tag:blogger.com,1999:blog-22320159516438451932024-03-05T18:17:13.858+11:00Cobra BlogThe ongoing story of a 427 S/C Replica Cobra buildBen Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.comBlogger69125tag:blogger.com,1999:blog-2232015951643845193.post-87548870584693714732015-08-29T11:14:00.000+10:002015-08-29T11:14:47.191+10:00UpdateThe sidepipes, headers and cats have all gone off to be ceramic coated, they are expected back next week. I had the tailshaft made by GJ Drivelines, all 34cm of it. Unfortunately it did not fit in with the diff and transmission in place - there just was not enough room to angle it in. The diff had to come out, which requires the removal of basically the whole rear-end. A 3 hour job (and a sore back) from go to whoa and now the whole rear-end is buttoned up again.<br />
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/08/img_4735.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://bencobra.files.wordpress.com/2015/08/img_4735.jpg" width="300" /></a></div>
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/08/img_4783.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/08/img_4783.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/08/img_4786.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://bencobra.files.wordpress.com/2015/08/img_4786.jpg" width="300" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/08/img_4774.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/08/img_4774.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
The windscreen came out as I had to drill the holes for the centre support bracket, and the rear view mirror.<br />
<div>
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/08/img_4737.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/08/img_4737.jpg" width="400" /></a></div>
<div>
<br /></div>
<div>
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/08/img_4738.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/08/img_4738.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
The tyres have been fitted to the rims. I had to use flush-mount valves to clear the big brakes.</div>
<div class="separator" style="clear: both; text-align: left;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
245/40x17 front</div>
<div class="separator" style="clear: both; text-align: left;">
275/40x17 rear</div>
<div class="separator" style="clear: both; text-align: left;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/08/img_4777.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/08/img_4777.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/08/img_4778.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/08/img_4778.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
<br /></div>
<div>
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<br />
<br />Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-14785653187809320442015-07-19T16:14:00.004+10:002015-07-19T16:14:31.601+10:00The small thingsThe sidepipes are still under construction, no real update to add there at this time. Have been completing a myriad of other smaller jobs, made a bracket and mounted the coolant overflow bottle, finished the charcoal canister plumbing, plumbed the fuel filler and bits, also wired the EGR purge valve and the temp sensor for the water temp gauge.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/07/img_4603.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://bencobra.files.wordpress.com/2015/07/img_4603.jpg" width="300" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/07/img_4599.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://bencobra.files.wordpress.com/2015/07/img_4599.jpg" width="300" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/07/img_4600.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/07/img_4600.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/07/img_4601.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/07/img_4601.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/07/img_4602.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://bencobra.files.wordpress.com/2015/07/img_4602.jpg" width="300" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<br />Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-75688117842644265202015-06-15T21:58:00.001+10:002015-06-15T21:59:44.485+10:00Sidepipes under constructionNot a massive amount has been happening lately, have just been to busy with work/family/life. Recently though I have grabbed the sidepipe job by the horns and been getting stuck into the cutting, grinding and welding. We ARE making progress.<br />
<br />
These pipes will be functional. 4" tube. inner 2.5" perforated and it will be stuffed with steel wool muffler packing stuff.<br />
<br />
The inner tube and mounting rings/hardware are stainless, the rest is mild steel. The 4-into-1 are 2".<br />
<br />
The tailpipe piece is flanged and will get mounted with a through-bolt so the internal baffle and stuffing can be removed and rebuilt.<br />
<br />
Still have to clean up some more welds and will finalise the 90-degree tail pipe once it is mounted on the car.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4264.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4264.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4265.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4265.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4266.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4266.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4267.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4267.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4268.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4268.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4269.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4269.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4270.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4270.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4271.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4271.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4272.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4272.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4273.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4273.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4274.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4274.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4275.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4275.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4276.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4276.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4277.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4277.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4278.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4278.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4279.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4279.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4280.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4280.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4281.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4281.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4282.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4282.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4283.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4283.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4284.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4284.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2015/06/img_4285.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2015/06/img_4285.jpg" width="400" /></a></div>
<br />Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-4227045401394996432014-12-20T21:21:00.003+11:002014-12-20T21:22:53.786+11:00The engine is in!A big day today, my Cobra mates came over to lend a hand and the engine and trans are in!<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/img_1504.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/img_1504.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
LS7 clutch</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/img_1505.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/img_1505.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/img_1506.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/img_1506.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/img_1507.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/img_1507.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/img_1508.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/img_1508.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/img_1509.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/img_1509.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
Removed the shifter to give more room while guiding through the tunnel</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/img_1510.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/img_1510.jpg" width="400" /></a></div>
<br />
<div style="text-align: center;">
I made heat shields out of 1.6mm aluminium, they are painted in high-temp black
</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/img_1514.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/img_1514.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/img_1515.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/img_1515.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/img_1516.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/img_1516.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/img_1517.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/img_1517.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/img_1518.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/img_1518.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/gregg3.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/gregg3.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/gregg4.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/gregg4.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/gregg7.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/gregg7.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/gregg8.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/gregg8.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/gregg9.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/gregg9.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/12/img_1519.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/12/img_1519.jpg" width="400" /></a></div>
<br />Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-79345520830766341422014-11-08T21:59:00.002+11:002014-11-08T22:00:59.628+11:00Making Headers part deuxContinuing work on the headers, first to clean the mill scale off the flanges with a flap disc<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/11/img_1392.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/11/img_1392.jpg" width="400" /></a></div>
<br />
Then welded up the headers to the 4-into-1, 2.5" outlet collectors. They will then get a 2.5" 90 degree turn towards the sides of the car, then the cats, then out into sidepipes.<br />
<br />
Yes, my welds need some clean-up, but hey, I work at a keyboard all day!<br />
<br />
Once all complete the headers and all the exhaust will get HPC coated in black.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/11/img_1393.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/11/img_1393.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/11/img_1394.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/11/img_1394.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/11/img_1395.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/11/img_1395.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/11/img_1396.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/11/img_1396.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/11/img_1397.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/11/img_1397.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/11/img_1401.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/11/img_1401.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/11/img_1402.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/11/img_1402.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/11/img_1403.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/11/img_1403.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
The 4-into-1 collector goes into a 2.5" downpipe with O2 sensor bung and then a flange that points sideways. To this will go a 2.5" cat, and then out into the sidepipes.</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/11/img_1413.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://bencobra.files.wordpress.com/2014/11/img_1413.jpg" width="300" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/11/img_1414.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/11/img_1414.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/11/img_1415.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://bencobra.files.wordpress.com/2014/11/img_1415.jpg" width="300" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/11/img_1416.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://bencobra.files.wordpress.com/2014/11/img_1416.jpg" width="300" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
Next up will be beginning to make the sidepipes......</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<br />Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-83426353522652912562014-10-19T09:06:00.003+11:002014-10-19T09:17:29.150+11:00Making HeadersI have been slack at updating this blog lately, just not had time, but not much has been happening anyway, again lack of time! With an hour here or there I have been making the headers. They are a shorty block-hugger 4-into-1 design, to allow me to put the CATs under the bonnet, nice and close to the engine. The shorty block huggers that are available off the shelf are not short enough and come to close to the chassis, hence I am making my own!<br />
<br />
I bought a bunch of mandrel bends and started cutting. The cuts are made mostly with a chop saw, also a couple by hand with a hacksaw.
