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Old 05-19-2005, 11:10 AM   #226
 
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Hi All,

Here is a photo of the car with Wayne as a height reference (Wayne is 6'-1" tall). We will publish the actual clearances after we have the car on all four wheels.

We have installed the gas tank and connected all the lines. We noticed that there is a connection on the top of the gas tank that is not connected to anything (see photo). The best we can determine is that it is a safety release valve. Anyone know for sure?

Also, I have included a shot of the modified drip rail areas. It is hard to tell in the photo, but the finished detail will be very similar to that found around the fastback "C" pillar vents.

I am currently assembling the trans, etc... More photos will follow.

Catch ya'll l8r.

Bob
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Old 05-19-2005, 11:46 AM   #227
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Looking good - It looks awesome low, just watch out for speed bumps.

Can't wait to see this car on the cover of Hot Rod or MM&FF
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Old 05-19-2005, 01:12 PM   #228
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This will Definately be a magazine car
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Old 05-19-2005, 02:33 PM   #229
 
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WHOA.
I just got reading all 10 pages, and I am really impressed. Is the invitation really open to come an see it?
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Old 05-20-2005, 07:58 AM   #230
 
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Quote:
Originally Posted by uvbnbit
WHOA.
I just got reading all 10 pages, and I am really impressed. Is the invitation really open to come an see it?
Hi U,

Yes, if your avitar is any indication, you can come anytime you want. :-)

Catch ya'll l8r.

Bob
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Old 05-20-2005, 08:48 AM   #231
 
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sorry, I'm a dude.
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Old 05-20-2005, 09:38 AM   #232
 
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Hi All,

Yesterday we got the trans modified with a new D&D 26 spline input shaft. We installed the new CenterForce flywheel, clutch, pressure plate and throughout bearing.

What a project...

After a lot of fiddling about, we finally got everything bolted up and installed properly. Note to self. ALWAYS READ ALL THE INSTRUCTIONS AND ENCLOSED DOCUMENTS. Also, ALWAYS HAVE THE FACTORY SHOP MANUAL HANDY AND REVIEW IT PRIOR TO INSTALLATION. That is all I am going to say on the topic. You can't make me say any more.

Today we install the engine, trans etc... Wo Hoo

Catch ya'll l8r.

Bob
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Old 05-20-2005, 12:05 PM   #233
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I cant wait to see the finished product!

Not only is this car going to be sick, but its going to be beautifullllllllllllllllllllll.

Keep up the good work!
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Old 05-21-2005, 08:15 AM   #234
 
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Hi All,

This is going to be real tight!!!

Will the valve covers clear the frame rails? Will the steering linkage line up as designed? Will the repositioned front suspension cause any problems (the connections for the hydralic lines are now 7" farther forward than the factory design)? How far will the engine "stick up" through the hood? Did we make a mistake when we relocated the motor mounts? If the engine hits the firewall, I am going to shoot myself...

Tune in next week to "SN65 The Series" and find out. We will be busy going over all the mechanical and electrical assemblies this weekend. Monday I will be posting photos of the installed drivetrain. Until then, here is a little preview.

Bob
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Old 05-21-2005, 10:27 AM   #235
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Yes, I will "Stay Tuned" as I have been

Amazing !!!
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Old 05-22-2005, 10:23 PM   #236
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She's beautiful already!
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Old 05-23-2005, 08:00 AM   #237
 
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Hi All,

As promised last week, we have posted photos of the installed drivetrain. :-)

I was going to list the items we installed, but rather, I will list the items we have yet to finish. We need to attach the clutch cable. We need to finish aligning the MagnaFlow exhaust system. We need to install some rubber around the AC line to keep it from rubbing on the relocated shock tower. We need to finish "tweaking" the break lines. We have them in place, but we need to get the contours and alignment correct. We need to relocate the intercooler pump to clear the front wheel. We have to modify the horn bracket for tire clearance.

