Fuel Tank Installation

My son Josey and his friend Thad helped me install the gas tank. It was a good opportunity for young helpers.

Thad helps carry the tank to the back of the car.

Thad will help hold the tank up while Josey installs the bolts.

Josey figures out this thing will go together before trying it for real.

Two buddies help each other out.

Then on to the front suspension and steering rack...

Installing the Rear Differential

The first parts we installed were rear suspension and drive components.

Before installing the differential we took it apart and sandblasted it. Then we waited for a warm day to spray paint it glossy black with the best Rustoleum money can buy.

Then we replaced the stock 2.73 gears with Ford Motorsport 3.27 gears. This will help us accellerate faster but will give us a higher cruising RPM. The penalty for quicker accelleration will be increased fuel consumption.

We installed new brake shoes and cylinders while they were apart. Later we will put new drums on.

It took 2-3 hours to install the differential along with the suspension gear. Those are Koni coil-over shocks. This suspension set-up is called a 3 Link.

That shiny bar at the bottom fixes the differential from being able to move sie-to-side while cornering. The bar is adjustable to center the rear wheels behind the front wheels. It's called a Pan Hard bar; I don't know why.

"What will your Cobra look like?"

Unlike production cars (Ford, Honda, BMW), kit cars all look different; no two are alike. Each builder creates their own interpretation of what a sports car should be. Some builders prefer a classic look (close to the originals), while other people like a modern feel with up-to-date paint colors and big 17" wheels.

This is an original 1965 427 Cobra. Notice the roll bar only protects the driver - also, it is kind of small tube, spindly. The seats are low-back, they don't go above the body of the car. This provides no protection to the occupants neck or head. The color on this car is Guardsman Blue, right out of the Ford catalog for 1965. It is not considered a "modern" color choice.

This is a kit car. Notice it has two roll bars. The roll bars have a bigger diameter to better protect the occupants. Also, the seats are high-backs; they offer protection to the neck and head in the event of a rear end collision. These things were not available in 1965 making the car look a bit more modern. The wheels on this car look similar to the originals (both use a 15" diameter.) The body paint choice is Guardsman Blue, like many of the originals, indicating the owner still likes the look of the original cars but with modern safety features.

This is also a kit car. The red is a modern (or up-to-date) shade and the shiny reflections indicate a clear coat that was not available in the 1960s. The dual roll bars also give it away as a kit car. What I wanted to point out on this car, though, is the modern wheels. They are a big 17" wheels, unavailable in the sixtys. The tires for these 17 inch wheels are able to handle much better than the 15 inch tires making the car feel more like a modern sports car. The 17, 18, and 19 inch wheels may handle better and look cool, but for me, "it just ain't right."

Here is an example of the dash layout on an original 427 Cobra. The guages are British made Smiths. Typical for 1965 are the black face with little white numbers and little white needle. These guages were functional but difficult to read while driving. They were poorly lit making them almost useless at night. Notice the walnut steering wheel and shifter knob; classy touches for an expensive sports car.

For contrast, the owner of this kit used creativity to assemble a cockpit better suited to his own taste. The digital, white face guages are usually easier to read, especially at night. And that steering wheel may not look classy but it is much more comfortable; the wheel is thicker and soft, making it easier to grip. You might notice the high-back seats as well.

"What will your Cobra look like?" Well, the short answer is, "I don't know yet." I tend to like the classic 1965 look. I believe mine will be Guardsman Blue with no stripes. Low back seats and a single, driver only, roll bar. Look for 15 inch wheels, similar to the originals. (The original wheels are super expensive requiring many modifications to the kit to make them work.) In short, I haven't even decided where I'm going to locate the battery yet so I can't really say what the finished car will look like. You'll just have to keep an eye on this blog to find out!

Today I'm sandblasting the rear differential getting ready to paint it and put it back together with different gears. We should have the suspension hung on the car in about one month. That is the first major assembly step.

Donor Tear Down

We started out with a 1989 Mustang LX with the 5.0 litre engine and 5 speed transmission. The body and interior were rough, the engine had a miss, the radiator leaked and 2nd gear didn't even work - so, we were able to buy it for less than $1000. Over the next two years we rebuilt the engine and transmission while also saving up for the cobra kit.

I'm lucky to have a friendly neighbor with a Kubota! Kubota mows the back yard, it moves dirt, it pulls engines. Is there anything it can't do? So far we've used that tractor to pull and install the engine twice. After rebuilding the engine I put it back in the Mustang to test it. Now the engine is sitting on a make-shift engine stand waiting to be installed in the Cobra. (Pictures of the finished engine to come later.)

Stripping the interior was necessary to access the wiring harness which will be used in the Cobra. This was a fun step. Its not very often I get to pull so many screws and bolts without paying attention to how this thing goes back together. This car will never go back together! It is being transformed into a different car.

The carcass is now being used to store parts. Some of that stuff, like the gas tank will be used on the Cobra. Other parts like the leaky radiator will go away with the carsass one day.

"How do you get rid of that thing?", you ask. Well, I'm not sure yet. As cheap as possible, I'm sure.