On each side I have one pipe which is one piece, the other three pipes are two or three pieces each. The driver's side front port needs a fair kink in it to clear the steering column, I will add more pics as the headers continue to come together.<br />
<br />
I have welded up the pipes with a scratch start TIG setup. The welder is a 140amp DC inverter stick welder, it is tiny! Plugged in a TIG torch to the negative, hooked up a bottle of argon and got TIGging! I have never TIG welded before, so spent a good couple of hours practicing on scrap. It took a couple of hours to get the muscle memory going that you need to remember to turn the gas on at the torch! The hardest part was the scratch start without the electrode sticking, but once you have the knack it is quite easy to start. With this scratch start TIG setup I can weld steel and stainless steel, but no aluminium as that needs AC. I decided to go the scratch start setup as I can't justify $1,000 for a decent hi-frequency AC/DC welder and I have no aluminium welding to do as of now. As you will see from the welds I am no weldmaster, but a flap disc will do wonders!
<br />
<br />
<div style="text-align: center;">
Below you can see the length of the single piece pipe. I am using 1 & 3/4" pipe. I'm more interested in low and mid-range torque than high-end HP, so from what I have read on these engines this is better suited than 1 & 7/8".</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/10/img_1278.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/10/img_1278.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
The trolley, big-old MIG on the top, AC stick on the bottom, and the DC stick that I'm using for TIG is hiding in the middle!</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/10/img_1281.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/10/img_1281.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
This thing is tiny! I have been welding up most of the joins at about 40amps.</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/10/img_1283.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/10/img_1283.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
The TIG torch cost more than the welder! It's a 17V with the valve for the gas. Also I added a gas lens kit from weldmongerstore.com. I have been using 2.4mm (3/32") ceriated tungsten electrodes and they seem to be working well.</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/10/img_1286.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/10/img_1286.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
Read for a tack</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/10/img_1284.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/10/img_1284.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/10/img_1285.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/10/img_1285.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
Not too bad, will clean them up with a flap disc. Once complete the headers will get HPC ceramic coated. If you can get the mating surfaces nicely matched then almost no filler metal is needed.</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/10/img_1279.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/10/img_1279.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/10/img_1280.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/10/img_1280.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/10/img_1297.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/10/img_1297.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-23581927591332326822014-08-03T20:09:00.001+10:002014-08-03T20:14:35.322+10:00Roll BarsOver the last couple of weeks I have got the driver and passenger side roll bars completed. They are a hoop with a third leg, 3mm wall thickness tube. The third leg gets welded to a plate that bolts through the boot floor and through the chassis underneath. Once the leg is welded to the plate the only way out for the leg is down and out, yet it is too long to pull out so it needed to be cut and sleeved. The sleeve is 4mm wall thickness chromoly tube and bolted through with M12 bolts.<br />
<br />
After tack welding the third leg to the plate and the top bracket to the hoop in the car, it all got pulled out to be fully welded and then the welds blended out smooth and ready for finishing. These will be black and I think I will get them powder coated.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/08/img_1135.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://bencobra.files.wordpress.com/2014/08/img_1135.jpg" width="300" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/08/img_1136.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/08/img_1136.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/08/img_11371.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://bencobra.files.wordpress.com/2014/08/img_11371.jpg" width="300" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/08/img_1138.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://bencobra.files.wordpress.com/2014/08/img_1138.jpg" width="300" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/08/img_1139.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/08/img_1139.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/08/img_1140.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/08/img_1140.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/08/img_1141.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/08/img_1141.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/08/img_1142.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/08/img_1142.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://bencobra.files.wordpress.com/2014/08/img_1143.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://bencobra.files.wordpress.com/2014/08/img_1143.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<br />Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-48284394804676130672014-04-22T20:55:00.000+10:002014-04-22T20:55:13.817+10:00Dash Mock-upMany moons ago I mocked up the aluminium dash panel with print-outs of my gauges. This is an excellent way of deciding on a layout without cutting any holes.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2014/04/img_0916.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="http://bencobra.files.wordpress.com/2014/04/img_0916.jpg" height="300" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
But I thought I would be doubly sure before cutting holes in that aluminium, so I mocked up a panel out of 3mm MDF and used the real guages and switches, happy with this layout I will proceed to wire up this mock-up and switch everything over to the aluminium panel before getting on the road.</div>
<div class="separator" style="clear: both; text-align: left;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2014/04/img_0917.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="http://bencobra.files.wordpress.com/2014/04/img_0917.jpg" height="300" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2014/04/img_0919.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="http://bencobra.files.wordpress.com/2014/04/img_0919.jpg" height="300" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
<br /></div>
Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-59000610650833416702014-01-04T16:47:00.004+11:002014-01-04T16:51:50.045+11:00LS3 Accessory Drive kitMy LS3 engine is a crate motor, which means it came complete with intake, throttle body, coil packs etc, but does not come with the accessory drive as this is typically chosen to suit the vehicle. The same crate motor is used in HSV, Camaro, Corvette, Cadillac etc, so the accessory drive components and brackets vary by vehicle. The accessory drive is made up of alternator, power steering pump, idler pulley, belt tensioner and belt, brackets and bolts etc. I am using GMPP part number 19299070, which is the setup used in Cadillac CTS-V LS3.<br />
<br />
