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Old 06-03-2005, 12:13 PM   #251
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Man, that's really starting to come togethter nicely! Can I drive it when it's done?

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Old 06-04-2005, 09:43 AM   #252
 
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SNIP...



SNIP...
Hi All,

Darren over at Corner Carvers has solved this riddle. This is the rear window defroster feed.

Thank you Darren.

Only the two prong grey drivers side connector to resolve and the electrical will be complete.

Catch ya'll l8r.

Bob
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Old 06-07-2005, 08:00 AM   #253
 
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Hi All,

Yesterday we installed the oil filter relocation housing. Because space was a bit on the tight side, we had to be a little creative in our approach.

As you most likely recall (from previous episodes), we could not use the Cobra oil filter casting with integral oil cooling jacket because of interferance with the relocated steering rack (7" forward). To solve this problem we ditched the stock Cobra casting and replaced it with the typical 4.6 (sans oil cooler) casting. In order for that to work, we had to have the castings radiator connection (see photo) altered from the standard 90 degree configuration to a straight neck.

This was all fine and good until we received the oil filter relocation kit and the item (item #1) that was supposed to bolt up to the oil filter casting was about 1/2" to thick to clear the rag joint on the steering linkage.

AAAUUUGGG!!!!

Not to be deterred, we started evaluating our alternatives, and since we felt running without a filter was not an option, we came up with the following game plan. The item designed to fit to the block (item #1) did not have enough meat on it to allow for modification. As we looked at all the parts we had to work with, we noticed that the remote housing (the one designed to mount the remote 5.0 oil filter, now known as item #2) was 1/2" shorter, narrower, thinner than item #1. To make item #2 function properly was fairly easy. First we had the mating surface machined with a groove to accept the oil filter gasket. Then we machined off the now useless mounting ears. Then we removed the threaded nipple (from item #2) that received the 5.0 oil filter and had that hole bored and threaded so that it would screw on to the engine just as a oil filter would.

Now it sounds like that should solve all our problems, but...

When we threaded item #2 onto the block, we found that, when tight, we needed about another 300 degrees of rotation. To gain this additional 300 degrees, we had to remove about 1/32" of material from the rubber gasket. To do this only required about 2 hours of sanding, fitting, sanding, fitting, sanding, fitting, etc....

In order to sand the gasket, Wayne used item #1 to mount the gasket and slowly sanded the surface over and over again until we removed just the right amount of material.

With all that said, here is the device mounted in the car. We now all we have to do is locate the in line oil cooler and remote filter housing and we are finished. Well, finished with this item anyway. Only another 100 or so to finish this month.

OK, it is now 7:30 AM, Time to make some coffee and get back to work.

Catch ya'll l8r.

Bob
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Old 06-10-2005, 06:59 AM   #254
 
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Hi All,

We are patiently awaiting the delivery of some key components, so today, we reviewed the status of the project and organized our thoughts.

First, we reviewed the intercooler installation and came up with a solid plan of attack. Due to interference with the relocated roll bar, we cannot run the lines, as the factory does, under the frame rail. We plan on running the intercooler lines from the engine, through the opening at the top of the core support on the passenger side and down to the recirculation pump and intercooler. These lines will end up underneath the cold air intake system. We are going to use as many of the factory pre bent tubes as possible. Some look to be almost exactly what we will need. A little modification and we should end up with a pretty slick installation.

Second, we trial fit the lower front valance and discussed how to route air to the intercooler radiator. We decided to locate two 4 inch diameter holes on either side of the license plate mounting area. Wayne feels that the round holes will fit in with the overall design much better than the rectangular trapezoid shapes I had originally worked up. We will connect the two holes together with 4 inch diameter tubing. We will then section off the back half of the tube, and fit it with a rectangular transition that will mate up with the front of the radiator. This is probably hard to picture in your minds eye, but we will be following with photos of the finished installation next week

Third, we reviewed the oil filter, oil cooler routing. We haven’t received the oil cooler yet, but we figure it will mount in front of the air conditioner condenser. The oil filter itself will mount to the inner cowl panel on the driver’s side. At this point I have to say that I don’t really care for the appearance of the anodized fittings and the braded SS hoses that came with the kit. Don’t get me wrong, they are very high quality items and they should work very well, but they don’t really match anything else on the entire car. Maybe if I keep the hose ends and just trade out the hose for the non-braded variety it will be less “flashy”. I guess, if I want to go off the deep end and also drive Wayne totally insane, I could paint them all flat black to match the look of the rest of the fittings.

