Excalibur Owners: Please Reply!

[SCOTTSCOBRA]

jay it seem s that there are no more for sale,,,,,,? ?

[ohekk]

#104, 105 & 106 were sold to: Car Choice, Dallas TX

then 107 went to Germany.

#145 was the one that was stretched 8 1/2" for an Ambassador in Africa.

The machine shop Mgr at Excalibur recalls it was Uganda.

He said he modified Corvette seats for it also.

Budman..I can't say for sure that your CD changer was installed at the factory but I would guess... yes!

Congratulations on your purchase!

Jay, #104 is 95 Porsche Iris blue

[Budman1955]

Can anyone tell me what the indicator light that is clear and closest to the steering column means when it is lit. Is it a service engine soon? I'm also wondering if the factory Excalibur side pipes have any baffles?

[BLACKJACK]

BUDMAN,

THE FACTORY EXCALIBUR SIDEPIPES ARE NOTHING BUT BAFFLES.

FIRST: THE HEADERS FLOW INTO THE SIDE PIPE COLLECTORS TWO OF WHICH ARE "BLOCKED OFF"

SECOND: THE MUFFLERS ARE "DOUBLE REVERSE FLOW". EXHAUST GAS ENTERS THE MUFFLER, IS DIRECTED TO THE BACK OF THE MUFFLER WHERE IT IS BAFFLED AND REDIRECTED TO THE FRONT OF THE MUFFLER WHERE IT IS BAFFLED AGAIN AND REDIRECTED TO THE REAR WHERE IT IS DISCHARGED OUT THE PIPE. THE ACTUAL "TUBE" DIAMETER IS JUST LESS THEN 1.25 INCHES. NET RESULT - - A GEO METRO HAS A BETTER FLOWING EXHAUST SYSTEM.

LUCIEN DENOFRIO OF "ARIZONA EXHAUSTS" USED TO MAKE THE GREATEST REPLACEMENT MUFFLERS HOWEVER HE HAS QUIT THE BUSINESS. LUCIEN USED TO MAKE THE CUSTOM MUFFLERS FOR J.C. WHITNEY. MY GUESS IS THAT J.C.W. HAS FOUND A NEW SUPPLIER AND I WOULD RECOMMEND TRYING THEM.

WHILE YOU'RE AT IT - - - GET RID OF THE "FOUR" CATALYTIC CONVERTERS UNDER THE CAR.

REPLACING THE MUFFLERS AND GETTING RID OF THE "CATS" WAS THE MOST EFFECTIVE PERFORMANCE TRICK I DID ON MY EXCALIBUR. IT ALSO SOUNDS LIKE A COBRA NOW - - ONLY SMOOTHER.

INCIDENTLY - - THE CLASSIC ROADSTERS MUFFLERS WERE/ARE THE SAME "WALT DISNEY ENTERPRISES" DESIGN.

D.V., DON SCOTT OR JAY NORDSTROM WILL PROBABLY HAVE SOURCES FOR REPLACEMENTS AS WELL.

Y'ALL HAVE A REALLY GREAT DAY,

BLACKJACK

[B. SMITH]

GOOD DESCRIPTION OF THE EXCAL EXHAUST SYSTEM.
I THINK EXCALIBER "ERNIE" IS INSTALLING A REPLACEMENT SYSTEM FROM "CLASSIC ROADSTER". HOPEFULLY WE WILL ALL HAVE A SOLUTION FROM THEM.
MY INDICATOR LIGHT COMES ON ABOUT 25% OF THE TIME. IT SEEMS TO HAVE NO EFFECT ON MY SUPERCHARGED CAR #121.

B. SMITH

[Budman1955]

Originally posted by BLACKJACK


I'M NOT CERTAIN WHERE I READ THIS BUT SOMEONE STATED THAT THE VDO TEMP. GAUGE READS ABOUT 15 TO 20 DEGREES HIGH.

MY TEMP - ON A HOT DAY - WOULD GET UP TO 215 TO 220. WHEN WE CHECKED IT - WHILE READING 215 THE ACTUAL TEMP WAS 195.