This setup is narrower than the Australian HSV setups and will fit nicely between the inner guards of the Cobra. The accessory drive kit 19299070 includes alternator, power steering pump, pulley, tensioner, belt and all brackets and bolts needed to bolt it straight onto the LS3.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2014/01/accessory_drive.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://bencobra.files.wordpress.com/2014/01/accessory_drive.jpg" width="303" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
All the components laid out that form the one GMPP part number</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2014/01/img_0365.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2014/01/img_0365.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
The front of the LS3 before install</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2014/01/img_0366.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2014/01/img_0366.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
The install instructions include torque specifications for all bolts for which I used my Snap-On digital torque wrench</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2014/01/img_0367.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2014/01/img_0367.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
And used anti-seize on all bolts</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2014/01/img_0368.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2014/01/img_0368.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: left;">
Everything bolted straight on in no time. The supplied plastic power steering reservoir is not very nice looking, and I will replace this with a black aluminium billet reservoir. Fitting the power steering pump necessitated removing the front-left engine lift bracket, so that will need to be swapped back for engine installation and then the pump can go back on when the engine is in the car. The pump has to come off anyway to be modified, read below for why.</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2014/01/img_0369.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2014/01/img_0369.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: left;">
These newer GM alternators do not use an exciter wire, they are controlled by the ECU. The engine loom I have is a modified VZ Commodore loom and the pigtail does not match the alternator socket, but not to worry my loom supplier <a href="http://www.sideshows.net.au/" target="_blank">sideshow</a> has already sent me the correct pigtail to match the alternator.</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2014/01/img_03701.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2014/01/img_03701.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: left;">
The power steering pump is going to need some modification. I will be using -6 AN fittings and Teflon hose for the power steering lines, for which I need an adapter fitted to the power steering pump high-pressure output. Such an adapter M16/-6 AN is easily sourced, but there's a problem in that there is minimal clearance at the back of the pulley to fit the adapter and then fit an AN hose-end in there. The solution comes from Detroit Speed and is a custom fitting designed to completely replace the factory outlet fitting but the Detroit Speed fitting is made with a -6 AN end, part number 090401. This will allow a -6 AN hose-end to fit in there with much more room.</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2014/01/img_0372.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2014/01/img_0372.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2014/01/img_0375.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2014/01/img_0375.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2014/01/img_0457-e1388813928903.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="296" src="http://bencobra.files.wordpress.com/2014/01/img_0457-e1388813928903.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: left;">
The pump is as fitted to the Cadillac CTS-V, and will supply 2 gallons per minute @ 1640/1740 PSI, which is too high a pressure for the VP Commodore steering rack that I have. So I will send the pump to a power steering specialist and have them re-valve it and test to a more appropriate pressure of 1200psi.</div>
Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-24327529687277069962013-11-25T21:58:00.003+11:002013-11-25T21:58:58.166+11:00Oil CoolerYes Yes Yes, I know I haven't written on here in ages. Life has been getting in the way! Slowly slowly little things are happening on the Cobra. The oil cooler is almost done. Here is a pic of the cooler I am using, from Finishline;<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/11/img_000002441.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="225" src="http://bencobra.files.wordpress.com/2013/11/img_000002441.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<br />
It has -10 AN fittings cast/machined into the housing. I am using all Aeroflow braided hose with black AN fittings for all my plumbing around the car. So the cooler gets mounted to the chassis with a couple of steel brackets which I fabricated and painted black, and then -10 braided hose with a couple of 90 degree hose ends;<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/11/img_0281.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/11/img_0281.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/11/img_0282.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/11/img_0282.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: left;">
Then comes the oil thermostat. A thermostat is important so the oil does not run too cold for too long, and has a chance to heat up to normal temperature before being totally passed through the cooler. This unit is from Improved Racing;</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div align="left" class="separator" style="clear: both; text-align: center;">
</div>
<div align="left" class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/11/img_0278.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/11/img_0278.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: left;">
More -10 hose, and some angled fittings. The two heading rearwards towards the engine are 30 degree, the one heading out the left to the cooler is also 30 degree and the right hand front is 120 degree. The hose is secured in strategic locations with rubber coated stainless steel P clamps, and extra zip-tied rubber in certain locations to protect the chassis from rubbing of the stainless steel braid.</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: left;">
I am yet to install hose ends on the engine end of the hoses, I will that in another post along with the after-market oil pan that I have going on the LS3.</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/11/img_0279.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/11/img_0279.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/11/img_0280.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/11/img_0280.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/11/img_0277.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/11/img_0277.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/11/img_0276.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/11/img_0276.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/11/img_0275.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/11/img_0275.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div align="center">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-31487654845318854742013-08-16T21:17:00.001+10:002013-08-16T21:17:19.605+10:00Fuel Pressure SenderNext up to go on is the fuel pressure sender. This again matches my VEI fuel pressure gauge, and is an electronic sender with a 1/4" NPT thread. This sender could theoretically go anywhere in the pressure fuel line, but I think the closer to the engine the better. As luck would have it the LS3 factory fuel rail has a fitting on it, although sadly it is not 1/4" NPT. The fitting on the end of the fuel rail has a Schrader valve in it, and is presumably there to allow diagnostic fuel pressure testing by service centres. The end with the valve can be seen in the centre of this photo with the black cap on it.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/08/img_00000250.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="225" src="http://bencobra.files.wordpress.com/2013/08/img_00000250.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: left;">
