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Old 02-10-2005, 07:47 AM   #126
 
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Hi All,

Well... I have been fitting the upper aprons to the engine bay and I ran into a bit of trouble. :-(

When fitting the fenders to the upper aprons and the aprons to the engine bay I encountered a slight, for lack of a better term, misalignment issue. While the passenger side fender lined up with the shock tower exactly as planned, the drivers side road up against (hit, butted up, overlapped, encountered, encroached, etc...) it. :-( The shock tower must have pulled a bit when I welded the rectangular tube upper tower braces in place.

We could have solved the problem by grinding off about 3/16" off the drivers side fenders lower mounting flange / lip, but my brother said we were not taking any shortcuts at this point. He said "We can solve this with a little pull on the frame rack".

Easier said than done.

He positioned the rack towers (one on either side of the car) and attached one chain to the bottom of the tower at the frame rail, and another chain at the top of the shock tower. Well, when he started applying pressure, nothing moved. He took it up to 1800 lbs and the entire front of the car was lifted off the blocks (usually the car is anchored to the frame rack, but this was just a "little" pull and no one thought it was necessary). Even at 2200 lbs, nothing moved except for the driver’s side rear. It was also off the support block. We all looked at each other and said "Maybe the car is a bit stiffer than we thought". We had the entire car supported by the chains and the passenger side support block.

We had to chain the driver’s side rear down as we took the pressure up to 2700 lbs at which point we got the top of the tower to move. Wayne set the position by giving it a couple of heavy smacks with a sledge hammer and a block of wood to distribute the impact.

I hope a "stiff" chassis is a desirable thing, because this sucker aint gonna have much "give" to it.

Anyway, we achieved our goal. We moved the top of the shock tower 3/16" and now the drivers side fender and engine bay aprons are right on.

Catch you all later

SN65
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Old 02-11-2005, 01:55 PM   #127
 
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Hi All,

Here is the mock up of the front end. I have the whole structure held together with tape and paint stir sticks. I needed to get a rough over all picture before I start bolting, screwing and welding together all the remaining panels.

This afternoon I will be bolting, screwing and welding this assembly together in an attempt to have all the fabrication done for a Wednesday meeting with the media blaster.

Also, note the preliminary placement of the dome for the hood. Our preliminary calc's tell us that we will need a max of 3" to clear the highest areas of the engine. We will know better when we have the aprons, etc. welded in place.

Catch you all later

SN65
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Old 02-16-2005, 06:39 AM   #128
 
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Hi All,

Panel after bracket after panel after bracket after panel...

GEEEZZZZZ!!!!

Will it ever end???

We are currently fitting and welding all the remaining panels to the chassis. Here are some photos of some of the rough cut panels clamped into place for prelim fit & trim work.

I know I have said this before, but we should be ready to go off to the sandblaster by the beginning of next week.

Catch you all later

SN65
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Old 02-16-2005, 07:53 AM   #129
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Do you know a guy named Kelly Winston? I'm just trying to gauge just how small my world is.
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Old 02-16-2005, 12:13 PM   #130
 
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Quote:
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Do you know a guy named Kelly Winston? I'm just trying to gauge just how small my world is.
Hi SG,

Sorry no.

Maybe you and Kelly can stop by one day. That way I can say I know you both.

Catch you later

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Old 02-17-2005, 06:46 AM   #131
 
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Hi All,

We are having a minor controversy here this morning. :-(

My brother is not very happy about my wanting to take this car on the power tour. His concern is that the paint (which he will be spending about 4 weeks to apply) will get all chipped up on a cross country jaunt. This is the first scheduled showing of the car and he feels that chipping it up would be a very bad idea.

I can see his point, but I really wanted to go on the tour.

In any event, I am wishing to show the car at some the major national events after it is finished in May. Do any of you have any recommendations as to the best events to attend??? Your help would be greatly appreciated.

Thanks in advance for your help.