I'VE SINCE INSTALLED A HYPERTECH PERFORMANCE CHIP AND THE ACCOMPANYING 165 DEGREE T-STAT. THE ACTUAL COOLANT TEMP STAYS (ALMOST FOREVER) AT 165 WHILE THE GAUGE READS 185.

Y'ALL HAVE A REALLY GREAT DAY,

BLACKJACK

Hey BlackJack,
I must say this forum is an excellent resource. I really appreciate all the help. I also what to put a hypertech chip in my car. When I call hypertech they ask for VIN# so I give them the VIN and explain that the car is a kit car. They get all confused and can't help me. Do you have the part# of he chip you used? I also asked hypertech if there is a number from the computer I can give them and they NO! These guys are not much help. By the way where is the computer located in the car?
I'm also going to try to get Burns Exhuast to manufacture 321 S/S headers and side pipe flanges for the car Then I will finish the exhaust with some 12" S/S ultra light mufflers and TIG it all togather in the car.

Thank You Again for you help!

[BLACKJACK]

HEY, BUDMAN - -

WHEN YOU TALK TO HYPERTECH JUST GIVE THEM THE ENGINE CODE. YOU WILL FIND IT ON TOP OF ONE OF THE VALVE COVERS. IT'S A WHITE LABLE APPROX. 1 INCH x 3 INCHES AND HAS THE CODE NUMBER IN "BAR CODE" AS WELL AS DIGITS. THIS WILL GIVE THEM THE YEAR OF MFG. AND ENGINE TYPE - H.O., ETC., AND DISPLACEMENT.

THE COMPUTER ON MY CAR IS LOCATED ON THE PASSENGER SIDE IN THE FOOTWELL ON THE RIGHT SIDE WALL. IT'S A BLACK BOX ABOUT 6" X 6" x 1,5".

GOOD LUCK AND LET ME KNOW HOW YOUR S/S HEADERS TURN OUT.

Y'ALL HAVE A REALLY GREAT DAY,

BLACKJACK

[Excaliber]

It is my understanding the Classic Roadster headers won't bolt up to the existing Excal side pipes. You need to order BOTH headers and side pipes. Approx $350 for hearders and $350 for side pipes. These are unpainted steel, you pay shipping (a TON of money if you live in Hawaii)! The sidepipes are a new design with better "flow". I removed the "cats" and had a custom pipe built (local exhaust shop) from the headers to the side pipe.

I've decided I want to keep my chrome side pipes! Evidence of how "restrictive" they are? I "blew out" the baffles a long time ago by down shifting at high rpm on the race track! The BAD NEWS is the baffled insert is now "rattling" around inside the "empty" shell of the side pipe. I hear it from time to time when I hit a bump. The sidepipes now have NO restriction, power is MUCH better, but man are they LOUD, like NO mufflers at all LOUD.

I'm having headers custom built to match the sidepipe inlet. Local exhaust guy says $450. Plus he thinks he can "tack weld" the baffle in the sidepipe to keep it from "rattling" around.

Ernie

[B. SMITH]

THANKS FOR THE UPDATE ERNIE....I WAS CURIOUS.....
NO COOKIE CUTTER REPLACEMENTS YET, I GUESS.

THE EXCAL EXHAUST SYSTEM MUST HOLD SOME SORT OF RECORD FOR RETARDED ENGINEERING THANKS TO "DOT".

STILL A GREAT CAR.....

B. SMITH

[Aloys]

Had my sidepipes "cleaned" out 2 years ago, now only the 4 cats keep back the noise (..as good as they can...)
This winter I`ll have new headers and a completely new routing for the pipes all the way to the collectors installed. Hope I will never again have to deal with that header-s...t.
Car so far has served me without any real problems for 43000km`s

[Excaliber]

By the way,,,,what kind of miles you guys have on your Excals?

I'm getting close to 19K on mine. Runs like it was new, uh,,,,actually better than when it was new!

