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-   -   Kirkham Motorsports Assembly Manual (http://www.clubcobra.com/forums/kirkham-motorsports/80230-kirkham-motorsports-assembly-manual.html)

David Kirkham 07-27-2007 05:01 PM

I wanted to get some pictures up today of the actual installation of the engine in a car. This car is going to be our next show car and I figured it would work well enough for our customers to see how we install an engine. Notice, there is nothing on the car right now. Usually, we would have the car completely assembled before we install the engine. But, we have several customers who want our new stainless side pipes and we need an engine in a car to make the final jigging on the side pipes so THERE WILL BE NO MORE WELDING ON OUR SIDE PIPES!!!! All you have to do is simply bolt them on when you get them.

The following pictures show the interior cockpit panels that we remove from the car when we are about to install an engine. We remove the tunnel, the "L" shaped panel that continues the tunnel shape in directly in front of the tunnel, and finally the "trapezoidial" shaped panel directly below the firewall. "Trapezoidial" is a dumb term we coined here...and it stuck.

I have to run to a piano recital tonight, and Sandwich is getting married tomorrow so I will post again on Monday! Have a GREAT weekend!




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David Kirkham 08-01-2007 05:56 PM

These are the 2 panels that we take out to install the engine. When we install engines, we install them with the transmission on the engine. You MUST remove these two panels and the transmission tunnel to put the engine and transmission in this way. The "Trapezoidial" panel is the one on top. The "L" shaped panel is the one on bottom.

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David Kirkham 08-01-2007 05:59 PM

We also remove the engine compartment panels that form the front inner wheel well. They are riveted in and we just drill out the rivets. Here you can see the transmission tunnel and the front engine compartment panels set aside for the big install. In this picture, you can see the hole in the engine compartment panel where the fresh air hose goes through the panel. Also, in this picture you can see that the hole for the shifter has not been cut into the tunnel yet...

:)

New secret billet parts are about to come out of the skunk works.

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David Kirkham 08-01-2007 06:01 PM

Here is a picture of the lower 1/2 of the motor mount. Notice the placement! The right and the left side are identical, but the larger amount of space goes toward the REAR of the car on BOTH sides.

We place these in the car BEFORE we install the engine. That way you don't have to go looking for them when you are under the car.

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David Kirkham 08-01-2007 06:18 PM

Here you can see the passenger side of the car with the engine compartment panel removed.

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David Kirkham 08-01-2007 06:20 PM

Here is a picture of the driver's side of the engine compartment with the panel removed.

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David Kirkham 08-01-2007 06:24 PM

Here is a shot of the engine and transmission all connected together and swinging on the fork lift--ready to find its home. Note the engine and transmission are COMPLETELY assembled BEFORE they go in. It is MUCH easier to work on the engine when it is OUT of the car! Just think of all the scratches and dings you will NOT put in your car now that you don't have to keep working on your engine after it is in the car.

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David Kirkham 08-01-2007 06:26 PM

Notice the exhaust ports are taped off. We don't want any hitch-hikers smuggling themselves onboard.

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David Kirkham 08-01-2007 06:29 PM

Notice the direction of the motor mount. Notice even the starter is already installed.

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David Kirkham 08-01-2007 06:31 PM

Notice the water pump pulley and the harmonic balancer pulley are already installed. The alternator bracket is installed, but the alternator is not installed. You have to install the alternator when the engine is installed because the alternator is so close to the head, you can NOT install the wires with the alternator on the motor.

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David Kirkham 08-01-2007 06:35 PM

Here you can see the slave cylinder and throw out bearing assembly is already on the transmission.

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David Kirkham 08-01-2007 06:37 PM

Here is a picture of the new shifter mount that we designed so you don't have such a big bump sticking into your cockpit.

NOTE!!!

VERY IMPORTANT!!!

Notice we have the back of the transmission plugged with a old drive shaft yoke. If you fill up your transmission (like we did) before you start swinging your motor, you will get a face full of red tranny fluid when you tilt your motor down to get it into the car. You will be amazed at how far 3 quarts of tranny fluid can spread out over your new Racedeck floor. After that, your friends will call you "Senor Exxon Valdez."

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David Kirkham 08-01-2007 06:47 PM

Here is a picture of the back of the motor. Notice we have the carburetor covered with a box to keep gremlins out. Gremlins are everywhere in shops and the LOVE to hide in motors.

Also, you can see a close up of the fuel pressure bypassing regulator. I highly recommend you run a bypassing regulator so you don't end up on the side of the road with a vapor locked carb (and the Corvette guys laughing at you.) You can see the plastic cover on the back of the regulator where we plug in our fuel pressure gauge. (Love them electric gauges; they make life so much easier.) Notice the carb return spring and all the fuel lines are ALREADY hooked up--much easier now!

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David Kirkham 08-01-2007 06:51 PM

Even the oil temperature sending unit is already installed--with Locktite. NO LEAKY, LEAKY! LEAKY, LEAKY, VERY BAD!

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David Kirkham 08-01-2007 06:54 PM

Notice the oil dip stick is already bolted down! We even put the alternator bolt back in the hole so we didn't lose it! Our totally cool billet aluminum radiator surge tank is already installed.


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David Kirkham 08-01-2007 06:57 PM

Now it is time to start swinging the motor! I love fork lifts! They make life SO MUCH EASIER. Ours has the very cool side shift option so we can move the motor side to side to get every thing perfectly lined up. Believe it or not, we can install a motor in about 10 minutes.

Notice we have our engine spreader bar set up so the engine and transmission tilt slightly down.

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David Kirkham 08-01-2007 06:59 PM

Now you need a buddy to push the transmission down so it can slip under the firewall.

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David Kirkham 08-01-2007 07:01 PM

You really have to push with our set up, but it makes it MUCH easier once the engine is actually in. We designed it so gravity HELPS us and doesn't fight us.


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David Kirkham 08-01-2007 07:16 PM

Now you have to be VERY CAREFUL as there is NOT much room to maneuver. You have to pay very close attention to the fuel pump hitting the steering column. Also, pay VERY CLOSE attention to the brake lines. IF YOU HIT ONE OF THE BRAKE LINES, MURHPY'S LAW STATES YOU WILL NOT FIND OUT UNTIL YOU ARE AT THE END OF THE STRAIGHT AT MILLER MOTORSPORTS PARK WITH A BIG GRIN ON YOUR FACE BECAUSE YOU THINK YOU ARE SOOOO COOL. THEN YOU WILL FIND OUT WHY THEY MADE SUCH LONG RUN OFF AREAS. IF YOU DO THIS AT MOST OTHER TRACKS, JAMO WILL NOMINATE YOU FOR A DARWIN AWARD!

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David Kirkham 08-01-2007 07:32 PM

There isn't much room! The oil pan only clears by 1/4 inch.

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