Next we found a supplier of electric actuators for the 65 door locks / latches. The problem we were having is that the typical actuators used in classic applications come with 5 leads that tie in to a separate dedicated controller. We needed actuators that would function with the 2 lead, 03 Cobra electrical systems. After talking to the staff at NPD, they suggested that I call their supplier Electric-Life directly. After talking to a few of their techs, I finally found the right setup for our project. Also, we found that the “door ajar” lead is at the very end of the door harness. We will have to unravel the entire harness, pull the wires all the way back to the door jamb and rewire them to tie into the old fashioned door plunger switches.

Today is going to be a good day. We should be receiving the cold air induction system, the oil cooler and a bunch of other miscellaneous items.

Catch ya'll l8r.

Bob
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Old 06-10-2005, 03:35 PM   #255
 
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Hi All,

Well we have received the cold air induction system today and have started the fit up. Opening the package was both exciting and anticlimactic at the same time. Because, unlike the kit you would receive, ours comes unpainted and un assembled (nothing welded together).

After examining all the parts we had to work with, we started trial fitting things together. We installed the rubber boot over the throttle body and were thrilled with the configuration. This was a big deal for us. In order to get the proper orientation of the pipes, we ordered the kit normally supplied for the 01 Cobra. With the boot in place we positioned and started rough trimming the pipes. Once we got a feel for the positioning of the pipes, we positioned the fender apron mounting flange and cut a hole in the apron. We have positioned everything in line and are ready to tack everything together. We will then disassemble the whole shebang and weld everything up. After that, we just have to fit the Mass air sensor and the rest of the vacuum lines and sensors.

We have also received the Maximum Motorsports shock tower brace. We will have to modify it to fit, but that has become the norm on this project. Doesn’t anybody manufacture standard products that fit a minor grafting of two cars 40 years apart?

The oil cooler has arrived, so we can now plan for the installation of the oil filter / cooling plumbing. In order to get the lines routed and looking correct, we will have to combine ½” diameter aluminum tube with formed rubber hoses. To get the tubes looking correct I will have to purchase some sharp radius tube bending equipment. Anyone want to loan me the one they got laying around their garage?

Wayne has been busy. He has laid the first coat of primer to the roof / top of the quarters / trunk surround areas. He will then start on the tail light panel and rear valance. He cannot start on the sides until we get the doors and fenders mounted.

We have an aluminum fabrication specialist coming in early next week. Their task, if they choose to accept it, will be to cut, shape, trim, bend and smack, and tweak and hammer the dash trim panels into submission.

I sent an e-mail request to NPD. I need a custom warranty plate for the door. I am going to intermingle the codes (as best I can) as there appears to be no relevant correlation from 65 to 03.

How does “63B-7-26-16B-13-E-5” sound???

I am also going to locate a “VIN” number (on an aluminum) panel with 67 VIN trim in the original 65 location. I will be keeping the original VIN info in my office. I was thinking about mounting the info under the rear package tray, but I think that that would just be asking for trouble.

We received the battery box and are struggling with the location of this monster. While of heavy construction, it is not exactly what I pictured in my minds eye. It is rather on the large side. Maybe I can have it covered in leather just like the rear fiberglass surround panels.

Enough for now, we need to get back to work.

Bob
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Old 06-16-2005, 08:41 AM   #256
 
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Hi All,

I am writing this note late at night. The house is quiet. Both the wife and our dog are fast asleep. Not a sound save the soft, cool breeze through the trees.

I am sorry that I have not been posting as of late, but Hydro-Flo (you know, the wastewater treatment company) has been very demanding of my time. We have had one of our sales staff and our project manager both leave in the past 3 weeks and I am the one who has been taking up the slack.

Is there anyone out there looking for a sales or engineering job???

Sigh….

