Building our AC Cobra 289 LeMan

28th January 2012 – Throttle linkage

jontowers — Tue, 31 Jan 2012 19:59:55 +0000

Once the throttle peddle and pivot where fitted, we moved onto fitting the throttle linkage to the carburettor. This is something we have been thinking about for a few weeks. We had the option to get the bits from Gerry but Mark wanted to design and make our own system. We had pictures of Andy Gordon’s Cobra at Silverstone, once again we used his car as the inspiration as we thought the solution he found was quite a neat one.

Mark spoke to his engineering department at work, asking them if they could manufacture the blades for the rod linkage and also some stainless steel strips, cut to size, that we plan to make a bracket from and mount to the inlet manifold. We have made a temporary bracket for now, that we will replace with a better one later. We have marked up for the new bracket that we hope to get our uncle Dave to wield for us.

We fitted the rose joint on the top of the footwell first. we then slid the 10mm rod into it. We then put another rose joint on the other end which we lined up and marked the hole to be drilled on our temporary bracket fitted to the manifold. Then drilled the hole and fitted the rose joint onto the bracket. We then fitted a blades to each end of the transverse rod.

We linked the blade to the carb using 2 female rose joints and 8mm rod. we had to tap a thread to both ends. We connected the other end to the peddle in exactly the same way using a shorter 8mm rod.
It took a little time adjusting the lengths of the rods to get the travel of the pedal correct but it works really well. We have just got the final bracket to make and fit now to finish this off.

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28th January 2012 – Fitting the peddle box and throttle peddle

jontowers — Tue, 31 Jan 2012 19:19:03 +0000

We started today thinking it was about time we fitted the peddle box. As we had already cut the hole in the footwell ages ago, its a job we could now do as the body is back on. The bolts go through the floor and flat section of the chassis and it was just a case of lining it up, marking up and then drilling the holes through. As the end of these bolts are exposed under the car, Mark had bought some stainless steel M8 bolts for this job, so they won’t corrode when exposed to the weather. Due to its position it proved a bit awkward getting these in and getting them tight. Mark bumped his head on several occasions while he had his head stuck down the footwell trying to get the bolts in (Hopefully knocked some sense in). We had noticed before hand that the floor of the body wasn’t quite square so we had to use a small piece of fibreglass, that we saved from cutting the original hole, to pack the front edge, getting a good seal between the vertical edge and engine bay.

Next up was to negotiate the position of the throttle peddle. The throttle pedal is posted through a hole in the top of the peddle box with the throttle pedal housing mounted on top inside the engine bay. We read through the Hawk manual and it didn’t really give any hard and fast rules for the position, although when we had spoken to Gerry at the NEC he told us to aim to mount it about an inch from the front of the peddle box. So this is what we aimed for. We initially drilled a small hole posted the peddle through to get a rough position. We wanted the accelerator peddle slightly further forward than brake and clutch peddles but for all 3 peddle to be equally spaced apart. From there we marked up the holes, drilled and fitted. This was also a bit fiddly due to it being under the wing and had to use a 90degree drill bit for this job.

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23rd January 2012 – Fuel pressure regulator(fuel king) & connecting to carb

jontowers — Fri, 27 Jan 2012 12:07:57 +0000

Happy New Year to everyone. Just a quick update as the last post was a while ago now. The cobra build was put on hold over christmas as I was away in NYC and Mark had his Uni work to crack on with. Even so, we have ordered more bits, fuel tank, radiator, throttle linkage, that we are waiting to arrive. We’re hoping to get some stuff done this weekend so more posts coming soon.

Mark has spent a little time fitting the fuel pressure regulator to the nearside inner wing, see pic below. He then cut a piece of fuel pipe to length to fit from the carb to the fuel filter/regulator. Now that we have a piece of pipe to length, we have sent it to BGC Motor sport components to make a braided pipe with the banjo connectors to go from the carb.

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5th December 2011 – Engine Bay

jontowers — Mon, 05 Dec 2011 19:51:45 +0000

Once we had got the body back on it was really late into the evening, but these are some pictures taken the next morning in proper daylight. We are delighted to finally have the body back on the chassis ready for further work over the winter months. We think the complete set of heat shields now fitted and polished up just look amazing! Thank you again to Dale and Phil and Slipstream design for the CAD work and production.

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3rd December 2011 – Body Bolt locations

jontowers — Mon, 05 Dec 2011 15:00:43 +0000

Since writing our post on 3rd December about getting the body back on, we have had a few people email us asking where the 20 bolts for securing the body to the chassis are located. So this is a little extra post with some pics showing the locations. 20 bolts in total. 2 each side at the rear of the boot, there is 1 each side of the rear wheel arch in the boot, 1 each side next to the sill in the cabin, 4 each side in the foot welld holding the dash frame and door hinges and finally 2 each side at the front. In the picture below, the front bolts are not in yet as we haven’t got around to drilling the holes through the heatshield panels. These 2 are alan key bolts going through to the front wheel arches.

