Untitled Document
  • 22nd July 2011 – Finishing off rolling chassis

    We had a few small jobs to get done to finish of the rolling chassis.

    1. Change the Rear Axle shims

    We realised once we got the wheels on the chassis, that there was too much play in the rear wheel baring. After removing the wheels to measure the end float we discovered the original shims we put in when building the axle back in February (read here) were 0.009 ” too big. So we striped the rear hubs to replace the shim, giving a final end float between 0.001- 0.003

    2. Prop shaft safety loop installed

    I’d received the prop shaft safety hoop from Gerry so we thought we’d fit that. It comes in two parts. The support bracket bolts to the chassis with 2 bolts, then four holes need to be marked up and drilled so the hoop can then be bolted to the support bracket.


    3. Fitting Rear brake pads

    We had the rear pads to put in. This is a fairly simple job. We painted a layer of copper grease on the rear side, this to prevent brake squeal. Then took the retaining pins out to slide the pads into the rear calipers and then secure again with the retaining pins.

  • 4th June 2011 – Handbrake and prop shaft

    We put in the handbrake lever and prop shaft. These were quite easy to install. We had to source the bolts for the prop shaft, which we got from a Landrover dealer Mark knows, and are from a Landrover Defender. Next we’ll have to fit the prop shaft safety loop.

    The handbrake was installed using counter sunk bolts then we connected the handbrake cable to the hand brake lever. We’ll leave the adjustment until later.

  • May 2011 – Rear brakes – Rear axle complete

    Unfortunately we haven’t spent much time on the build in recent weeks due to holidays, Marks university work and other things taking priority. We have spent some time ordering lots of new parts though and Mark has done a few bits and bobs. We are planning to get more build time over the summer and make some really solid progress.

    Here’s a little update from recent weeks.

    Firstly, we have now replaced the old rusty bottom ccntre bolts through the base of the differential with the shiney new ones we were waiting to arrive.

    Having built up the rear calipers back in April, Mark has now also installed them onto the rear axle again. Attaching with 2 bolts and then lock wiring them in place. Then connecting the handbrake cable to the handbrake calipers. Other than a bit of tinkering, thats the back axle complete. Even though it has been a bit of hassle and time getting all the parts together, it has been a great learning curve, and we are now really pleased with the way it has turned out.


  • 2nd April 2011 – Rear Calipers arrived back and get re-assembled

    The rear calipers arrived back all zinc plated and all shiny. They have done a great job. Mark spent some of Saturday building them with his new apprentice, little Phoebe (showing off her new spanner skills)! First picture show the original condition, coming off the donor axle, then the next stage after sand blasting and cleaning and then following on the pics show the stages of re-assembly after zinc plating. Now they’re ready to be refitted to the back axle which we’ll do the next weekend we get free to work on the car.

  • 26th March 2011 – Back Axle installed – Basic Rolling Chassis

    We finally got the 2 arms of the back axle together – newly coated and painted, new barings and bolts etc. We are still waiting for the brake calipers to return from the zinc platers and some new bottom bolts but we thought this shouldn’t hold us back getting to a rolling chassis as, for now, we could use the bottom bolts from the old axle and replace with brand new once they arrive. We had already installed the specially made mounting to the diff a few weeks ago, so all we had to do is  simply jack the axle up into position and , using the ready made holes in the chassis,  bolt it into position. Simple.

  • 19th February 2011 – Rear axle coming together 2

    We took receipt of the shortened lower arms and drive shafts. First thing was to spend some time wire brushing them down, using an angle grinder with a wire brush on the end makes short work of this. Once clean we then primed them and spraying them black. We set Marks shed up as a make shift paint shop, with bits of rear axle dangling from wire in mid air while we sprayed them.

    start assembling the axle back

    Once the paint was dry we could eventually start assembling the axle back. Firstly we bolted on the chassis backets to the base and top of the differential. These parts came as part of the chassis from Gerry and Hawks

    Then attaching the brake disks the newly painted arms and drive shafts, with new UJs and the hubs we built up a few weeks back. Also putting in the new upgraded rear springs and suspension. We were a little unsure how many spacers to use when attaching the suspension parts as we had quite a few in the box. After a call to Gerry, he confirmed all you need is a large and small one either side at the bottom to balance the different size backets with no spacers required at the top.

    All we need now are the brake calipers that are being currently being Zinc coated and are due back next week. Then we can bolt the axle to the chassis, put the wheels on and we have a rolling chassis.

  • 5th February 2011 – Rear Axle coming together

    Getting all the parts together for the rear axle has proved to be quite a slow process, especially getting the lower arms and drive shafts returned that we sent off to be shortened. This has delayed us getting to a rolling chassis stage –  Even so we cracked on with the parts of the rear axle that we had, which are the rear hub, fitting new barings, seals and drive shaft UJ. Firstly we wire brushed and cleaned up the hub carriers and sprayed them silver.

    Trouble with the shims

    It wasn’t as simple putting the hub together as we first imagined as the barings and hubs require a spacer shim inside the hub. There are about 16 different sizes of shims from 2.22mm to 3.47mm and as we had brand new rear hubs and barings, it was almost impossible to work out at first hand which size we needed. So quite a bit of trial and error with different sized shims that Mark managed to get from his mate at work, but  when we tried them were all too tight.
    Eventually after a few calls and a bit of advise, we ordered a set of the largest shims from Ed at www.jaguaraxles.com. We then assembled the hub ‘dry’ and then measuring the end-float using a dial gauge and comparing the actual end float with the desired. We could then order the correct size which arrived a couple of days later from Ed. We then disassembled the ‘dry’ hub before fitting the appropriate thickness of shim, and finally reassembling again while greasing up all the bearings.
    This was quite a lot of bother and I can tell you, but got there in the end.

  • 25th September 2010 – We have rear hubs!


    We’ve been waiting for new parts to arrive from various places for a few weeks now, which has been quite frustrating, but today we received the rear hubs that Gerry has had manufactured especially to fit our back axle. which is why we had to wait. They’ve done a really nice job! Hopefully we will soon be showing you pictures of the build in progress rather than just pictures of new parts.

  • 24th August 2010 – Rear differential reconditioned

    We sent the rear differential off to Coventry Transmissions (recommended through Pete) last week, for rebuilding and reconditioning. Mark picked it up last night. WOW! They have done an amazing job. They have fully replaced the inners and totally cleaned it up as good as new. Its totally unrecognisable from the greasy parts we got from eBay those weeks ago. We have nearly got all of the components to assemble the rear axle now. Just waiting on the shortened bottom arms and rear hubs to arrive from Gerry at Hawks. Once they arrive we will spend another weekend putting the rear axle together and assembling it to the chassis.

    and this is it before reconditioning

  • 7th August 2010 – Striping the back axel

    We managed to source a Jaguar XJS back axel from ebay that arrived, and to an untrained eye looks like a piece of greasy junk. Well in this condiction maybe, but this particular axel is the recommended one for this type of Cobra 289. We won’t be using much of the original axel, so replacing with new upgraded parts, but the differential and suspension arms are the bits we will be keeping, and need to be reconditioned back to mint condiction.

    So we spent some time striping down the old axel into its individual parts. The suspension arms we sent back down to Gerry at Hawks to be shortened in order to fit our frame, while we source a company to striped down and recondition the differential. When we get the bits back it will then be a case of building the axel back up with the new parts and bolting it all to the chassis.