy fab, they are parallel with the frame so only had to adjust for offset on one plane.
http://www.clubcobra.com/photopost/d...771_Small_.JPG
Some things got a little tight, like the starter and the oil filter
http://www.clubcobra.com/photopost/d...777_Small_.JPG
http://www.clubcobra.com/photopost/d...780_Small_.JPG
Yes I smashed the oil filter during positioning, it will come off don't worry.
Patrick

The last of the wooden supports came out of the body today. Meaning that I have finished the Major body support system of the bird cage. What fun it is to work in a fiber glass cave fitting tubing to the underside of a body that has been twisted by time and temp. But enough whining and here are some shots of the progress of the last couple of weeks. A few more tubes to fit and the door sills to do(those will be oh so fun, not) and we should be good for more parts to mount.
Patrick
http://www.clubcobra.com/photopost/d...783_Small_.JPG
http://www.clubcobra.com/photopost/d...784_Small_.JPG
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http://www.clubcobra.com/photopost/d...791_Small_.JPG

Well,
I said previously that I had some complaining to do so here. Went though FFR to provide my exhaust parts because of the Mod 4.6 and their development. figured that it should work with little modification (hey come on this isn't a stock build), I was ready for that. But what I got was aggravation and a whole lot of rework,and:mad: I hate rework! some parts came right away some took two phone calls and a few e-mails to even get an answer when they would ship. One side pipe was crooked, had to cut it apart and re-weld it strait, not only person thats happened to. J-pipes, well lets just say these I knew I would be modifying but not to this extent. But after two weeks and lot of work we have side pipes mounted on the car and they look as good as I could get them. There are lots of new pics in the gallery take a look.
Patrick
http://www.clubcobra.com/photopost/d...805_Small_.JPG
http://www.clubcobra.com/photopost/d...796_Small_.JPG
http://www.clubcobra.com/photopost/d...798_Small_.JPG
http://www.clubcobra.com/photopost/d...803_Small_.JPG

Well, this step was refreshing. After the PITA of the exhaust we went on to mounting the fuelcell in the car. This was a piece of cake and went together without any problems. It fit right where I wanted it to go and did exactly what is supose to. Tied the upper suspention mounts together nicely. Too bad I can only carry about 12 gallons, but my clubs will still fit in the trunk (or chairs and cooler). Now we are moving on to the seats they are not going in so quietly.
Patrick
http://www.clubcobra.com/photopost/d...809_Small_.JPG
http://www.clubcobra.com/photopost/d...815_Small_.JPG

Now I didn't spend big money, for seats that may need to be modified to fit, but these weren't all that bad. Now finding room in this car for them, well thats a whole other thing. after figuring what angle and how far back they needed to be we set out to fab up brackets to do so. decided not to use the adjusters they only raised the seats up higher and they felt high enough just bolted to the floor. Have come up with a solution for different heights of drivers, I'm going to make the pedals adjustable. Now that should make for some serious headscratching when the time comes.
Now second, I know that a lot of people are following this build. Well I'm not just posting this for enjoyment. I want feed back So please try to interject some of your thoughts. I have incredibly thick skin so don't be afraid. Oh and Mick sorry still no vroom-vroom shot but my spouse caught me sitting in the car, Yes she gave me a hard time.
Patrick
http://www.clubcobra.com/photopost/d...822_Small_.JPG
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http://www.clubcobra.com/photopost/d...828_Small_.JPG

Well let's start with a casualty report. Thurs. angle grinder died bought new cheap one (with the abuse they get from me good ones don't last much longer). Fri. belt sander blew a bearing, fixed it with parts from broken angle grinder. Sun. melted hole in air hose will fix at work.

With everything going wrong I was still able to get my removable backbone finished and in the car. 12 bolts, tight fit, told ya I could it. I don't think I need to worry about another cross member with that cage bolted to the frame. Kind of ties the rear suspension together also should cut down on twist as well.
Patrick
http://www.clubcobra.com/photopost/d...835_Small_.JPG
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Well I've made another installment in the saga I'm going to refer to as breaking the laws of physics, or making something larger on the inside than it is on the outside. We have steering and it works. It was a tight fit with the huge engine in the way but we got it all in there. Can any one guess what the column is out of? I'll give you ford but you have to be more specific. oh and it's been modified quite a bit. Thanks to everyone for the Intel on what everyone else is using. now I have to start thinking about pedals, Oh Boy oh boy.
Patrick
http://www.clubcobra.com/photopost/d...856_Small_.JPG
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http://www.clubcobra.com/photopost/d...852_Small_.JPG
http://www.clubcobra.com/photopost/d...853_Small_.JPG

Hey just a quickie bent this up for my roll bar hope you can bear it. I just never liked the double hoop look, just to busy for me. But with this one it is one piece and can be removed without taking the legs off. You will either love it or hate it, I don't care It's my car.
Patrick
http://www.clubcobra.com/photopost/d...858_Small_.JPG
http://www.clubcobra.com/photopost/d...860_Small_.JPG