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3rd December 2011 – Body goes back on!

jontowers — Mon, 05 Dec 2011 14:45:17 +0000

After the final bits of painting and polishing, finally it was time to get the body back on the chassis. By this point we had been working on the body all day and was getting quite dark so had to work quickly. We thought the best way to do it was to wheel the rolling chassis out onto the street and get the body on where it was flat and where we had more room.

We acquired some help from a couple of the neighbours to lift it, one person on each corner, and very quickly on it went. It wasn’t quiet that straight forward getting it in the correct position though, as we quickly realised we had to cut away some of the floor to allow the prop shaft and safety loop to fit through the hole in the floor. We did this very quickly and we will go back and tidy the holes up at a later stage.

Once back in the garage we fix the body down with the 20 bolts we took out back in July 2010 when we detached the body. Seems a while and much work ago now. 4 bolts at the front in the engine bay, 10 in the cabin and 6 in the boot. They fitted very easily giving us confidence we had got the body on correctly. It actually looks like a car now, which is another real milestone. Still lots to do though.

We will probably be looking at doing the wiring and electrics next and getting the master cylinder fitted and connected up. Check out further posts coming soon.

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3rd December 2011 – Fitting Inner wing heatshields

jontowers — Mon, 05 Dec 2011 14:39:14 +0000

We fitted the remaining side panels heatshield next, which would also neatly fit over the top of the new well section panels. As we had with the other panels we used a metal folder to create a really neat edge on the bend where the panel would wrap around the corner of the wheel arches. We then fitted by drilling the holes through the fibre glass and riveting into place. As they were pre-made these panels fitted very quickly and easily.

Once all the panels were fitted we gave them a really good polish up to really bring out the shine. We are really happy with the results and completely glad we spent the extra time getting the CAD design done.

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3rd December 2011 – Engine bay – extra metal panels

jontowers — Mon, 05 Dec 2011 14:37:13 +0000

We decided after a little discussion to make some extra aluminium panels for the well sections connecting the inner wings to the peddlebox and footwells inside the engine bay. Originally we had planned to leave these as a fibre glass finish, but as we had some extra aluminium sheet left over from the manufacture of the other heatshields, we thought this might really finish the engine bay off nicely. So as we did before, we made simple templates from a couple old cornflakes box to get the shape and size of the 2 well sections. The offside proved a little trickier than the nearside as we had to negotiate the gap for the peddlebox.

It was Marks idea to give ourselves enough overlap of metal to be able to fold the aluminium right over on its self on the edges which would give us a really neat finish. So this is exactly what we did.

We then used tin snips to cut the template out of the 1mm aluminium before using the metal folder to get the shape and the vice to fold the edges getting a really neat finish. Then finally fitting and riveting into place on the car.

I have to confess this was more Mark’s handy metal work than mine (in fact my first attempt was rubbish and we threw this away as a tester piece) but when Marks stepped in, his metal work skills got them both fitting beautifully. With a little polish, we both agreed that this little addition really added that little extra quality to the overall appearance of the engine bay and well worth our efforts. I hope you agree from the pictures.

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3rd December 2011 – Fitting side vents

jontowers — Mon, 05 Dec 2011 14:29:05 +0000

We managed to get another day set aside to do some kit car. Today we were determined to finally get the body back onto the chassis and in the garage before winter and the bad weather really kicks in.

First job to get out of the way was to getting the side vents fitted. We had cut the holes out some time ago (link to post). The standard way to do this is to make some aluminium brackets and to fibreglass them in place. Mark had spent a few hours the previous week making 4 brackets, 2 for each vent top and bottom. He drilled out holes in the brackets to allow the P40 fibreglass to grip the bracket better against the body. We lined the vent up to the hole then used masking tape to secure into position, then mixed up the P40 fibeglass and layered in over the bracket. As it was a cold day it took a little while to go off and harden but we did 2 layers of fibreglass in the end which seems to have set ready solidly. This is a really messy and fiddly job.

After doing the first one we realised we had put the vent in the wrong way around. Doh! so quickly unbolted it from the bracket then turned it round 180 degrees, we realised at this point we’d have to modify the bracket slightly by drilling 2 new holes for the bolts holding the vent in place.

Once both fitted, the final thing we did was to carefully mask up the inner wings areas and spray paint the area black to cover the newly fibreglassed area and also give a nice neat edge between the outer wing and the footwells painted white.

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29th October 2011 – Fitting Heat shields

jontowers — Sat, 29 Oct 2011 18:31:54 +0000

We started fitting the heat shields today. We started with the bulk head panel, carefully positioning before marking up the holes, drilling and finally riveting into place. We used 4.8mm diameter rivets. The first 4 panels have gone in fairly easily with only a few minor tweaks. We had to file a few millimetres off a couple of edges to get them to fit absolutely perfectly. We are really pleased with the way they look and well worth getting the CAD design and laser cut out.

We just need to fit the front inner wing panels now, then polish out any small scratches.

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