The thread on this fuel rail fitting is -4AN, so we need an adapter to fit our 1/4" NPT fuel pressure sender. While a straight adapter is available, this would make it stick out a fair way, looking less than average and may also interfere with the not-yet-fitted power steering fluid reservoir. So I decided to dog-leg it, and use a -4AN / 1/4" NPT 90 degree elbow adapter together with another elbow which is 1/4" NPT on both ends, and then the sender attached to that. Here are the parts together with the thread sealer for the NPT thread.</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/08/img_00000248.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="225" src="http://bencobra.files.wordpress.com/2013/08/img_00000248.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: left;">
Here is the Schrader valve fitting, remove the Schrader valve with the valve tool ($3 off ebay)</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/08/img_00000251.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="225" src="http://bencobra.files.wordpress.com/2013/08/img_00000251.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/08/img_00000252.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="225" src="http://bencobra.files.wordpress.com/2013/08/img_00000252.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/08/img_00000253.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="225" src="http://bencobra.files.wordpress.com/2013/08/img_00000253.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
Then the fittings can be installed. The chosen method of turning it 180 degrees makes it three pieces long, but tucks it away nicely behind the injector wiring and coil pack brackets.</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/08/img_00000254.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="225" src="http://bencobra.files.wordpress.com/2013/08/img_00000254.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/08/img_00000255.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="225" src="http://bencobra.files.wordpress.com/2013/08/img_00000255.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/08/img_00000256.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="225" src="http://bencobra.files.wordpress.com/2013/08/img_00000256.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-81197504192781839712013-08-09T20:05:00.000+10:002013-08-09T20:05:10.174+10:00A few engine bolt-onsI need to change and add a few things to the engine, and it is far easier to do most of this stuff before the engine goes in the chassis. First up is adding a water temperature sender. The factory sender is in the left-hand cylinder head, and will plug into the GM wiring harness and ECU. This factory sender is GM specific and cannot be used to feed an aftermarket gauge, but is critical to ECU operation so that the ECU knows the engine water temp. But the gauge I am using of course needs its own sender. The left and right cylinder head castings on Chev LS engines are the same alloy casting, so the location for the factory sender is also in the right-hand cylinder head and is blocked with a threaded bung from the factory. This is the best place to house the aftermarket water temp sender.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/04/img_1058.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/04/img_1058.jpg" width="400" /></a></div>
<br />
The gauges I am using are from VEI Systems and they came with the water temp sender. Like most aftermarket senders the thread is 1/8 NPT. The thread in the cylinder head is M12x1.5, so we need an adapter. Autometer make such an adapter, part number AU2277, but the internal diameter of it is just slightly to small to fit the sender, so I drilled it out by about 1.5mm<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/04/img_1059.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/04/img_1059.jpg" width="400" /></a></div>
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/04/img_1064.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/04/img_1064.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: left;">
Then the body would fit inside the I.D.</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/04/img_00000021.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="225" src="http://bencobra.files.wordpress.com/2013/04/img_00000021.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: left;">
And sadly this is where it all went wrong. Drilling out the I..D by 1.5mm weakened things enough that the housing of the thread adapter cracked upon tightening in the head - I didn't do it that tight I promise! I felt it give when tightening, and thankfully stopped quick enough that I was able to back it out with snapping it off in the hole, and without damaging the head. The crack can be seen in this picture just below the end of the thread.</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/04/img_00000023.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="225" src="http://bencobra.files.wordpress.com/2013/04/img_00000023.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: left;">
Time for Plan B. I bought another thread adapter, and Autometer also make a "shorty" temp sender which fits natively in the adapter (part number 2259). I am not using Autometer gauges, thus I could not be sure that the resistance from the VEI sender and the Autometer sender would be the same, so I had to test it. So I cracked out the water temp gauge, a 12v battery, and for each sender I ran it under the hot water kitchen tap for a few mins and monitored the temp reported on the gauge - this confirmed that both senders are sending the same resistance to the gauge. In this pic it is measuring the VEI sender and the Autometer sender can be seen on the bench. Both senders reported the same temperature on the gauge</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizwHr0-489HNbHSrcjVLbLURkE_bcUb6wnP0_iou9XXcqgEDFIYBcnno-gPA5cYbGh7tz_sm1huvCEgI8tWw4QRxPwOJIiMEKtoUpyfyDTMrhntEnNd9rQ8KKK5l1Mx6slmGpeu4Q5oio/s1600/water_temp.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="223" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizwHr0-489HNbHSrcjVLbLURkE_bcUb6wnP0_iou9XXcqgEDFIYBcnno-gPA5cYbGh7tz_sm1huvCEgI8tWw4QRxPwOJIiMEKtoUpyfyDTMrhntEnNd9rQ8KKK5l1Mx6slmGpeu4Q5oio/s400/water_temp.png" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: left;">
So the shorty sender went in the thread adapter with a bit of thread sealer and it's all buttoned up ready for attaching the sender wire.</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/08/img_00000245.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="225" src="http://bencobra.files.wordpress.com/2013/08/img_00000245.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: left;">
</div>
Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-19122276239285526382013-04-22T22:05:00.000+10:002013-04-22T22:05:59.963+10:00Have an engineThe right deal came up at the right time, so I went ahead and purchased an engine! It is an LS3 crate motor. The LS3 is a Gen IV Chev small block, with it's roots in the legendary LS1. The LS3 is 6.2L (376 ci) and rated at 430 bhp (321 kw) and 424 lb-ft (575 Nm) of torque. This is standard equipment on the current model Corvette, and the local HSV VE Commodore derivatives.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/img_1021.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/03/img_1021.jpg" width="400" /></a></div>
<br />
The engine needs a couple of tweaks before being installed. Firstly the oil pan needs changing. The oil pan that you see in the picture is as delivered from the GM factory, and suits the Corvette and local HSV (VE Commodore). My CR chassis has a cross-member in the way, so this oil pan will come off and an afermarket unit will go in which has the "hump" more towards the rear of the engine.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/img_1023.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/03/img_1023.jpg" width="400" /></a></div>