Anyway…

This past weekend (and this week for that matter) Wayne has been concentrating on getting the tail panel, quarters, doors, etc. in primer, while I worked (Saturday only) on getting the inner fender details complete. We are doing everything we can to get the fenders mounted so that Wayne can start on the front fender flares and also complete the detail work on the sides of the car.

That being the case, I worked on finishing off the inner fender wiring details. I drilled the holes in the cowl panels for the door looms and also finished off a few misc details, but I have not finished the inner fender wiring or any of the other details I was hoping to finish this week. I am just a few details away from getting the fenders mounted. Wayne has been very understanding, but I know it must be wearing on his nerves. We are so close to the finish and yet I am the one holding the project up. I am so depressed. I cannot even find the time to take the occasional progress photo.

We set the Maximum Motorsports strut tower brace in place and were trying to picture how we were going to get it to fit under the hood. We discussed a number of alternatives, but all of them seamed to interfere with one device or another. Wayne said, “To bad we can’t run the brace in front of the engine”. I took the brace flipped it over and rotated it 90 degrees and walla, it fit. We just have to remove and re-weld the mounting brackets for the revised positioning.

After we get the doors and fenders mounted, I will concentrate on getting everything associated with the engine complete. If there were only 48 hours in a day, I might be able to spend some time on the car, but I do not see any free time in the immediate future. I have to find replacement personnel, train them, etc…

On another note, we are listing things for sale on e-bay starting Friday night. We are going to list everything with a starting bid of one dollar and no reserve. I will post a link to the forum for those interested in bidding on some of these items. The demand for some items may be high, but the demand for many others will be very low. If there was only some way for us to create some demand for these miscellaneous items.

Hummm… Let me think….

I know…

I can pull a Shelby.

Some of these low demand items may be of interest to those who just want a small inexpensive souvenir of the project. If that is the case, we will be happy to autograph the item for display in your garage.

It must be getting late. I can’t stop laughing. Damn... I just woke up the dog. You ever get so tiered that you just can’t stop laughing? Anyway, if I really wanted to pull a Shelby, I would have a minimum bid of $500 for everything and then charge an additional $250 for the autograph.

BRAAAHHHAAA!!!!!

I know this is going to sound really stupid in the morning, but you know what. I am going to post it anyway. I really need to get to bed. Tomorrow is going to be a long day.

Bob
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Old 06-17-2005, 03:56 PM   #257
 
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Hi All,

Below is a link to the infamous Cobra seats currently for sale on E-Bay. Click on the "View sellers other items" button to see all the other items for sale.

SNIP... I have to list this later

Good luck to all who bid. I hope you find the items you need at a price you can afford.

Catch ya'll l8r.

Bob
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Old 06-18-2005, 07:08 AM   #258
 
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Hi All,

Oops... I tried linking to the auction before it actually started. I guess they frown on that. Here is a link to all the items I have listed.

http://motors.search.ebay.com/_W0QQs...amQ5fnotQ5fbob

Hope this works.

Again, I hope you find the items you need at a price you can a-Ford. :-)

Catch ya'll l8r.

Bob
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Old 06-20-2005, 03:31 PM   #259
 
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Hi All,

After hours of debate, we have decided to come clean. The entire project has been an elaborate hoax. All of the work we have been showing has been done in PhotoShop. All this time we have been working on a typical 66 "rest-o-mod".

Here is a photo of the real project. A little more work and we will be ready to start assembly.

I know what you are thinking. What about all the people who have seen the car in person. Well... Have you ever heard about group hypnosis???

Again, I am so sorry for my deceitful ways. I am so ashamed. :-(

Bob
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Old 06-21-2005, 01:52 PM   #260
 
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Hi All,

Well that was my attempt at humor. I guess I should stick to the serious stuff. Also, I couldn’t PhotoChop my way out of a paper bag. The green car shown is a 66 coup that my brother is “rest-o-moding” for a local fire fighter. It is one of the cleanest 66 coups I have ever seen. He is having the car built for his sons. His personal stang is a 71 Boss 351. They are some of the nicest people you would ever want to meet and we are proud to build this car for them.

Anyway….