Welcome to the site! What a cool build! I love that you are doing all the fab yourself! How long have you been at it? Yeah it can be frusterating at times (understatement!) but doing it yourself adds a lot to it!! :thumbsup:

Well, running out of room quickly but I think this will have to do. Put the pedal assembly and foot box frames in the car, tried to make as much room as possible. This engine is so wide, my feet will be within 2"of the exhaust manifold . Now I still have to come up with a throttle pedal (cable type). Thats where all of you come in, show me your pics, need ideas to steal. Still searching for radiator and windshield.
http://www.clubcobra.com/photopost/d...875_Small_.JPG
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http://www.clubcobra.com/photopost/d...872_Small_.JPG
Patrick

Well those who weren't afraid of the old sever knew that I put the throttle peadal in the car. So now I'm reposting the pics to keep the build thread up to date and complete.
http://www.clubcobra.com/photopost/d...878_Small_.JPG
http://www.clubcobra.com/photopost/d...877_Small_.JPG
http://www.clubcobra.com/photopost/d...880_Small_.JPG
Patrick

Well I've been busy mocking up some new found parts in the car. The radiator and fan have been added to the done list of things to do. the rad is an Allstar Performace 16X28 ford style two row. The fan is well, we'll see if anyone can figure it out. Thanks to all who helped with my info search this step turned out be on of the larger head scratchers.
http://www.clubcobra.com/photopost/d...882_Small_.JPG
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I'm just going to keep plugging away at the list.:cool: Patrick

Well I've reached a pivotal point with this project. It is time to start the process of mounting the body(or at least the mounting points to the frame). Now this is fairly new ground for me fiberglass is a medium that I have little experience with so this will be lots of fun. So soon it will be time to trim the furry of my raw body and put to sleep all the remarks that the untrimmed body received.

Now for the photo junkies out there I've taken some new shots of the chassis at its current state. things that have been crossed off the list seatbelt mounts, battery tray, and finished the firewall bracing.

http://www.clubcobra.com/photopost/d...887_Small_.JPG
http://www.clubcobra.com/photopost/d...889_Small_.JPG
http://www.clubcobra.com/photopost/d...895_Small_.JPG
Now for the first of many questions what is the best way to trim the crappy edge on my body. I'm thinking rotozip but what bit? I don't have a clue. Also what is the best way to adhere metal to fiberglass(door, hood, trunk frames) like I said now I'm a complete rookie. Patrick

Well, we've made a huge milestone in forum history, over 10,000 hits that puts this thread on the leader board. Thanks for keeping interested, now let's get that reply number up.

Here's an update, Body has lost it's fur, finally got around to trimming that sucker it don't look half bad but she's going to need lots of work. Bird cage is 99% fabricated just a few braces left. New parts on done list coolant fill bottle, rear bumper mounts, and hood hinges. Now here's the gratuitous pics that we've all come to enjoy.
http://www.clubcobra.com/photopost/d...907_Small_.JPG
http://www.clubcobra.com/photopost/d...909_Small_.JPG
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http://www.clubcobra.com/photopost/d...903_Small_.JPG
Patrick

Wow, nobody piped up with the teaser photo, well then here. In keeping with the overbuilt chassis concept we have door frames. They are as beefy as the rest of the chassis.
http://www.clubcobra.com/photopost/d...921_Small_.JPG
http://www.clubcobra.com/photopost/d...924_Small_.JPG
http://www.clubcobra.com/photopost/d...925_Small_.JPG
http://www.clubcobra.com/photopost/d...927_Small_.JPG
http://www.clubcobra.com/photopost/d...928_Small_.JPG
Now we'll see if there is something to say. Patrick

Well I've had problems with my build but this was like herding cats. standard swing hinges just didn't put the lid in a good spot given the location of the roll bar. So I came up with these I spent way to much time doing this.
Now they will need some final tuning but they should give me the desired effect.
http://www.clubcobra.com/photopost/d...938_Small_.JPG
http://www.clubcobra.com/photopost/d...936_Small_.JPG
http://www.clubcobra.com/photopost/d...937_Small_.JPG
So with that said I move on to the Hood.
Patrick

I think you should buy an alum body and junk the fiberglass.

Well cross hood hinges and latch off the list. This wasn't as difficult as the trunk as I found some usable (with modifications of course) hinges at the junkyard. and a tailgate latch from a wagon. I am still proud to say that I have not needed to use a GM piece in my build. Just need to make a Popper system to allow me to grab the hood to open it, after hitting the latch release.
http://www.clubcobra.com/photopost/d...939_Small_.JPG
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http://www.clubcobra.com/photopost/d...942_Small_.JPG
http://www.clubcobra.com/photopost/d...943_Small_.JPG
Now I have three things left to do and the mock up will be complete, E-brake handle, brake and clutch reservoirs, and windshield. Patrick

Well I've got three pictures here can you guess what it signifies?
http://www.clubcobra.com/photopost/d...42_Small_1.JPG
http://www.clubcobra.com/photopost/d...46_Small_1.JPG
http://www.clubcobra.com/photopost/d...44_Small_1.JPG
Now, I've officially ran out of major components to mount to the chassis. and will have to break this mock-up down and completely finish weld it and then make all the body mods, mounts, and fiberglass pieces fit. I will post up some pics of the chassis naked before break down. Patrick