<br />
The crate motor comes with everything you see on it, including inlet manifold, throttle body, water pump, exhaust manifolds, coil packs, knock sensors, cam and crank sensors, etc. The only other things it needs are an accessory drive setup - meaning alternator, power steering pump, idler pulley and belt tensioner pulley. This is all available from GM as a single part number. LS engines have three different harmonic balancer setups available. Which one is used depends on the vehicle that the engine is being installed into. There is one for Corvette, another for F-Body/Camaro, and another for trucks. The difference being the distance that the belt-line sticks out from the block. This crate motor came delivered with the Corvette line (the closest to the block) which suits perfectly the aftermarket drive kit that I intend to use, more on that in another post.<br />
<br />
Further reading about LS engines here: <a href="http://en.wikipedia.org/wiki/GM_LS_engine">http://en.wikipedia.org/wiki/GM_LS_engine</a><br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/img_1024.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/03/img_1024.jpg" width="400" /></a></div>
Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-48172588746820816372013-03-20T22:53:00.004+11:002013-03-20T22:53:59.798+11:00The DiffThe Classic Revival round-tube chassis is built to take the ZF diff unit as fitted (amongst others) to the VE Commodore. There are both LSD and non-LSD options available for this unit, along with a large number of ratios. While a second hand unit can be had quite readily from a wrecking yard or ebay, the ratio options are quite limited. This is because with a manual transmission either a 3.45:1 or 3.7:1 is preferred. Manual SS VE Commodores came with 3.45:1, while manual HSV's got 3.7:1. The second-hand 3.7 units from the HSV's get snapped up quick smart, and go for (in my opinion) to much money considering their mileage and condition.<br />
<br />
Back in the day I had a VX SS LS1 Commodore, and although the diff in the VX was different to the VE's ZF unit, it had the same ratio of 3.45:1, and I was not 100% happy with it. When paired with a T-56 manual transmission I feel that a 3.7:1 ratio is a better fit. A diff from a wrecked HSV is hard to find, as they are snapped up quickly by Commodore owners looking for a cheap and easy ratio change for their SS. I never really wanted a second hand unit anyway - I view my Cobra as a new car, and I want to use new parts wherever it is feasible. So I picked up a new 3.7:1 LSD from Holmart, new old stock.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/img_0534.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/03/img_0534.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/img_0532-e1363779382842.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/03/img_0532-e1363779382842.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
The front pinion flange on the diff needs to be swapped out because the three-pronged flange that Holden fit has quite a large radius and interferes with the round-tube chassis.You might wonder why the chassis was not made to fit the flange, but it would have meant altering an otherwise straight (and hence strong) structural piece of the chassis - a better solution is to change the flange for one that clears the chassis, in this case it is a Ford BA flange, part number BA4851A.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/img_07321.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/03/img_07321.jpg" width="400" /></a></div>
<br />
After removing the pinion nut it's fairly easy to pull the flange, no doubt a well bedded-in unit may have been harder to remove.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/img_0733.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/03/img_0733.jpg" width="400" /></a></div>
<br />
The next problem is that the dust cover on the new flange sits a couple of mm to low, and touches the diff housing. I pressed the cover on a little bit further in my workshop press, but that made it loose so a couple of tack welds sorted that out.<br />
<br />
The last problem is that the new flange tube outside diameter is very slightly smaller than the original, this means the oil seal does not contact the flange and it would possibly leak oil. So the old seal gets carefully levered out so as not to mark the seal seating surface.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/img_0734.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/03/img_0734.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/img_0735.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/03/img_0735.jpg" width="400" /></a></div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/img_0736.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/03/img_0736.jpg" width="400" /></a></div>
<br />
Then a new seal SKF part number SKF21283 gets knocked in, the old VE rear wheel bearing came in useful again for knocking the seal in square over the pinion.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/img_0737.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/03/img_0737.jpg" width="400" /></a></div>
<br />
Even though this unit is brand new, I went ahead and purchased a new pinion nut from Holden, as these are a one use item as the nut stretches when tightened. The nut is GM part number 92194936 and costs $27.25 - no that is not a misprint - it really is a $27 nut.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/photo-11.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/03/photo-11.jpg" width="400" /></a></div>
<br />
<br />
Now the unit is ready to go into the chassis, but that is easier said than done. As I am not removing the body from the chassis during this build, it was very awkward to fit the diff unit up into the chassis. It doesn't look difficult, but it soon becomes apparent that it needs to go in at a very odd and very steep angle, not so easy when the car is on stands and the diff weighs over 40kg so you cannot simply lift and tilt it by hand from underneath the car. I jacked the diff up while simultaneously using a strap over the chassis to tilt the diff to quite a severe angle to get the pinion over the chassis rail and line up the three mounting locations. Then in with three M12 grade 8 bolts, and it's done. This pic is after the angle shenannigans, ready to bolt-up.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/img_0773.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="298" src="http://bencobra.files.wordpress.com/2013/03/img_0773.jpg" width="400" /></a></div>
<br />
I contemplated changing out the factory rubber bushes for an aftermarket polyurethane type. Manufacturers such as Pedders and Superpro have a few different stiffness' available, but some research leads me to believe that these polyurethane bushes in this diff in the Commodore community have resulted in some people complaining about ride harshness, and in a Cobra that weights 600kg less than a Commodore this is likely to be even more pronounced. So we're staying with the factory rubber mounts for now, I can always upgrade them later if the need should arise - although that will require the tricky job of removing and refitting the unit to the chassis!Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-88440513934685040992013-03-18T22:10:00.003+11:002013-03-18T22:10:31.794+11:00Oh goody! Toys!<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/photo-1.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/03/photo-1.jpg" width="400" /></a></div>
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/03/photo-2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/03/photo-2.jpg" width="400" /></a></div>
Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-24394621360911015072013-01-06T23:40:00.002+11:002013-01-06T23:40:24.761+11:00Rear Suspension KnucklesThe rear suspension of the Classic Revival round-tube chassis is based on the VE Commodore rear. In fact, it is the same as the VE rear with the following changes;<br />