And the biggie is that we need to have a custom "oil filter relocation" fitting fabricated. The steering linkage fits as designed, but when we tried to install the oil filter relocation fitting, there was about 1/2" of interference. We examined the billet fitting and decided it should be easy to eliminate at least 1/2" from the design. We just have to find the right shop to do the work. I wonder if the people who manufactured the kit can help us out on this one?

Getting this engine to fit was not without it's issues. Clearance between the frame rails is very tight. And, once the engine is in place, there is very little room to work. We found that we would get so far before we would have to remove an item from the engine for clearance or install an item that would not fit when the engine was fully installed.

Getting the break lines reconfigured was a rather tedious process and we still have a ways to go. After messing with the lines for a while your hands just get to sore and tired to go on.

With all that said, the installation went pretty much as planned. I feel as if we made significant progress over the past few days. Now we have to knuckle down and keep pushing toward the finish. Today we will double check the installation and make sure we did not miss anything (loose bolts, fittings, electrical connections, etc...). After we are sure that everything is in order, I will move on to the dash / interior installation and Wayne will concentrate on the exterior bodywork.

Wish us luck

Bob
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Old 05-23-2005, 08:57 AM   #238
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Nice choice on the exhaust - same as me... Keep up the hard work and get a Pulley on that thing...
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Old 05-23-2005, 09:07 AM   #239
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super duper nice work.

are you using factory lines or did you bend up your own?

will the air conditioning be functional?

i wonder what kind of cooling troubles you will have, if any.
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Old 05-23-2005, 10:06 AM   #240
 
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Quote:
Originally Posted by ShelbyGuy
super duper nice work.

are you using factory lines or did you bend up your own?

will the air conditioning be functional?

i wonder what kind of cooling troubles you will have, if any.
Hi SG,

Thanks for the kind words.

We are using the factory lines and modifying them as required.

Yes the AC will be functional.

As far as cooling troubles, I don't forsee any at this time. I have already installed the LDC Chicago driver's side head cooling modification. Everything else will be factory. Should I be concerned about other cooling issues?

Bob
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Old 05-23-2005, 11:27 AM   #241
 
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Quote:
Originally Posted by uvbnbit
sorry, I'm a dude.
Hi U,

Damn... You have crushed my dreams. :-)

Even so, feel free to stop by anytime. We will be having a big blowout when the project is finished. We will look forward to seeing you then, if you don't get the opportunity to stop by before that.

Catch you l8r.

Bob
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Old 05-25-2005, 08:16 AM   #242
 
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Hi All,

The past two days have been spent reviewing the connections over and over again. I have been concentrating on the engine bay and the suspension. I am at the point where I have to start thinking about installing the dash and steering wheel.

I have attached photos of the rear wheel mechanisms I will not be installing, the car sitting on its wheels (I still have to fine tune the ride height, but that will have to be accomplished on the laser table, and the car from the front showing the engine height.

Today I will go over everything one more time and if satisfied I will start on the dash. I can't wait to get started on that rat’s nest of wiring and vacuum lines. I hope upon hope that I don't have any wiring issues when we go to fire this sucker up.

If there is a problem I will have to call in the big guns, because I will be totally lost... without a rudder... without a compass... in the dark... sad... alone...

Say a little prayer for me.

Bob
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Old 05-26-2005, 08:06 AM   #243
 
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Hi All,

Yesterday we installed the dash. Most of the issues were with the defroster ducts, but I think we have them figured out. Wayne was a madman with the pneumatic saws-all. He has things roughed in. He will be doing some fine tuning today while I continue with the interior.

Damn, am I sore today? Being bent up like a pretzel on the steel floor pans has really taken its toll. Also, my hands and arms are bruised and cut from all the contortions required to get the wiring installed under the dash. I really shouldn't complain. Wayne really has the tougher row-to-hoe. All of the filling, sanding, filling, sanding, filling and sanding really takes its toll after a while.

I just need to find a quality interior shop in the Chicago area. There are a number of shops in the area, but I want a shop that is capable of doing invisible dash modifications. And while the shops I know do good leather and upholstery work, they have no experience with the type of mods I am looking for.