SN65
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Old 02-17-2005, 11:19 AM   #132
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Quote:
Originally Posted by SN65
Hi All,

We are having a minor controversy here this morning. :-(

My brother is not very happy about my wanting to take this car on the power tour. His concern is that the paint (which he will be spending about 4 weeks to apply) will get all chipped up on a cross country jaunt. This is the first scheduled showing of the car and he feels that chipping it up would be a very bad idea.

I can see his point, but I really wanted to go on the tour.

In any event, I am wishing to show the car at some the major national events after it is finished in May. Do any of you have any recommendations as to the best events to attend??? Your help would be greatly appreciated.

Thanks in advance for your help.

SN65
Come see this WIP at
Julian's Collision Center
St Charles, IL
630-762-0387
How about the FFW in St. Louis May 13, 14, 15?
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Old 02-21-2005, 08:18 AM   #133
 
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Hi All,

Here is a list of shows that we are planning on attending over the next year. Please review the list and let me know if there are any obvious omitions.

1) The Rod Rod Power Tour (June 4th, 5th, 6th, ect...). We have desided to do the tour, but we are going to have to determine just how far we are going to go based on our schedule at the time. We will at least do the Wisconson, Illinois, Indiana legs. If we can work it into our schedule, we will complete the tour to the end.

2) GoodGuys, Ohio (July 8th, 9th 10th). This show is a must for us. There are going to be many fine cars brought by many of the most notable builders in the country. I am hopeing for consideration in the Goodguys 2005 Street Rod & Street Machine of the Year competition. I guess if you have to dream, you might as well dream big.

3) GoodGuys, Wisconson (Aug 12th, 13th, 14th). Local event....

4) MCA Grand Nationals, Youngstown, Ohio (Sept 2nd, 3rd, 4th). Gotta go.

5) SEMA, Las Vegas (Nov 1st, 2nd, 3rd, 4th). Gotta Go.

6) World of Wheels, Chicago (Jan). Local event...

7) World of Wheels, Indianapolis (Feb). Local event...

8) Autorama, Detroit (Mar).

9) World of Wheels, Minneapolis (April). Local event...

10) World Ford Challange, St Louis (May).

Thanks in advance for your input.

SN65
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Old 02-23-2005, 09:40 AM   #134
 
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Hi All,

Well here is how the car sits right now.

Note that we are using the 03 hood hinges. We like these items because of the integral locking tab that prevents the hood from sheering off the bolts in the event of a collision.

I have all the brackets, plates, etc... ready for installation. I have everything preliminarily fit up, but there is still about two days of final adjustments and welding to go. I would jump right in on this, but I am afraid it is beyond my rudimentary capabilities, at least if I want things to line up just so. Also, my brother and the other bodyman capable of doing the quality work that this project requires have been buried with collision work lately.

I have found out something interesting in regard to the ways both of these cars were fabricated. The tolerances are COMPLETELY different. While it is relatively easy to fine tune the 03 chassis to within 2mm, the 65 body is all over the place. Some items are off as much as plus or minus 1/4" from side to side. I thought that maybe it was an issue with the 65 donor car we were using, but that is not the case. I measure my original 65 fastback and find that (even tough the car looks straight as an arrow) it is off as much as the donor we used for this project. This is nuts. I can see why it takes so much effort to get the fit on these cars anywhere close to right.

Anyway...

If things go according to plan, we should finish up all the fab by this weekend. If we don't it won't be because I was holding up the project on my end.

Catch you later.

SN65
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Old 02-23-2005, 01:59 PM   #135
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Looks bitchen, maybe you should go talk to Ford and train them on how to build a car right.
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Old 02-24-2005, 07:25 AM   #136
 
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Quote:
Originally Posted by 10th03cobra
Looks bitchen, maybe you should go talk to Ford and train them on how to build a car right.
Hi 10th,

As if they would listen to the likes of me.