<ul>
<li>Driveshafts are shortened by 65mm each side</li>
<li>The top suspension A-arm is custom made</li>
<li>There is no rear K-frame, with all arms and components having mounts built-in to the chassis design</li>
</ul>
All the components I am using for the suspension are either brand new where there are moving parts (eg bearings), or stripped and fully-rebuilt/painted where it is a static component (such as a simple steel suspension arm). I will make a video shortly of assembling the rear-end, but first this post explains the rebuild of the rear suspension knuckle. I thought this was worthy of its own blog post because there are so many parts to the knuckle. After the knuckle was stripped bare, blasted and painted, assembly can begin;<br />
<br />
Clockwise from the bottom left corner we have;<br />
<ul>
<li>Main drive-flange</li>
<li>Handbrake backing plate and retaining bolts (backing plate has been trimmed as per <a href="http://cobrablog.holnet.net/2012/08/rear-disc-backing-plates.html" target="_blank">this blog post</a>)</li>
<li>Handbrake shoe and retaining spring</li>
<li>Main driveshaft bearing and retaining circlip</li>
<li>Top A-arm heim joint</li>
<li>ABS sensor and retaining bolt</li>
<li>Handbrake adjustment and actuating mechanism components</li>
<li>Two polyurethane bushes and crush tubes</li>
</ul>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0055.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0055.jpg" width="400" /></a></div>
<br />
<br />
The first job is to press in the polyurethane bushes. The cast knuckle unit itself is extremely unwieldy and an awkward shape. It is difficult to fit in the press for some components and impossible for others. There are 5 pressing operations to be made, for which I used a combination of workshop press, vice, and socket/bolt methods. The main drive bearing and drive flange must be installed with a proper press.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0056.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0056.jpg" width="400" /></a></div>
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0058.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0058.jpg" width="400" /></a></div>
<br />
<br />
Once the bush is in, it is greased up and the crush tube can be installed by hand with some force.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0062.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0062.jpg" width="400" /></a></div>
<br />
<br />
The top suspension A-arm mounts to a heim joint unit which is pressed into the top mounting of the knuckle. This is an awkward piece to install. I started it and seated the first 3mm with the socket/bolt method, and then this is one of the awkward press positions you need to use to drive it home.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0064.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0064.jpg" width="400" /></a></div>
<br />
<br />
<div style="text-align: center;">
Fully seated</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0068.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0068.jpg" width="400" /></a></div>
<br />
<br />
Next up the main drive bearing has to be pressed in. The bearing has the ABS reluctor built-in to the inner race, so the bearing must be installed in the correct direction for the ABS sensor to work. Installing this bearing is fairly straight-forward in the press. To push it home the last few millimetres I took the old bearing housing, ground it down by a few thou on the grinder so it wouldn't get stuck, and used it between the press and the new bearing, this insured I was pushing square on the new bearing and only on the outer race (there is no picture of this step, sorry). The old bearing also served nicely as a spacer underneath while pressing.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0070.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0070.jpg" width="400" /></a></div>
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0073.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0073.jpg" width="400" /></a></div>
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0076.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0076.jpg" width="400" /></a></div>
<br />
<br />
<div style="text-align: center;">
Then the bearing retaining circlip is easily installed</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0080.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0080.jpg" width="400" /></a></div>
<br />
<br />
<div style="text-align: center;">
View from the back, ABS side</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0078.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0078.jpg" width="400" /></a></div>
<br />
<br />
Now the handbrake backing plate and actuation/adjustment mechanism can be greased, assembled, and installed. The dumb thing about this knuckle design is that once it is fully together the handbrake mechanism cannot be removed without removing the drive flange, an action which destroys the wheel bearing in the process. I guess GM thought they could make money out of selling wheel bearings as part of a handbrake rebuild!<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0083.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0083.jpg" width="400" /></a></div>
<br />
<br />
The two retaining bolts for the actuator housing and the one top bolt on the backing plate all get thread-locker - once it is finished there is no way to tighten them! The top bolt is out of view in this photo, directly above the bearing housing just under the middle-top of the handbrake shoe.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0085.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0085.jpg" width="400" /></a></div>
<br />
<br />
Next the main drive flange is pressed into the bearing. It's important here to have a supporting socket or other suitably sized spacer underneath the knuckle, with the inner bearing race resting on the spacer underneath (I used a large 3/4" drive socket, size-wise it needs to be suporting the inner bearing race). This is because the bearing inner race is actually two pieces, one on each side, which are held in place by the drive flange. Failure to support it means pressing in the drive flange will sepaate the bearing. In the end the bearing is held together by the drive flange. With the lower race supported, pressing in the drive flange forces the bearing together.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0087.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0087.jpg" width="400" /></a></div>
<br />
<br />
Insert the ABS sensor, thread-lock the retaining bolt, and voila. Finished!<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0090.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0090.jpg" width="400" /></a></div>
<br />
<br />
Repeat for the other side. I didn't time it, but I estimate that the first knuckle assembly took me at least 3 hours, the second one took 50 minutes :-)<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0092.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0092.jpg" width="400" /></a></div>
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2013/01/dscn0100.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2013/01/dscn0100.jpg" width="400" /></a></div>
<br />
<br />Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com1tag:blogger.com,1999:blog-2232015951643845193.post-62213723049597955202012-12-29T20:52:00.000+11:002012-12-29T20:52:05.529+11:00Under-Guard Body DeadenerI have painted under the wheel guards with thick and gooey body deadener. This was for two reasons, firstly to provide some body deadening (duh) and provide a more "solid" on-road sound. Second is to provide some level of protection for the paint. While the vinyl ester resin in the Classic Revival body is very strong and quite thick in places, there's always the chance that a large stone strike from under the wheel guard could cause a crack in the paint on the other side of the guard - hopefully the deadener will help to reduce that chance of this from happening.
