Been awhile

Well, it's been awhile since I last posted. Spring has sprung here in San Diego and there are many things to do, I've been spending time enjoying the nice weather and working outside in the yard. In addition, I did some traveling for work and Baseball season has started. Somehow I did manager to squeeze in a little time working on the car.

I took the hit and ordered the Ford computer module kit. This kit includes the fly by wire pedal assembly, the computer, MAI, air box (I won't be using this part) a relay box and an another wire harness plus some miscellaneous parts. This kit is needed to allow the coyote motor to run in a non-mustang build. pretty much designed for use in a custom hotrod or a retro upgrade. With this installed kit you can use a OBII code reader to trouble shoot the motor.

Whew, another wire harness... , FFR has provided a good instruction guide to tie the two harness together! I will be spending a lot of time checking and rechecking this part of the build.

 

Here is the computer. I will need to fabricate a bracket to mount this box in the engine bay (away from a heat source.. like the headers!). So far, it seems to me that the best location will need to be on top of the passenger foot box. We'll see as we go along on where the best place to install the computer will be. 

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  OK, so this kit was over $1400.00 and what was the first thing that I needed to do to installed this in the car... yep, cut up the pedal assembly to allow it to be mounted into the space much thinner then a standard mustang foot box.. thankfully, Lori reminded me of the old saying... "measure twice, cut once" following her lead and the good FFR documentation I worked my way through the modifications. Pretty much cut off some of the mounting flanges, cut off the front of the petal assembly. The ford pedal is a rigid design while the FFR pedal have a pivot and spring to allow it to rotate.

The Ford pedal is on the left and the FFR pedal on the right.

 

after removing 2 of the mounting flanges.

 
 

 removing part of the FFR pedal, drill some holes add a mounting plate and some other hardware...

 

 and there you have it a new pedal assembly that is fly by wire and a pivot point.

 

 

installed very nicely into the foot box. I know that I'm the only one to see it. but I took the time and sanded and painted the assembly before installing.

 

 

 

I placed in one of the seat in the cockpit and did a trial fit of the pedals.

 

 

yep, can see myself enjoying many years behind the wheel of a car that I built!

 

 



Well, I finished the cockpit sheet metal... well almost, the transmission cover goes on much later in the build and there is still a couple pieces of the driver foot box that will also be installed later.

So, some of the stats on this portion of the build, Almost 200 rivets were installed! That means that around 400 holes were drilled n sheet metal and sub-frame.

 

The back panel sheet metal has 100 rivets installed and no I did not use a pneumatic riveter. Does look pretty cool. unfortunately I'll be covering it with thermal/sound deadening material and carpet at least I will know how cool  looks. Got to hand it to Factory Five most of the sheet metal fit very tight without any adjustments. Only one panel needed to be formed a little bit to fit nicely.

 

 

 

All of the Aluminum surfaces that are facing outside of the car are coated with Shark Hide to help preserve the Aluminum.

 

So I think the next thing is to prepare the driver side foot box (drilled holes) and use the Cleco’s instead of riveting them for now to allow me full access to the pedals, brakes and fuse panel.

With the cockpit sheet metal done I took the opportunity to place the seat and steering wheel in place to see how I fit. Being 5’-10”… no problem looks/feels like plenty of room. I’ve been thinking about adding a quick release on the steering wheel for theft protection. Park and lock the steering wheel in the trunk.

 

Passenger side Footbox sheet metal work

This weekend was I able to spend a few hours working on sheet metal panels. Lots of holes to drill and just as many Rivets to install. I was able to get a little more experience in using the Clecos! and learning that Harbor Freight 1/8" drill bits are good for about 2 holes in the frame and then they are done. Need to find a better source for the bits! I need to go on-line for some contractor, bulk package bits.

In addition, to riveting on the panels I've ran a bead of silicone around all of the flanges and any gaps in the pieces to help ensure that I'll be able to keep out any water. I know it's going to be tough when the car doesn't have a top! Thankfully living in Southern California I won't have too worry to much about rain.

 

The kit came with a template to help with the spacing of the rivets. Note: not every hole has a Cleco installed just enough to keep the panels from moving around.

 

Here is a picture of the internal side of the foot box. As the build progress I will be installing some sound deadening and thermal material and then the top layer of carpeting.

 

Here is a picture of the completed foot box.... pretty! Too bad most of the sheet metal will be covered.

 

Here is a picture showing the parts that I will be working on next. Passenger floor board, side panel, transmission tunnel (partially) and rear cockpit

Here is a current view of the front of the car.

 

Once most of the sheet metal is installed. I will be working on installing the brake and fuel hard lines! Looks like I'll be learning how to make flares and how to make nice bends in the tubing.



She's a roller now....

Its been an interesting week on the build. If you remember last time I was making good head way on the foot box and was preparing to installing the steering rack. (I'm adding some notes to pictures to help define just what I'm talking about)

 

 Well, the steering rack went on fine until I went to install the tierods on to the steering control arms. It turns out the the steering  control arms have a tappered hole to line up with the tappered hole on the tierod.

 

So I thought no problem I'll just unbolt the control arm and swap sides... no brainer and in theory should have been done in ½ hour. Well, wishful thinking…. the control arm would not slide out pass the Lower ball joint attached to the lower A-arm. and I could not remove the arm out the other direction. Well, I've now learned a new skill, breaking apart a ball joint. I hit the net to do some research and found a lot of "helpful" suggestions. Tried (and failed) at more then one. Finally had a chance to talk with my neighbor about my problem and he commented... no problem have them a part in a few minutes. Which he then took two sludge hammer and started whacking at the spindles and sure enough... pop the joint came apart! Well, not to be out done I grabbed the hammers and proceeded to done the same to the other joint and wham! success...