Ernie

EDIT: Yo Blackjack, I also replaced my rear axle bearings when I first got the car. It was leaking oil onto the rear wheels when I bought it.

[BLACKJACK]

ERNIE - -

JUST PAST 16K.

HAD THE TRANSMITION OVERHAULED TWO WEEKS AGO. (FORD AODE). IT NEEDS TO GO BACK TO THE SHOP AGAIN.

REPLACED THE REAR AXLE BEARINGS IN JUNE - - NOW DEVELOPED AN OCASIONAL "GRINDING" SOUND FROM THE REAR END WHEN STARTING OUT, ESPECIALLY WHEN TURNING. NOT SURE WHAT THE HECK THAT IS.

REPLACED THE RADIATOR TWO YEARS AGO.

REPLACED THE "MICKEY MOUSE" MUFFLERS TWO YEARS AGO.

OTHER THAN THAT, IT'S BEEN PRETTY GOOD.

Y'ALL HAVE A REALLY GREAT DAY,

BLACKJACK

[SCOTTSCOBRA]

[B. SMITH]

BLACKJACK, THE NOISE IN THE DIFFERENTIAL IS THE POSI CLUTCHES CHATTERING. EASY FIX.

GO TO ANY AUTO PARTS STORE AND GET A TUBE OF POSI REAR END TREATMENT, ANY BRAND WILL DO. SQUIRT THE TUB IN AND WITHIN ABOUT 50 MILES THE NOISE WILL DISAPPEAR.

I HAVE USED IT ON 3 CARS AND A JEEP SO FAR WITH 100% SUCCESS.

A GOOD PLACE TO START,,,, B. SMITH

[BLACKJACK]

HEY - -

THANKS VERY MUCH. I'LL TRY THAT. I'LL PICK SOME UP TOMORROW.

BJ

[MilwDoug]

Blackjack,

I happened to be at a local car show last night and ran into another ex Excalibur employee. He had been there for several years and confirmed everything you said about the exhaust system. It was all necessary to meet DOT noise and pollution specs. He also told me that the very early Cobra's were built under some kind of exemption that allowed them do ignore most of the DOT specs. Several of these had 351's. When they reached a higher production level, I think around late 84 they had to start complying.

Barry,

Last year when I had several holes in my exhaust after breaking the support arm welds, my light came on a lot too. When I fixed the exhaust it stopped. I think it's a check engine light which comes on if it senses the pollution controls are out of spec.

Doug

[ohekk]

...and you're right...Excalibur was given an exemption however I understand it was for front/rear and side impact tests requiring the shoulder restraints.

They were given the exemption because they built less than 50 cars per year.

It was the required crashing of 3 cars that inevitably forced the production to stop.

NOTE: It was later learned that DOT was responsible to pay for the vehicles that were to be tested. Of course, Ford, GM and Chrysler could afford donating cars whereas Excalibur could/would not.

Also: Excalibur Cobras were marketed and sold as EPA compliant and therefore had to pass the emission test...and that's why they have that goofy exhaust system!

Doug...stop over this weekend if you have time!

[MilwDoug]

I have just over 10,000 on mine. Bought it 2 years ago with 3,000 on it. Only problems have been exhaust and I had to replace the clutch cable last spring. Runs just great. Sometimes on rough roads the car rattles a little, but on smooth roads it' a pleasure to drive. The air works pretty good to, even with the top off.
I think we'll all find that the Ford drive train in such a light car will be pretty much indestructible, but we'll have minor problems with other things due to the fact that it's a hand built car.

[Excaliber]

I had a rattle I couldn't figure out for awhile. It was the HOOD!! I adjusted it so that it latched tighter and adjusted the rubber stoppers on both sides so the hood is nice and firm now. I also tightened up all the bolts and screws I could under and around the dash and center console area.

Much better now!

Ernie

[Budman1955]

Hey has anyone found a better air intake system? I removed and cleaned what I'm assuming is the factory K&N air filter (part# RU-2790). I've had larger air filters on my ATV's. It seems like once you get the exhaust breathing better the air intake will be a problem.