<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/12/photo-12.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/12/photo-12.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/12/photo-22.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/12/photo-22.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/12/photo-32.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/12/photo-32.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div style="text-align: center;">
To do all four under-guards took just on half of this 4-litre tin
</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/12/photo-41.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/12/photo-41.jpg" width="400" /></a></div>
Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-13204251202758637872012-11-07T22:11:00.002+11:002012-11-07T22:11:49.576+11:00Front End Suspension Assembly<div class="separator" style="clear: both; text-align: center;">
<iframe width="560" height="315" src="http://www.youtube.com/embed/ZHrPwk3RURs" frameborder="0" allowfullscreen></iframe>
</div>
<br />Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-90791093516093344042012-10-07T22:43:00.000+11:002012-10-07T22:47:07.311+11:00Penske ShocksA couple of months ago I received the Penske shocks that I am using for my Cobra. Penske shocks are all hand-built and custom made to-order to individual specifications. They are truly a work of art, with astounding quality and finish<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/img_0109.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/img_0109.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: left;">
These shocks are the PS-7500-DA double adjustable for bump and rebound with 48 settings for compression and 20 settings for rebound, and are an adjustable coilover-spring-seat design for a 2.5" spring. These shocks are a good deal more expensive than an off the shelf shock such as AVO, QA1, KYB etc, but Penske have a reputation for being the best and if build quality is any indication then I would have to say they are up there at the top!</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/img_0103.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/img_0103.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/img_0106.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/img_0106.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/img_0107.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/img_0107.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/10/7500-da.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="http://bencobra.files.wordpress.com/2012/10/7500-da.png" width="333" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
Here are the spec sheets on the front and rear shocks that were built for me;</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/10/7500-front.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="287" src="http://bencobra.files.wordpress.com/2012/10/7500-front.png" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/10/7500-rear.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="292" src="http://bencobra.files.wordpress.com/2012/10/7500-rear.png" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: left;">
</div>
Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-44789410444680993542012-08-29T00:05:00.003+10:002012-08-29T00:08:51.004+10:00The Hunt for SeatsSeats are a problem in one of these cars. The space in the cockpit for the seats is very narrow. Coupled with the fact that to get ICV engineering approval and subsequently registration, the seats must be <a href="http://www.infrastructure.gov.au/roads/motor/design/adr_online.aspx" target="_blank">ADR</a> approved. As far as my search has taken me I have not be able to find an off the shelf aftermarket seat which both fits in the cockpit space available and is ADR approved, let alone happening across one that actually looks good. There are a couple of custom made options floating around, but frankly they're expensive and not necessarily the type of look I am after, although they do of course actually fit in the space.<br />
<br />
It's off on an OEM search we go. The current <a href="http://www.comlaw.gov.au/Series/F2006L01377/Compilations" target="_blank">ADR 3/03</a> came into publication in February 2007 and applies to vehicles manufactured after 1 July 2008, so I need seats from a car that is no older than 1 July 2008. So recently I hit the second hand car dealers one Saturday with a tape measure in hand. The plan was to find an option which fits, hopefully is aesthetically pleasing, and then source some good condition second hand units. On one Saturday I visited about 8 different car yards and measured the seats in at least 15 different cars, small cars, compacts, convertibles, sports cars, you name it, I could not find a seat which would fit in the confined space.<br />
<br />
Then the other day I was driving along behind a small car and I thought *bing* - I haven't measured that car. The car was a Suzuki Alto. In case you're wondering, a Suzuki Swift has bigger seats than the Alto. So I found a second hand Alto, measured it, and it looked promising. So a quick visit to the local Suzuki recycler and I have a pair of very good condition 2009 Alto seats, cheap too. There appears to be a couple of different options on an Alto of this vintage, some with height adjustable drivers seat and some without. I opted for without as it would just be more "stuff" I would have to remove and I would not be able to get the frame any lower with that option anyway.<br />
<br />
In some of these pictures the seats are reversed which is why the airbags are facing inwards. This was a test fit to see if they fit better on opposite sides, but both diver and passenger seats appear to be the same dimensions.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_02621.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_02621.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
I have recently been thinking that I really want to get this car on the road ASAP, so will not be spending coin on things like fancy custom made seats, interior trim, radios, etc, until after registration. With this in mind I purchased the seats and hope to make them fit.<br />
<br />
In this picture the Alto mounting brackets and sliding mechanism are still attached to the seat, as you can see the seat is too high up. That mechanism adds at least 40mm to the height.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_02571.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_02571.jpg" width="400" /></a></div>
<br />
The seats have side air bags in them which I will need to disable/remove at some point. The air bags are not required by the ADR. As a side note, ICV's have exemption from requiring front air bags, ABS, and Electronic Stability Control.<br />
<br />
Like all modern car seats the Alto seats are bulky and quite high. I have unbolted the sliding adjustor mechanisms and associated brackets, and the seats are now low enough (just) to be usable. Another 1 inch further back and 1-2 inches lower wouldnt hurt, but they're definately usable.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_02641.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_02641.jpg" width="400" /></a></div>
<br />
I will need to make some stand-off brackets to bolt the seats to the floor/chassis mounting points provided (the brackets that came on the seat prop the seat up to high in the air and are not positioned well for mounting anyway). I cannot find anything about sliding (or tilt) adjustment being <em>required</em> by the ADR, and in fact the ADR says in several places "if the seat is adjustable." I will check with my ICV engineer but if sliding adjustment is not required then I will go without for now.<br />
<br />
Removed the plastic mouldings and the slide adjustors;<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_02681.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_02681.jpg" width="400" /></a></div>
<br />
This picture shows where the tilt adjustor mechanism hits the body, stopping the seat from being placed any further back:<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_02671.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="http://bencobra.files.wordpress.com/2012/08/img_02671.jpg" width="297" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_02651.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://bencobra.files.wordpress.com/2012/08/img_02651.jpg" width="238" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_02701.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="http://bencobra.files.wordpress.com/2012/08/img_02701.jpg" width="297" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_02711.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_02711.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_02661.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_02661.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_02691.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_02691.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_02631.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_02631.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: left;">
Provided I can fabricate suitable brackets then these seats should fit the bill nicely to get the car on the road. I will not be able to accurately tell comfort level of the seat position until it's drive time, but if they prove comfortable then there's no reason why I could not get them re-trimmed and in the process shave off a bit of padding (or just have then repadded from scratch) to effectively move seating position lower and more rearward - the factory padding is very thick so there should be plenty of scope for work there.</div>
<div class="separator" style="clear: both; text-align: left;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
<div class="separator" style="clear: both; text-align: center;">
</div>
Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-6530302442191988302012-08-07T21:03:00.002+10:002012-08-07T21:19:37.807+10:00Custom-Made Ball JointsA few of us building round-tube <a href="http://www.classicrevival.com.au/" target="_blank">CR's</a> had some issues with the ball joint supplied with the front suspension so we went about finding a replacemnt. This was not a trivial task, as we needed a ball joint with a very specific sized housing to suit the suspension arm, and correct taper to suit the VZ Commodore knuckle. <a href="http://www.howeracing.com/" target="_blank">Howe Racing</a> to the rescue! The guys at Howe stepped up to the plate and made us some custom made studs to our specification, and mated to their existing "hybrid" housing we had the solution. These ball joints are very awesome, beautifully designed and machined and are totally rebuildable.<br />
