AP2289 Build log 'stage 2'

[xb-60]

Working on the windscreen wiper installation. The drive needs to go through the firewall from the top of the LH footbox, so need to clad that section of the firewall with insulating sheet and 1.2mm thick stainless steel sheet.

I need some (grommetted) 25mm dia. holes in the firewall for temp gauge senders (2), oil pressure gauge tubing and also electricals.

First attempt at drilling the SS sheet didn't work, so then tried a 25mm dia ceramic tipped trepanning tool. That worked a lot better than I'd thought, so then had to fix the already botched first hole. Used my very trusty jigsaw to take the hole out to the 25mm markup. That worked better than expected as well, so now just have to tidy up that hole. Then I'm ready to do a trial install, then cut the holes in the aluminium alloy firewall and estimate where the hole for the windscreen wiper hole goes and cut that one out too. Not a lot of fun today, but should have that part of the firewall sorted soon.

Here's what the SS sheet looks like at the moment. It will look better when finished.




Cheers,
Glen

[Jaydee]

Try using a hole punch. It leaves a much neater hole. You only need to drill a 12 mm hole the you place the die on one side and the punch on the other and tighten the bolt and it pulls through. I have several sizes. JD

[xb-60]

JD - more details? I'll check 'em out. Does sound easier.
Mine should tidy up OK though, particularly when fitted with the grommets.

[Jaydee]

I bought them many years ago. It has the same color as impact sockets. Sorry I don't know where to get them. I'll try to search them. JD

[xb-60]

Originally Posted by Jaydee

I bought them many years ago. It has the same color as impact sockets. Sorry I don't know where to get them. I'll try to search them. JD

Found them on ebay. Thanks.

[BJ's Snake]

Can't just notch out the cross member for clearance?

Cheers

[xb-60]

From memory the tube is around 30mm diameter and I would have to notch out around 12mm or thereabouts to clear the speedo cable.
It's a structural member, so don't want to do that. I don't want it to bite me back one day

Cheers,
Glen

[peterpjb]

nice fuel pressure gauge

[xb-60]

Thanks Peter. They are not very common

Finished the under-hood insulation....finally....


Cheers,
Glen

[xb-60]

Originally Posted by xb-60

....Finished the underdash insulation....finally....

Just kidding ...it's still happening.

The SS firewall sheet is now back in, and I'm working on fitting the SS panels that cover the aft part of the engine bay.

Cheers!
Glen

[xb-60]

Might seem to be a backward step to 'de-polish' SS heat shields.... but it's just too shiny for a Cobra....

[xb-60]

....and here's the same panel, 'scuffed'....

[Gaz64]

Originally Posted by peterpjb

nice fuel pressure gauge

Although I think it is mechanical, I hope it is electrical, for safety.

[xb-60]

Hey Gary!

Yes, it's mechanical ....hey, it's a Cobra (replica)....we don't use that modern electrical stuff on gauges.
Yes, the gauge is decades old, and exactly as used on FIA cars.

If it's ever actually connected up (the gauge), my engine will need to be carb'd, not EFI....which I hope to be able to do eventually (carb fueled) if our SA club is successful in it's negotiations with the state rego boys.
....and if so, no, for safety, the fuel will not go any further south than the firewall, so should be quite safe enough to satisfy my compliance engineer, as well as me

Cheers,
Glen

[Jaydee]

My dyno guy said with the right cat it should pass emmisions with a carby. JD

[xb-60]

JD,

If I go the 'standard engine' route, there's a simple idle emissions check and a noise check as my engine is ADR37/01 compliant. Easy.

If I go the 'carb' route, it would most probably require multiple dyno tuning sessions, and then an IM240 test. Expensive. One of our club members has done this, and it was a long, long road. Again....expensive.

As I mentioned previously, our club is in conversation with our state DPTI regarding emissions (and other) standards for ICVs; with a degree of luck, we may gain some worthwhile concessions that would allow carbies to be used. I'm not looking for power, I'm looking for something that looks more period correct than a modern EFI sitting on top of the engine

Cheers,
Glen

[BJ's Snake]

They fitted my body as well. The wrong panels weren't evident until radiator fitting.
Was your radiator fitted at Pace before delivery?
No Adelaide trips in the near future, you will probably be over here before I get over there.

Cheers

[xb-60]

Brett,

My radiator wasn’t fitted by PACE. You have me worried now! Fitting the radiator is next on my list.

Yesterday I went to start on the RH front inner guards and I wasted 2 hours looking for one of the aluminium alloy panels (the one the steering goes through). Couldn’t find it anywhere.
I’ve tried ringing PACE previously for things that were wrong or missing, with no luck, so I went to Paramount Brown’s (best ‘hardware’ in Adelaide) to buy some 1.2mm sheet aluminium to make a new panel. The guy serving me asked what I was using it for; told him about the Cobra, and he halved the price of the sheet! There are some nice people around still.

I’ll let you know how I go with the radiator fit.

Cheers,
Glen

[1795]

Glen,

Hope that it works out well for you. Of course, you will find that part 5 minutes after you have installed the one that you spent countless hours on manufacturing...

[xb-60]

Hi Jim,

Made the new panel....2 hours ago.
The missing panel? Well, it wasn't in the packaging with the related panels, so I think it just wasn't packed in the first place. No matter, slowed me down by a day, but...had a nice drive up through the hills to my favorite hardware, and an hour this morning to fab. a new one, and it's fitted now, so all good.
Will finish it tomorrow, and then must start on the radiator installation to see what surprises I might find there....from what BJ says, might take some ingenuity to get around it.

Hey, here it's around 25 degC (around 75degF), so life is good! Cool in the garage in the morning, and pleasantly warm in the pm.

Cheers,
Glen