Another Car - Why Not?

Nigel Montgomery
Sydney NSW 2126
Australia



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This site chronicles the process of building a kit Cobra.

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Sunday June 27, 2010

If you haven't heard yet I have taken delivery of my new toy. The car was delivered last Thursday - a couple of months early. Any doubts I have had about the project disappeared when the car was delivered. Hopefully I can turn it into something special!

Here is some text

To wet the new arrival's head we are having a BBQ and drinks on Sunday 27th June, 2010 at 1pm.

(I don't need the engine Lifter Lach, as it is too far back for the arm to reach. The builder advised that I use a chain block.) The engine and gearbox were temporarily fitted for transportation.

We are supplying the meat, so just BYO alcohol.

And here she is

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Finally Started!!

The project has finally got under way with some tidying up of the chassis around the gearbox. The brake line has been reattached to be flush with the frame. The gearbox has now been removed and the car placed on jacks/blocks. The chassis frame has been handy for supporting straps to hold the bellhousing and gearbox in position whilst the engine has been disconnected. My friend Ron Taylor has lent his ninja skills and machined a dummy shaft for me to enable the clutch to be fitted. At this stage I need to get a few more parts to move forward. The clutch release fork and bearing was not included with the gearbox so I have to hunt them down. This is part of the fun....completing a jigsaw puzzle without the picture!

I have engaged an Engineer to supervise the build. John Wilson comes from Queanbeyan and has done his initial inspection. He has advised me of many products I can use to comply with the strict RTA rules. I am confident he will help me get the car through to registration. My first and most important task is to get an official engine number. This was to be done by applying at a rego place that does "Blueies". An RTA inspector was to come out to see the car/engine and give me the number. I was to then enscribe the number onto the block near the lower right front side of the engine.Lucky I am a draftsman!!However further information from the RTA has changed these plans. The build will be examined in one inspection at the end of the build. He has also suggested I check out Honda CRX seats. These are narrow yet have good shape and should fit into the small space. He has also suggested I get H4 headlight units that have a twin globe set-up. All exhaust components have to have a small plate welded on with the nam "NM007". This is to ensure all parts have been assessed and are for this build.

Monday 20th September I tracked down some great Honda CRX seats. One of the nicest things you experience when you build a car are the people you meet along the way. Nick at Baulkam Hills was a pleasure to deal with and hopefully he will swing by to check out the car when it is finished. I will get black leather covers made up for them as it will go better with the interior. Also CRX logos would look a bit dodgy!

28th September, 2010 - I have built a beam in the garage to lift out the engine.

New Seats

13th October, 2010 - Back from holidays at Kangaroo Island and have made up an engine support trolley.

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26th October, 2010 - Ordered the complete fuel system i.e. Fuel Pump, Charcoal cannister, sending unit and hoses. Also have included the massive fuel filler cap, which is a feature of the car. As the kit car builder is now by himself I ordered the radiator as well. I thought I better get everything now.

Friday 7th October - Finally got some time after spending the last 2 months working in my new business. With the help of my son-in-law Mike and good neighbour Maurice the engine and gearbox were removed. The chain block was a good choice over the engine lifter as the lifting postion was perfect. Next thing to do is to get the pilot bearing (spigot bearing) for the 6 speed T56 fitted. This is different to the standard bearing as it has a 15mm input shaft diameter. Hopefully I can get the bearing soon and install the clutch and bleed line.

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February, 2011 -The last 3 months ordering parts and buying bits and pieces. My business has really stalled things for a while, but hopefully that will change! Bent the fuel lines to fit under the car adjacent to the driveshaft. The pathway is very tight so I have used some fence wire to plan the shape of the line then replicated this on the floor of the garage. The fuel lines are in tandem as with injection systems there is a return line form the regulator for unused fuel not required by the fuel rails. Bought a VL Charcoal Cannister on ebay for $10 that was covered in bird crap. This is the first dodgey item I have bought. Decided that it will be the last so I am trying to hunt down a new VE unit. These items don't usually fail but when they do can cause all sorts of problems.

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March, 2011 - Purchased 0.9mm thick stainless steel sheets from Austral Wright at Wetherill Park. Tried cutting it with a nibbler but found that it leaves a jagged edge that looks too rough. Ended up using the world's biggest tin snips inherited from my dad. The cut is pretty good and can be cleaned up with a file and angle grinder. I think I have cut my hands about 50 times but only once that probably needed stitches. The stainless steel is very rigid and is a good material, but extremely hard to drill. I have gome through heaps of drill bits fixing the lining to the steel chassis. The self tapping hex heads will be replaced by a flat Phillips head screw to make upholstering easier in the cabin area. Behind the stainless steel I am using Neoprene lining to reduce the heat and vibration. Buying a rubber that will cope with significant heat is difficult. Viton is about $600 a metre so opted for the cheaper option. The heat hopefully won't exceed 100 deg C. The dashboard template has been fitted and fixings made. I am adopting the 427 layout that seems to be the neatest arrangement. I have enquired about the original Smiths Cobra gauge set and been assured that the bezels can be chromed. Everything else I have read on the subject says that you cannot have any reflective surfaces so I think I will have to retro fit the black bezels.

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April, 2011 - marked out headlight and indicator cut lines on fibreglass. Used a jigsaw to cut headlght and holecutters to fit indicators. This has really given the car a lift and I am inspired to pick things up and get on with it! The tailshaft and extractors have arrived. The extractors look awesome after having a chrome ceramic coating at "Competition Coatings" at Guilford.

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May,2011 - Installed windscreen wipers. Bought a set specifically designed for Cobra kit cars from a firm "CAE Performance Products Pty Ltd". Cutting elliptical holes exactly at right angles to the windscreen is difficult, as the centres have to be exactly right for the cable driven wheel boxes. The tubes are known as "bundy tubes" that protect the cable drive. I had to shorten one by 5mm and the motor tube by 50mm to allow the unit to fit correctly and not hit the chassis/body. The company were great. They did the alteration and returned the part with 24 hours! The dashboard has evolved from a piece of plywood into metal. I have made an orange version the match the car but , if it works out, will do a turned metal version. I had to buy a drill press to fit "cratex" sticks to do the rounded "turn" finish.

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A good friend and outlaw, Hans has given me some ninja advice on controlling the surface rust that is affecting the few parts that are non-alloy or fiberglass. It is phosphoric acid mixed with water. The recommended dose is 5% acid to water, but I will increase this as more rust still needs converting to a galvanised like finish. It is a really good way of halting what could be a messy issue!

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The wonderful paint job has been done by "Specialty Paint Projects" at Labrador in Queensland. Des does excellent work, and makes sure you let him know exactly what you want. I like the old flat orange as opposed to the pearl finish that you see in the XR3 and XR6 Fords.
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Catching up

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