It is now time to drag my tired old bones out to the shop. :-)

Bob
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Old 05-27-2005, 08:29 AM   #244
 
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Hi All,

Yesterday we were moving along just fine when we decided to trial fit the seats. I plugged the driver’s seat into the harness and applied power to the battery terminals and thought that would get power to the seat, but nothing happened. I still have to finish a few things as far as system grounds, etc... I am sure that everything will work just fine when I get the last of these wiring items resolved. At least I hope so.

But...

The Cobra seats are great, and I really like them, but I can't use them. I need to lower them 2" front and back and there is not enough "play" in the track areas to allow that. I could alter the cushion (remove foam, etc...) but I do not think removing 2" of foam is a good idea, even if it was possible. If you are wondering why this is an issue, the interior height of the 65 is just about 2” less than that of the 03 Cobra. I was hoping that this would be something we could resolve by modifying the seat tracks, but, as I stated above, there just is not enough room to shave 2” from the tracks.

So, I need new seats. I would like seats similar to the 03 Cobra’s with good, lateral support.

Also, I talked to Ford and their recommendation in regard to the air bag use in this car is....

If we use the air bags, we need to use the factory 3 point restraint. If we go to a 4 or 5 point harness, we should disconnect the air bags. I really wanted to use a 4 point harness tied into a rear roll bar assembly, but if I do that I will have to disconnect the air bags. THIS IS SOMETHING EVERYBODY SHOULD TAKE NOTICE OF. If you have altered the restraint to something other than the factory system, you really should disconnect the air bags. The factory restraints have a certain amount of give to them and this is factored into the air bag system. If you use a 4 or 5 point system, there will be no give and if the air bags deploy, you will be smacked in the fact with a fully deployed air bag. For the air bag system to work properly, you should contact the bag before it is fully deployed.

So, the seats and harnesses have to be addressed as a single issue. If we go to the 4 point restraint, we should get seats designed for use with a 4 point system. The people at SVT suggested using the same setup they used in the GTR concept car.

Any recommendations??? What do you all think???

Also, another wiring item I can't figure out is the use of two grey, two prong plugs in the under dash wiring harness. They are located to the far right and the far left among all the connections right at the kick panels. Any ideas???

Bob
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Old 05-27-2005, 08:40 AM   #245
 
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SN65 I offically hate you..... j/k looks great im really jealous!!!!
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Old 06-01-2005, 07:58 AM   #246
 
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Hi All,

I hope everyone had a good holiday. I took some time off to lazy about the house and also knock a few items off my “honeydew” list. It is good to be back to work. I sent a lot of my free time puzzling out some of the issues we have been facing.

I have resolved all the electrical connections in the 03 harness save two. There is one grey two prong connector near the driver’s side kick panel and one small black connector located over the drivers side rear wheel housing. I guess I am going to have to bite the bullet and pick up the 03 Cobra wiring diagrams.

I have found replacement seats that should fit just right. They are Recaro LXF seats. They should sit exactly 2" shorter than the stock Cobra seats. They are seeing if I can get them with the same charcoal leather and grey suede as the Cobra seats. Now, I just have to figure what I am going to do for seat tracks.

With that said, I am also installing a rear roll bar and 4 point harnesses. This will require the disengagement of the air bags. I know I have been struggling with this for a while, but (as far as safety goes) the 4 point harnesses will do us just fine. Many feel that the 4 point restraint is a step up from the 3 point air bag combo.

Also, we are getting down to the short list. Today, I will be reviewing all the tasks left to accomplish, organizing them and prioritizing them.

Again, it is good to be back.

Bob
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Old 06-01-2005, 03:53 PM   #247
 
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All I can say is WOW ! Your write up on this is just amazing ! Its so nice to see a true craftsman share his experience (highs and lows) with everyone . You have my up most respect in what you have done with this project.