<br />
<div style="text-align: center;">
From left to right we can see the dust boot, outer housing (already </div>
<div style="text-align: center;">
screwed in to the arm), stud and nut, and seat and grease nipple.</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_0212.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_0212.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
The Howe part numbers are 2247102 for the stud and 22329 for the housing</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_0211.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_0211.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
The dust boot Howe supplied is not ideal for this application as it is quite large and doesn't seat very well due to the design of the suspension arm. Five minutes at Repco solved that problem, and the TE8 dust boot ($7 / pair) is a perfect fit, and nicely concertinaed so it doesn't deform under stud deflection. The springs are not used in this application, and I may actually glue the boots on to the outer of the housing to stop them "popping" off under stud deflection.</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_0210.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_0210.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
The Howe boot on the left, TE8 on the right</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_0213.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_0213.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
After dropping the stud through the housing, the seat screws </div>
<div class="separator" style="clear: both; text-align: center;">
in to the housing, and the grease nipple screws in to the seat</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_0214.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_0214.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
The boot is a nice snug fit over the protuding part of the housing</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/08/img_0215.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_0215.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/08/img_0216.jpg" width="400" /></div>Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-42851277352291025432012-08-02T21:59:00.000+10:002012-08-02T21:59:21.693+10:00Rear disc backing platesThe rear suspension of a <a href="http://www.classicrevival.com.au/" target="_blank">Classic Revival </a>Cobra chassis uses VE Commodore suspension, except for the upper control arm which is custom made. The suspension knuckle, arms and brakes are all standard (I am using aftermarket toe-links, but more on that in a future post). In my case I will be installing brakes significantly larger than stock, partly because I will do some track days and partly because I like big brakes :)<br />
<br />
The big brakes however mean that the large rear discs will foul on the OE disc backing plates. While the backing plates on most front brake systems simply serve as stone-guards, on many rear braking systems (VE included) the backing plates also serve to hold the handbrake assembly together so the plates cannot be simply discarded. I would have liked to discard the immensely complicated (you will see in a future post) VE handbrake assembly altgoether and use a seperate small hydraulic handbrake-caliper as you see on many race cars, because it is clean, simple, and saves weight, but the approving engineer frowned on the idea of a non-OE handbrake, so the VE system will remain.<br />
<br />
To clear the large discs I am planning on using, the backing plates need to be trimmed down. This is a simple 5 minute job with an angle grinder and cutting wheel, and then cleaned up on the bench grinder.<br />
<br />
<div style="text-align: center;">
The original plate, purchased new from Holden.</div>
<div style="text-align: center;">
This is the right-hand side part number GM-92195997. The left-hand is GM-92195996.</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/07/img_0142.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/07/img_0142.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
Excess removed, easy done by clamping the plate to the table and using a cutting wheel</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/07/img_0144.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/07/img_0144.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
Cleaned up on the bench grinder</div>
<div class="separator" style="clear: both; text-align: center;">
The mounting holes etc you can see are for the handbrake mechanism</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/07/img_0145.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/07/img_0145.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: left;">
There was of course the option of using a HSV backing plate, as VE HSV uses a much larger disc than Holden VE's, however I will be using a different caliper to the HSV such that even the HSV plate would have required modification.</div>Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-16072886156096810552012-07-31T22:38:00.002+10:002012-07-31T22:38:27.528+10:00Parts are back from blastingThe suspension parts are back from being soda blasted, and have come up nice and clean. A couple of small rust spots remain which will get a dab of rust treatment, and then the whole lot will get new poly bushes and satin black enamel paint<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/07/img_0185.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/07/img_0185.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/07/img_0186.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/07/img_0186.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-48380842539698506602012-06-10T21:39:00.000+10:002012-09-24T22:31:46.074+10:00Rear Suspension Knuckles StrippedI have stripped the second-hand rear suspension knuckles now. This involved removing the drive flange, the handbrake shoes and mechanism, the OE rubber bushes, a pressed-in heim-joint and the main driveshft-carrier bearing. I bought a new 20T press from <a href="http://www.radum.com.au/catalog/">Radum</a>, it's very heavy duty, solid and works great.<br />
<br />
In the below pic you can see the two rubber bushes in the left of the knuckle, the mounting at the bottom right is where the heim joint is pressed in. First job is to get the inner flange out of the main bearing. This is not an easy job. Pressing it out would be nice, but it doesnt really fit in the press due to the width of the flange which is designed to mate the face of the disc rotor. It is standard and expected procedure (according to the GM workshop manual) that the bearing will be destroyed while removing the flange, and they're spot on. I used a large socket as a drift to knock (bash!) the flange out, and it destroyed the bearing in the process, but that's ok it's supposed to come apart at disassembly.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/20120602-165156.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/20120602-165156.jpg" width="400" /></a></div>
<br />
A 32mm socket fits perfectly.<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/20120602-165223.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/20120602-165223.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
With the flange out you can see why the bearing is destroyed in the process. The inner bearing race mates to the flange during installation, and presumably after receiving load and heat through normal operation the inner race is basically inseparable from the flange. This is why I bought new flanges in advance, I knew I wouldn't be able to use them again (<a href="http://cobra-cr3514.blogspot.com.au/" target="_blank">thanks Dave</a>).<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/20120602-165253.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/20120602-165253.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
After taking out the flange the remnants of the bearing can be seen.<br />
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/20120602-165654.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/20120602-165654.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
With the flange out of the way, there is a large circlip that needs to be removed before the bearing housing can be removed<br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/img_0068.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/img_0068.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
...and then the bearing housing can be pressed out fairly easily in the press - its a massive unit!</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/img_0069.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/img_0069.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/img_0070.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/img_0070.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/img_0071.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/img_0071.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/img_0073.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/img_0073.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/img_0075.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/img_0075.jpg" width="400" /></a></div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
Then the kncuckle is stripped and ready to go to for sandblasting</div>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<div class="separator" style="clear: both; text-align: center;">
<a href="http://bencobra.files.wordpress.com/2012/06/img_0074.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="http://bencobra.files.wordpress.com/2012/06/img_0074.jpg" width="400" /></a></div>
<br />
I have also removed all the bushes from the other rear suspension components, lower arms, trailing arms etc, they too are all heading off to be sandblasted and then will get painted up nice and new, and get new poly bushings.Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0tag:blogger.com,1999:blog-2232015951643845193.post-6501612999092399132012-05-25T22:25:00.002+10:002012-05-25T22:25:36.644+10:00Components are coming...I spoke to my local supplier today, and some components are on their way from the US for local assembly of some important parts for my build. I'm excited. Watch this space.Ben Hhttp://www.blogger.com/profile/00493240849907061028noreply@blogger.com0