 

 

I felt pretty good about getting the steering corrected, installed and functional. It was time to move backwards (really, forwards with the build but towards the back of the car!) with installing the rear end into the chassis. I needed to enlist some muscle to lift and place the rear end into the proper location. I asked Jacob to come over and with Lori's and his help we were able to install the rear end! It weights around 200 pounds and had to be lifted and positioned about 10" off of the ground.

 

 

With all four corners ready for tires and rims it can be consider a "roller"!

Completed Front suspension

Completed rear suspension

 

 

I feel like I'm making some great progress.  This week I'm moving to get the Gas tank assembled and installed into the car.

and after that its on to install some of the sheet metal.

 

Still no decision on her name or her color...

moving forward , Rear end and Footbox

Well it's been a few weeks since I written anything. We have been busy fighting flu's and colds here at home and finally everyone in the family is on the road to being healthy.

This morning I was up early (5:30am) and headed for the garage. put in a good six hours working on the car, plus a few hours on Saturday.

The rear end is almost complete (got to say without upsetting Lori... that is one good looking rear end!) and should be ready this week to be installed on the chassis..
.

 

 

It will look much better when she's fully dressed (Tires and rims) and wrapped up in a tight fiberglass body!

Which kind of leads me into the fact that the car does not have a name yet... I'm sure that it needs to be a women's name or perhaps something like Black window or the beast... nah, boring got to be a women's name... Any suggestions?
 

Anyways, I got a little bored turning wrenches sitting on the floor of the garage working on the rear end. Still a little chilly here in the morning and I don't have a heated garage. So, I worked on the bench on the foot box. Assembling the Brake and clutch components into the chassis.

In addition, I installed the firewall sheet metal and the heater assembly.

 

By the way climbing in and out of the chassis installing the firewall and heater my pants got caught on some sheet metal and torn them...that and a couple of bruises and skinned knuckles, she plays a little rough..Even had  to modifiy a tool to work on her...

Next, after completing the rear end install I'm moving to installing the steering.

 

 

This week I'll be ordering the Accelerator petal and the computer system. This kit might be modeled after a 1960s Cobra but, with the motor that I'm using I'll be able to go to any Ford dealer and be able to get a full diagnoses done through the OBII port.

 

This week my next door neighbor brought over an engine lift for me to have as well as I should be recieve an engine stand to have...

 

Soon I'll be asking for people opinion on the color....I have a couple of colors in mind but, I'm curios to what everyone else thinks would be a great color.



Getting serious now, Front suspension.

I had some time this weekend to work on the Cobra. Moving beyond the sheet metal and started some serious wrench turning.With my trusty torque wrench and a pile of parts in hand... of course, the build manual near by. I dove into the front suspension. This picture shows only some of the parts used on the front suspension.Spindles, upper/lower A-Arms, Steering arms, shocks and hardware.

Here is a picture of where I'm at now. This is just all of the parts put into their right location (mocked-up). I still need to torque everything down. The upper A-Arm assembly is fully adjustable.... Ummm, by I professional once the car is complete. You can see the hub in the lower left side. Once that is installed I'll begin to work on installing the brakes.

 

 We did take a few minutes to stop by our local Albertsons and visit with the Oscar Myers Weinermobile. Isn't as cool as the cobra. But, it is a pretty cool automotive design. Based on a GM motorhome chassis. Hmmm, Cobra painted Yellow with Orange strips, HOT DOG!.... I don't think so. The cobra needs to be paint a color to blend in a little more.

Even Jenn and Dominic showed up and get their hands on a Whistle and sticker!

 

 

 

Well, that's it for this week. Next week is Superbowl. So, I don't expect that I'll be spending to much time in the garage.

First sheet metal part installed

Well, it looks like I should make this a "I'll post when I make some progress"...blog.

So, I did made some good progress on the build this weekend.

One of the big highlights of the weekend was a Factory Five Builder/Owner (Ray and Jodie) stopped by on Saturday morning with his roadster! It was very motivating to talk with both of them about their build and some of the improvements that they see from their version.

He even took me for a ride.

Between you and me... this was my first time going for a ride in Roadster!I've sat in a few of them... but, to feel the power and hear the roar of the side pipes...Yes, I made the right choice!

 

It was a blast! very quick and...a very manly ride! Ray has offered his help when I need it and I'll take it!

 

 

 

One of the other things that happened this weekend was that several neighbors came over to the garage and looked, asked question about the car... Neighbors that I have only nodded to in passing. I've learned that I have at least four neighbors that are or were mechanics in their careers and they offered help. Pretty cool. I'll be talking with them all in the future for advice and/or lifting help. 

 

 

Progress on the car, I pulled all of the Aluminum off of the chassis.

 

Now we can see all of the structural members of the chassis. Very well designed and excellent craftsmanship on the fabrication.

The next step was to install the first piece of sheetmetal. Its called the "F" panel and it goes over the front suspension. One on each side.

There is some prep work the needs to be done to the sheetmetal before installing them.

So before removing the sheet metal from the chassis each part is marked where the mounting tubes come in contact with the sheetmetal. Once marked using a template holes spaced 1-1/2" apart are drilled through the sheet metal.

Once you have the holes in the panels you place it back on the chassis and transfer the through holes into the chassis. I'm using Cleco's to hold the piece to the chassis.Kind of a third hand.

 

Once all of the holes in the chassis are drilled. Each panel is held onto the chassis with Silicone sealant and Pop rivets.

Next step is on to installing the front suspension!! good story from Bill Cosby on the AC Cobra