Installing the Engine, Transmission, Exhaust System The final steps in the assembly of a CobraB.-replica are just as critical as the first. With the transmission and engine mated together (see episode 104 of DIY's Build a Kit Car, the entire power-plant is ready to be mounted on the chassis. Once that's done, the basic structure of the vehicle -- excluding the body and exterior accessories -- is essentially done. At that point, the assembly will include the close-ratio four-speed transmission hooked up to a performance rear-end, a customized exhaust system that's itself a work of art, a rigid custom-built chassis, a performance suspension and a 427 engine capable of out-performing nearly anything else on the road. Because of the careful planning and methodical assembly that's gone on thus far, the installation of the engine, transmission and exhaust system onto the chassis is simpler than one might imagine. The engine-transmission assembly is suspended on a roll-around engine hoist. It's very important to have a reliable hoist to safely install your engine, and for this installation a 3-ton engine hoist is recommended. If you don't choose to purchase this piece of equipment, you may rent one. The engine and transmission, which are installed as a single unit, have a combined weight of around 675 pounds. To provide ease of access for installing the big-block engine onto the chassis, the right-front wheel and tire are removed from the rolling chassis. Maneuvering the engine/transmission assembly into place is a two-person job. One steadies the suspended engine while the other rolls the hoist to position the assembly for lowering onto the chassis (figure A). The engine is carefully lowered until the engine rests in the engine-mounts and the end of the driveshaft lines up flush with the rear-end differential. With the engine sitting squarely on the mounts, it is secured in place with washers and nuts (figure B). The driveshaft rests securely in a cradle (figure C). With the driveshaft aligned correctly with the differential, the two are joined together using nuts and bolts. Thread-locking compound is used on the bolts (figure D ) to ensure that they will not come loose later because of use and engine-vibration. Once the engine and transmission are installed, and the driveshaft is coupled with the rear end, the starter may be put into position and installed using three mounting bolts (figure E). The next steps in the process comprise installation of the impressive exhaust system. Since this part of the process requires lifting sizable parts into place, and holding them in position while they are secured, this is another part of the assembly that is best done with at least two people. For the first major step, the header pipes are attached to the heads. Before positioning the header pipes, however, adhesive is applied to the head at the attachment point (figure F). In order to avoid any exhaust leaks, sealant is applied around the exhaust ports on both the head and the header flange (figure G). The sealant also helps to hold the head gasket in position as the pipes are installed. The head gasket is put into place (figure H) and the header is carefully lifted into place, being careful not to allow the gasket to shift. As the header pipes are held in position, the mounting bolts are installed and tightened down(figure I ). With the header pipes installed, the next step is to install the side pipes. As before, sealant is applied to the surfaces where the header and side-pipes are joined (figure J). The side pipe is lifted into place and secured with bolts (figure K). The side-pipes are long and cumbersome, but not difficult to installed if there is a second person assisting in the process. The same process is repeated on the other side of the vehicle, and the front wheel and tire are re-installed. At this point, the wiring harness for the vehicle's electrical system is installed according to the manufacturer's instructions, as well as the foot-box heat shields that protect the passenger compartment from the heat that will be given off by the exhaust system. The heat shields, which are provided by the kit manufacturer, consist of layered fiberglass and foil. They are installed between an aluminum panel and the foot-box on both sides of the vehicle.
RESOURCES :
cobracountry.com
Premiere online resource for all things related to CobraB. reproductions. Established by enthusiast Curt Scott, and maintained by Crown Communications of Santa Clarita, CA, the site contains news, articles archives, a directory of Cobra-replica specialists and manufacturers, aftermarket sources, announcements of upcoming shows and rallies, listings of Cobra clubs, links to other Cobra sites, and more.
Cobra Country
Website: www.cobracountry.com
Unique Motorcars
Unique Motorcars
(Unique Cobra Specialists)
Manufacturers of high-quality Cobra® replicas since 1977, Unique Motorcars also maintains an informational and well-illustrated web site providing information about their Cobra reproductions and related products. Assembly manuals for their kits (including the one used in DIY's Build A Kit Car workshop) are available on their site.
230 E. Broad Street
Gadsden, AL 35903
Phone: 256-546-3708
Web site: www.uniquecobrareplicas.com
Information also available at:
www.cobracountry.com/unique
The Cobra Story: A Man, His Dream and His Automobile
Author: Carroll Shelby and John Bentley
1965, Trident Press
Carroll Shelby website
Shelby Cobra: The Shelby American Original Color Archives 1962-1965
Model: 0879387572
Author: Dave Friedman
(1994)
To order this title from Amazon.com, click here.
Motorbooks International (MBI Publishing)
Essential AC Cobra : The Cars and Their Story 1962-67
Model: 1870979850
Author: Rinsley Mills
(1997)
To order this title from Amazon.com, click here.
Motorbooks International (MBI Publishing)
Shelby Cobra Gold Portfolio, 1962-69
Model: 1855200236
Author: R.M. Clarke
(1990)
To order this title from Amazon.com, click here.
Motorbooks International (MBI Publishing)
Carroll Shelby's Racing Cobra
Model: 0850454573
Author: Dave Friedman and John Christy
To order this title from Amazon.com, click here.
Motorbooks International (MBI Publishing)
Shelby's Wildlife: The Cobras and Mustangs
Model: 0879380454
Author: Wallace A. Wyss
To order this title from Amazon.com, click here.
Motorbooks International (MBI Publishing)
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