Actually, I think there is a great deal I could learn from them. I think they could shed some light on a lot of aspects in regard to auto production. Also, I am sure that a lot of decisions made in regard to producing these cars has a bit more to do with ecconomic considerations than they do with the cars overall performance.

Catch you later.

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Old 02-24-2005, 02:38 PM   #137
 
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Hi All,

Today, since I have gone as far as I can on the front aprons, I started roughing in the rear fender flares. My goal is to locate the top of the wheel openings at 26". That should place the opening along the same plane as the major body line (the top line of the side scallop) along the side of the car.

What a pain in the butt. I thought that you just located the flare on the side of the car and glued it in place and you were done.

Well...

if you want a solid finished product, you have to flare the quarter panel behind the FRP flare. Look at the photos and you will see what I mean. Again, this is as far as I can take it. A real bodyman has to do the finish hammer and dolly work and then finish the project off by welding all the tabs together.

Catch you later.

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Old 02-25-2005, 08:00 AM   #138
 
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Hi All,

Anyone out there know where I can find the driver and passenger side SS channels that retain the window gaskets. These do not appear to be available through any aftermarket supplier.

HELP!!!

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Old 02-28-2005, 09:05 AM   #139
 
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Hi All,

This weekend was not as productive as I could have wished. We got a lot done, but unforeseen issues, slowed the progress to a crawl.

The most notable of these issues, was caused by me due to a basic design error. It was a simple geometry, of all things, and, after it revealed itself, I felt so stupid. Why is it that the simplest issues always are the ones that cause the most headaches?

Anyway...

I was making every effort to use the 03 Cobra hood hinges. I was determined to use these because they feature an integral safety interlock that is supposed to keep the hood from breaking free in the event of a head on collision. Well, after locating and welding the hinges to the hood and positioning the hood on the car, I got a nasty little surprise. The hood would not open. Instead of pivoting up away from the cowl, as I had predicted, it pivoted into the cowl. In order for this hinge to work, I would have to relocate the hinge backward into the cowl area about 1 1/2". If I did this, I would have to slot the top of the cowl in order for the hood to open.

AAUUUUGGHHH!!!

I needed to have the hood / hinge installed before any of the final fit up of the front aprons. So, not having the hood ready put the breaks on the whole front end. I was so depressed.

We have revised the design to incorporate the hinge used on the Ford Explorer. It should work well, but the redesign and installation will have added another week to the project. I will keep you posted as to this week’s progress.

I have posted some photos of the final fit up of the rear wheel flares and the panels we fabricated to seal off the quarter panels, rear tail light panel etc... to the floor and structure of the 03 chassis. Note: The welds look a bit uglier than they really are. After they are media blasted, sanded and caulked, they should fade seamlessly into the structure of the 03 chassis.

Fitting up the flares was quite an ordeal in and of itself. The flares are not exactly the same. The overall shape, contour and wheel opening are a bit different from one side to the other. Getting them to line up the same on both sides was difficult, to say the least. I had to position one side, measure it, position the other side, measure it, make adjustments to the first side, measure it, make adjustments to the second side, measure it and then repeat the process over and over until I finally got them to match dimensionally on both sides of the car. All in all, I am very happy with the final results.

Catch you all later. I have a lot of work to get started on.

SN65
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Old 03-01-2005, 08:37 AM   #140
 
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Hi All,

We have ordered the new hinges and also, the replacement oil filter casting we need to clear the steering linkage.

Once the hinges are mounted / installed, we will be able to finalize the upper aprons and move on to media blasting, priming, painting, assembly, tuning, driving, cruising, racing, showing, fun.

Catch you later.

SN65
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Old 03-03-2005, 07:01 AM   #141
 
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Hi All,

I spent yesterday struggling with the hood hinge issue. The new hinges we ordered would have solved our problems if they fit, but they were so large that I would have had to cut down into the lower cowl (into the passenger compartment) to get them to fit. Well, that was not going to happen, so I drew up some ideas on how we could modify the 03 cobra hinges and ran them past Wayne. After resolving a few issues with the design, I asked Wayne if I could do all the fab work. He said "There are plenty of other things I need to do, so go for it".