Hey I promised pics with out the body before I broke it all down to finish welding the chassis together so here ya go.
http://www.clubcobra.com/photopost/d...948_Small_.JPG
http://www.clubcobra.com/photopost/d...949_Small_.JPG
http://www.clubcobra.com/photopost/d...950_Small_.JPG
http://www.clubcobra.com/photopost/d...952_Small_.JPG
How's that for almost two years of planing and work? Now I'm going to leave it like this for awhile till I have the guys over for coffee and dough nuts then I'm taking it apart. Patrick

OK, just for the record, yes I have a knack for doing everything the hard way. This avoidance of the infamous prop-rod was the cake taker. I spent the better part of two weeks and many failed attempts at using anything but a prop-rod to hold up the trunk lid. Few even were worthy of calling a trunk-a-pult. So when gazing upon these pics understand that this was not easy or fun (most of the time).
http://www.clubcobra.com/photopost/d...953_Small_.JPG
http://www.clubcobra.com/photopost/d...954_Small_.JPG
http://www.clubcobra.com/photopost/d...955_Small_.JPG
OH Ya I'm still waiting for the club to get together before I take her apart.
Patrick

Now while waiting for the club to come and share the glory of finishing the chassis mock-up, I've completed some other optional components. We now have sway bars front and rear. Both are highly modified stock units, the hard part was finding room to squeeze them in.
http://www.clubcobra.com/photopost/d...964_Small_.JPG
http://www.clubcobra.com/photopost/d...963_Small_.JPG
http://www.clubcobra.com/photopost/d...959_Small_.JPG
http://www.clubcobra.com/photopost/d...958_Small_.JPG
Now I know I've said this before. Please respond to these posts I could easily just keep all this to myself, but I enjoy the opinions of others and sharing info so all you lurkers out there speak up

Well I've broken her down to the bare frame. There is nothing bolted to her at this point and will comence finish welding shortly. But I figured you guys might like to see what it looks like with nothing on it.
http://www.clubcobra.com/photopost/d...968_Small_.JPG
http://www.clubcobra.com/photopost/d...969_Small_.JPG
http://www.clubcobra.com/photopost/d...972_Small_.JPG
Patrick

just thought I would share this photo with everyone to prove that I do work on my car. The fact that it's just a cool pic helps too.
http://www.clubcobra.com/photopost/d...975_Small_.JPG

Still plugging away on the welding about half done ran out of gas for welder. Time to pick up and rest : Patrick

This is the only time I ever want to see this chassis in this position. Just a quick update welding is about 99% finished and I'm cleaning up the welds with a little grinding and wire wheel action.
http://www.clubcobra.com/photopost/d...976_Small_.JPG
Patrick

Well after just a short life I lost another angle grinder. I beat this one down cleaning up the welds and removing surface rust on the chassis and other pieces(smoke, sparks, and fire it was way cool). Boy I'm glad they're cheap, now don't start telling me about cheap tools my first one was a quality brand It lasted about three projects I beat these tools like "redheaded step children" I don't expect them to last.

Here is some more pics of the project the metal is now somewhat shinny. Boy you really get a good picture of the scope of this build;
http://www.clubcobra.com/photopost/d...981_Small_.JPG
http://www.clubcobra.com/photopost/d...982_Small_.JPG
http://www.clubcobra.com/photopost/d...983_Small_.JPG
http://www.clubcobra.com/photopost/d...985_Small_.JPG
Now I have to get busy with the fiberglass part of this so, should I start a new thread or keep using this one I know it is getting very long? Patrick

I have begun the glass part of the build. Yuck, what a mess, I don't know what is worse the smell or the itching. But progress has been made we now have extra glass in the door jams and lowered rocker panels.
http://www.clubcobra.com/photopost/d...0/IM000990.JPG
http://www.clubcobra.com/photopost/d...0/IM000993.JPG
Thats all for now.
Patrick

Well thank all of you for your input. Here is what I came up with. I have eight points that will be glassed into the body for hidden mounts,plus the three points around the door sill (anti intrusion pins through the body) and the bumper mounts.
http://www.ffcobra.com/photopost/dat...008_Small_.JPG
http://www.ffcobra.com/photopost/dat...009_Small_.JPG
http://www.ffcobra.com/photopost/dat...007_Small_.JPG
http://www.ffcobra.com/photopost/dat...006_Small_.JPG
Now I can mix up some goo and fix the pads to the body and continue with the panel construction portion of this build; Patrick

Most of you,(Okay some of you) know that I'm building my cobra the hard way, from scratch. Well here are some pics of the rear wheel well panels I've been working on. Working with glass is not fun, but forming sheet metal into these shapes would require way to much work.
http://www.ffcobra.com/photopost/dat...003_Small_.JPG
http://www.ffcobra.com/photopost/dat...002_Small_.JPG
http://www.ffcobra.com/photopost/dat...05_Small_1.JPG
http://www.ffcobra.com/photopost/dat...04_Small_1.JPG

Patrick