This weekend Wayne spent all his time on the passenger side quarter panel. This panel has been a royal pain in the butt. In fact, every time Wayne has had an issue with the bodywork, it has been with this panel. He finished all the revision to the flare and sealed the entire area with feather fill. Feather fill is a polyester product similar to Bondo, etc. Wayne likes to use it as a sanding base prior to applying the final coats of primer. The advantage of this material is that it will not shrink up over time.

If you look at the photos, you will see that the flare is very close in design to the 03 flare. The lines are sharp. The angle and width of the flare are very close. The only difference of note is the width of the “flat”. Ours is about an inch whereas the 03 is about 2. I am very happy with the results and believe that they fit in with well with the 65 bodylines.

While Wayne worked on the quarter panel, I worked on a number of miscellaneous items. I painted and mounted the front core support / hood latch brace. I cleaned, sanded, primed and painted the brackets and mounts for the intercoolers heat exchanger and a number of other odds and ends.

That’s all for now.

Bob
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Old 06-21-2005, 02:08 PM   #261
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Looking Awesome!!!!!
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Old 06-25-2005, 08:35 AM   #262
 
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Hi All,

All the items up for auction on e-bay closed last night.

The entire 03 interior went for $1,076. It looks like someone got a pretty good deal.

Someone bought the 65 rear bumper for $1.25 and after the auction declined the purchase because the bumper was sand blasted ready for paint or re-chroming. All of that was stated in the text, but I guess they did not read it until after the auction was over.

Other items of interest were....

The 03 doors went for about $65 each.

The used clutch, PP, FW and input shaft went for $90.

The Cobra oil cooler went for $125.

The Cobra front control arms and coil springs went for $165.

The Cobra mirrors went for $130.

The Cobra tail lights went for $115.

All in all I generated about $3,700 for the project. This will allow us to hire a full time helper to get this project moving over the next 3 weeks.

And, we still have a bunch of stuff to auction off.

We should get a LOT accomplished next week. Wish us luck.

Bob
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Old 06-28-2005, 08:06 AM   #263
 
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Hi All,

Let the blocking begin. :-)

After a day of blocking, this is what we have accomplished. Both quarters. Sides and top.

WoHoo!!!

Now on to the roof and trunk.

Here is a photo of the collision center from the outside (for anyone who is a bit curious).

Also, here are some photos of the battery cable run. We are pretty much set except for the final location of the battery box. We just need to find a location that will clear the gas tank and any existing wiring. Sounds like a snap, but I am sure that this will give us a bit of hartburn before it is all over.

Also, when we ran the chassis grounds, we tied a couple of seperate of items together and grounded them with one terminal. I hope this dosen't end up biting me in the butt. A ground is a ground is a ground.

Right???

Bob
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Old 06-30-2005, 07:44 AM   #264
 
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Hi All,

Into the booth we go.

Wayne finished the blocking of the quarters, roof, etc...

Here are some photos of the car in the booth after it was primed.

Now we will mount the doors, fenders, trunk, hood, front end, etc... and go through the same priming and blocking procedure.

Catch ya'll l8r.

Bob
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Old 07-01-2005, 08:00 AM   #265
 
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Hi All,

For the 4th, my wife and I are heading up to the great white north. We have a summer home up near Spooner WI (near the nose).

You all have a great holiday. See you when I get back on Wed.

Bob
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Old 07-07-2005, 07:18 AM   #266
 
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Hi All,

The 4th of July weekend was pretty much a bust, at least as far as the car goes.

While all of you were busy with barbeques, picnics, parties, family, friends and of course fireworks, I was up in Wisconsin opening up the summer cottage. For those who have never done such a thing, it is often rather eventful. You never know quite what to expect. Past experience has taught me to be prepared anything. For example, I have had to deal with frozen plumbing, trees falling on the driveway and the house, malfunctioning yard equipment, shattered toilets, renegade mice, carpenter ants, wild turkeys, deer, bear and bats.

So… While you were all having a wonderful time I was fixing this year’s problem, namely pier crushed by ice. All I had to do was lift the wet end of the pier a scant 5 feet and slide the pier supports back into place. An easy task if you have any type of jack, which of course, I was sorely lacking. To make a long story short, I finally elevated the pier using tactics that the ancient Egyptians would have been proud of.