I hope everything comes together for you in time for the Power Tour this weekend. If all goes well I can wait to take a few pics of this sweet ride. If you see a Red 03' Cobra and a White 04' Mach catch up to you in Bloomington to Springfield take it easy on us .

Hope to see ya in Springfield
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Old 06-02-2005, 08:23 AM   #248
 
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Hi All,

We are plugging along, slowly but shirley. Wayne is concentrating on the bodywork and I am concentrating on the dash right now.

Wayne is sanding his little heart out, and the attention he is paying to all the little details is nothing short of amazing. For Example, the bead he has sculpted along the passenger and driver’s side windows are just fantastic. They are faithful reproductions of the bead around the perimeter of the "C" pillar air vents. (Actually, they are more exact and precise than the factory castings, but don't say that to Wayne, it will just go to his head) This detail, while very labor intensive, is light years ahead of the typical "chop off the drip rail and smooth" process used by others in the past. I am very impressed. And while it is not something that will reach out and grab your eye, like 22" spinners or a chrome blower sticking through the hood, it is the subtle detail like this that will make the car stand out from the crowd.

Wayne’s goal is to have the body (sans doors and fenders) in primer by this weekend. Mine is to get the items completed that need to be finished before he can proceed and try my best not to get in his way.. I will post photos as soon as he is done.

I am working on the dash. The path we have decided to walk is going to be a bit tricky, but we expect the results to be worth the effort. We have trimmed the factory dash pad back to a point that will give us a nice transition from the 03 pad to the 65 cowl. We are then going to fab a mettle filler panel that will span the gap from 03 to 65. This panel will then be covered in vinyl that matches the dash. It will even have the openings for the defroster. We are going to take the same approach to the dash side trim panels. When complete, it should look better than our original plan which would have required us to black out the bottom 2" of the windshield.

Even though I do not have photos of the car to post (it looks like a bondo bomb just went off), I can post a photo of the current task list. Also, here are some photos of just a few of the items we will be listing on e-bay over the next week or two. We have a seemingly endless supply of parts to sell. I guess when you think about it, we have half the parts of one car, and half the parts of another to sell.

Anyway... Catch ya'll l8r.

Bob
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Old 06-02-2005, 12:02 PM   #249
 
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Hi All,

I am getting a lot of requests for pricing on the parts I am going to list on e-bay.

Here is the deal. I will accept offers that are in line with the price typically achieved on e-bay (search completed auctions for finished auction results).

If we can't come to terms, I will list the item on e-bay and you can bid on it then. Maybe you will get a deal, maybe not. :-)

Bob
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Old 06-03-2005, 11:42 AM   #250
 
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Hi All,

Things are moving along a bit.

Not to beat a dead horse, but these are the two connectors we are having trouble identifying. Wayne has ordered the shop manuals, but if anyone knows what these are, I would appreciate any help.

Here is a shot of the car on the ground. We have adjusted the coil over shocks a little bit. We still have to tweak them a bit, but we are close for now. When all is said and done we should end up with 4" of ground clearance (plus or minus 1/4").

We have resolved the issues we were having with the cold air induction system. K&N, BBK, etc... were of no help what-so-ever. Anything out of the ordinary, and they have not a clue. I finally came across a company called Western Motorsports www.wmsracing.com and they are going to help us out with one of their high velocity intake systems. They are even going to help by supplying a number of alternate tube configurations so that we can piece together something for this rather unique installation. :-)

Western Motorsport and LDC Chicago, along with Maximum Motorsports, NPD, MagnaFlow and CenterForce Are all on my preferred vendor list.

We have figured out how to reconfigure the intercooler plumbing (the original factory configuration was interfering with the front sway bar. We now have to solve the same issue with the engine coolant lines and we will be able to push toward firing up this beast for the first time.

We should be receiving the revised oil filter relocation kit today. If this works as planned, we should have a pretty slick setup. I will post photos of this setup next week.

Well that’s enough for now.

Catch ya'll l8r.

Bob
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