Here are the photos. I had to section the hinge, add 1 1/2" of 10 gage and shape the section into a gooseneck to clear the cowl when the hood opens. I think they came out great.

Today, I can fab the brackets for mounting the hood and re-align the front end so that we can complete fabrication on the chassis this weekend.

WoHoo!!!

Catch you all later.

SN65
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Old 03-03-2005, 10:02 AM   #142
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Looking Good!!!

Let us know when you want to have Get Together and we can drop by to check it out.

Keep up the awesome work.
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Old 03-03-2005, 11:59 AM   #143
 
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Quote:
Originally Posted by 10th03cobra
Looking Good!!!

Let us know when you want to have Get Together and we can drop by to check it out.

Keep up the awesome work.
Hi Jeff,

How about 10:00 AM the last Saturday in March. Things will be far enough along at that point and there should actually be something fun to look at.

Catch you all later.

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Old 03-04-2005, 11:06 AM   #144
 
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Hi All,

Today, I have fit the hood hinges to the car preparing for the final fit up of the front clip this weekend. I will be tweaking things this afternoon. Move this a bit, shift that here, etc...

Also, not to get ahead of ourselves, we have mocked up a simple graphic on the passenger side. It is a play on the Boss 302 stripe packages of the late 60's. We were thinking of different designations for the car, you know, things like Boss 4.6, 4.6 Cammer, etc. But I like the simple SN65 designation for this car. I think it is kind of fitting.

The graphics would be painted black along with the center section of the hood.

Anyway... Enough foolishness for now. Time to get back to work.

Catch you all later.

SN65
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Old 03-04-2005, 11:33 AM   #145
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Can't wait to see her, but I believe the last Saturday in March is the dyno day , isn't it?
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Old 03-04-2005, 01:43 PM   #146
 
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Quote:
Originally Posted by CobraSusie
Can't wait to see her, but I believe the last Saturday in March is the dyno day , isn't it?
Is dyno day in the St Charles area??? If so, maybe people can come back and forth between the facilities??? If not, we can always pick another Saturday for our GTG.

Catch you all later.

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Old 03-04-2005, 01:52 PM   #147
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Quote:
Originally Posted by SN65
Is dyno day in the St Charles area??? If so, maybe people can come back and forth between the facilities??? If not, we can always pick another Saturday for our GTG.

Catch you all later.

SN65
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This time the dyno day is a Sutton High Performance in Matteson.
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Old 03-05-2005, 06:11 AM   #148
 
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This time the dyno day is a Sutton High Performance in Matteson.
Hi W,

How about if we do the GTG a week later on the first Sat in April. Are there any conflicts there???

Catch you all later.

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Old 03-08-2005, 09:22 AM   #149
 
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Hi All,

We came close, but did not completely finish the front aprons this past weekend. We were having trouble with the front end dimensions and gaps. We finally got them as close as physically possible (nice consistent gaps, dim's within 1/4"). But to achieve that we had to assemble and disassemble the front end about 7 times. Each time we would resolve one issue and have another rear its ugly head.

We still have to position and weld the cowl in place, but that is something that we can accomplish in an afternoon.

Also, we contacted the media blaster and he cannot fit us into the schedule until early next week. That being the case, we will continue with finer and finer detail work. For example, we are working on the brackets for mounting the trunk latch. You will notice that we have reversed the typical trunk config and mounted the latch on the car and the striker will mount on the lid.

We will continue to work on brackets, and fitting up different pieces until the blaster is ready for us.

Time to get back to work.

SN65
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Old 03-08-2005, 10:26 AM   #150
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Quote:
Originally Posted by SN65
Hi W,

How about if we do the GTG a week later on the first Sat in April. Are there any conflicts there???

Catch you all later.

SN65
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I would start a POLL
in the get together section, this date would be fine with me
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