We are moving along nicely at this point, but nothing worthy of a photo. After all, how many photos can you show of sanded primer? Also, as we get closer to the completion, we have decided to only show detail shots. We are going to save the long overall shots for the big finish later this month.

With that said, I am off to work. Tomorrow, I will post some detail photos of the velocity tube installation.

Catch ya’ll l8r.

Bob
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Old 07-07-2005, 09:50 AM   #267
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you're supposed to take the dock out at the end of the season ya big silly!
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Old 07-07-2005, 02:33 PM   #268
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Looking good Bob - let me know if you still have that Cobra rear bumper, I may need one.

Jeff
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Old 07-07-2005, 06:13 PM   #269
 
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i cant wait to see this beast
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Old 07-11-2005, 03:12 PM   #270
 
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Hi All,

We are getting down to crunch time here and are looking for additional hands.

So...

If you live in the St Charles, IL area. If you are really into mustangs. If you are mechanically inclined (or have body working skills). If you are not afraid of hard work, etc, etc, etc....

Send me an e-mail at [email protected]

Bob
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Old 07-11-2005, 08:38 PM   #271
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all i have to say is....you da man awsome job!!1
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Old 07-12-2005, 07:05 AM   #272
 
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Hi All,

I am having a real tough time deciding on the seats to use (if you remember, the Cobra seats sat about 2" to high).

I have considered Recaro, Sparco, Flow Fit, Corbeau, etc...

There are so many choices out there that I am having trouble making up my mind. Also, I have never planted my butt in any of these seats. This makes the decision very difficult at best.

As far as requirements go, I want seats that look, feel and fit similar to the 03 Cobra seats. I would really like them to be leather with suede inserts, but all leather will suffice. Electric controls are not mandatory, but they would be nice if I can keep the seat 2” shorter than the originals. The seats must be useable with a 4 point harness. And I also need the seats to fold forward (for access to the rear).

The seats need to be a compromise of performance and comfort (If they are not comfortable, I will never complete the power tour next year). They need to accommodate butts of all sizes (you never know who is going to end up driving or riding).

The Sparco Milano, Recaro LXF, Cobra Misano L, Corbeau legacy, etc... all look pretty good, but all I have to go on are the looks.

So... Your input would be greatly appreciated.

Bob
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Old 07-12-2005, 12:44 PM   #273
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I don't think NASA puts as much time and detail in the space shuttle as what you have in this car. You have a mechanical masterpiece in the making.

As for the seats you would probably want something a little higher quality than the Corbeaus. I have the A4s and they are great seats for your garden variety Cobra, but won't be good enough for your project. I don't know about the quality of the 2 models you listed though.

The good news is that you should have no problem finding that 2 inches of room you are looking for. Besides shedding some dead weight, I gained about 2 inches of leg room (I'm 6'1", I needed it). They sit lower, too. With the H&R race springs and these seats, most ATM machines are unusable from the seat (I'm sure I look like a dope climbing out of my door like Bow Duke to retrieve my Jacksons from the money god).
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Old 07-12-2005, 03:56 PM   #274
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C'mon!! Is this thing done yet? Geeze...!!

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Old 07-13-2005, 02:39 PM   #275
 
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Hi All,

What a rush. Lately I don't know if I am coming or going.

Anyway....

Wayne has been busy solving body fitment issues. Here are a couple of shots. The first is of Wayne hard at work. He is contemplating the gaps. If you listen closely you can hear the buzz as he thinks about the best way to even out all these inconsistent gaps. He has had to weld extensions on to some panels while trimming back others.

Shush. Be very quiet. We better move on before we disturb him. :-)

Next is a photo of what the gaps look like before Wayne works his magic. Compare that to the 4th shot showing the repaired gaps on the opposite side of the car.

Last we have a shot of the car starting to go together for final bodywork. We are currently fitting / clearancing the hood (stock 65 with a bulge for the massive blown 4.6)

Wish I could go into more detail, but I really have to get back to work.

Catch ya'll later.

Bob
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