Welcome to my Cobra Replica build blog.
Please contact me if you would like to know more detail as i progress."CR3514@live.com.au"

Sunday, November 15, 2015

Inlet Tray - Part 2.

Some more progress on the inlet tray.
After completing the mold, I took it to Fiberglass Concepts in Pakenham.
Mario Licciardi the owner finished the mold surface, before laying up two parts with a combination of weave and chop.

The intention is to put away one of the parts to use as a plug if I needed later, or as a backup if i stuffed up my first attempt at machining up to fit the quads.

This is the mold as I finished it before Mario coated with Gel-coat and prepared for laying up some parts.

This is the mold after a couple of parts have been done.
A bit worse for wear, a chunk of plaster I used for the radius-ed edges came away in the bottom RH corner.

Repairable with a bit of filling and sanding.
However, if I need to make another, I would use the second part as a plug for a new mold.

The part out of the mold with flange still on the side.

Next job was to make some mounting rings to fit to the tray which would finish off the edges and locate the air cleaners.

150 x 50 mm billet of 2011 Aluminium

Lots of chips later, 2 inlet tray mounting rings.

Removed the flange and cut out the 2 quad holes.
In this pic, you can also see I've surface a flat area around the holes for the Air Cleaners to sit level and flush.

The tray thickness is fairly consistent at about 4 mm, but has high spots in it where the chop was used.
Hence the need to surface the Air-Cleaner seats.

Rings inserted into the tray

A bit of a buffing will polish out the Gel-coat scratches.

Finished up the inside with Stone Guard paint, then coated in Satin Black paint

I'm going to use the Motorspray Stone Guard paint on the under-body as well.
I bought the optional nozzle attachment for spraying which works excellent.
Several very light coats allowing to dry a few minutes between each coat builds up a very thick rubbery feeling surface which can be over-painted in what ever paint you want.

All that's left is to locate a hole in the tray and Air-Cleaner for IAT (Inlet Air Temp) sender.

Friday, November 13, 2015

Quick Jacks & Mounts

Made up a small jig that bolts to the quick jack chassis mounts which I can set the height to get leveled to the body and make sure the holes are 2.25" apart to match the Quick Jacks I purchased from Finishline Accessories.

The jig has a plate with 2 holes 2.25" apart.
A bolt fits through one of the mount holes in the chassis bracket.

I drilled a 1/4" (6.35 mm) hole through another bolt which then goes through the other chassis bracket hole and onto that I screwed a bit of aluminum solid with a 1/4" hole all the way through it and drilled and tapped one end to suit the bolt.

I used 1/4" holes because that is the pilot drill size on my hole saw kit.

I then bought a long 1/4" drill bit and drilled through the tube using it as a guide and through the body.

While the jig is still in place, I then used the hole saw  to cut the quick jack hole through the body from the outside using the tube centre hole as the guide.

Using the hole saw on slow speed created a very nice un-chipped hole.

After drilling the hole, swap the jig around for the next hole.
Unbolt the tube, put through a bolt and nut to lock the jig in place, then undo the original mounting bolt and replace it with the tube and bolt assembly for the second hole.

Same deal with the front of the car.

Slow and steady as the body is on a sharp angle at the point.

The hole saw is controlled by the pilot drill being inside the guide tube behind the body.

The quick jack tubes are made from 3/4" steel solid which I then drilled a 10mm hole through.

Through this goes a 10mm stainless threaded rod cut to suit.

Drilling the quick jack tubes with a long 10mm drill bit.

So... whats it all look like.

I also purchased Body Grommets from Finishline.
I will definitely fit them to the rear as the mount holes go through to the boot, but I'm undecided on the front, I like the look with out the grommets.

The quick jacks kit comes with 2 large and 2 small lift brackets. (the black bits)

Lots of conjecture about which is which for front and rear, but assuming the lifting dolly has a fixed length to it, I've mounted the large on the back so that the lift radius points are similar heights off the ground to the front.

Vent and Side Pipe Holes

Cut the side pipe holes in to each side.
Drew up the side pipes in Sketchup then created a template to clear the pipes.

Printed out the shape of the template to scale on some paper,

Taped onto the body, leveled to the chassis and penciled around the shape

Cut the holes out with an air powered mini saw.
Very easy to control for a neat cut and minimal dust.

Finished off the holes with a file sandpaper taped to a bit of rod in the hand drill.

Also held the vents in place and found the vent holes not very well formed, a bit of sanding and aligning to get the edges parallel.

On the hoist.


Installed the Headlights, Front Indicators, Rear Indicators, Rear Brake Lights and a High Mount Stop Lamp.

Rear Tail Lights

Front Head Light and Indicator

Centre High Mount Stop Lamp
This lamp is from a 2012 Mazda MX5 roadster.
There is a few different versions of this lamp.
The 2 visual differences are Clear Lens versus Red Lens, and the not so visual differences are the lamp bases are different with retractable roof versions having a bolt on lamp and the non retractable version has plastic retaining clips.

Mine is the bolt in type so i could mount on to the 6mm thick fiberglass body.

Helper springs, Keeper springs,

Here's some follow up pics with the Helper Springs after installation.
The kit came with 2 springs and 2 saddles which sit between the Helper and the Main springs and keeps them aligned.

The springs are 2" tall uncompressed and compress to about 12mm solid as the suspension takes up.
They are made from flat material,

Pic of RH rear assembly

Close up of installed Helper Spring.

In this pic you can see the red anodized saddle that locates between the 2 springs.
The original spring top hat seat is used on top of the Helper Spring