The majority of kit cars are factory-assembled before they're shipped off to their new owners. This segment provides a quick tour of a manufacturer's facility to show some of the steps in that process.
Frame Construction
This particular manufacturer is distinguished from some others in that it doesn't use donor frames, or frames taken from other vehicles. The manufacturer builds a sturdy foundation for the kit car, hand-constructing a custom frame for each kit using high-quality steel tubing.
A liquid-cooled band-saw is used to cut through the tubing safely and precisely (figure A) without creating excessive amounts of heat.
Once all the frame pieces have been measure and cut, the frame builder utilizes a frame-jig (figure B), a fixture that holds the varying lengths of cut frame in place to ensure that all components fit together precisely and correctly. Elements are then clamped into place and welding can begin.
The pieces are first joined together with a tack-weld. The welder then comes back and completes each connection with a finish weld (figure C). This kind of professional welding results in a high-quality "bead," indicating a secure bond. If the kit purchaser requests, the welded seams can also be sanded and finished off smoothly.
Once the custom frame is completely assembled, it can be painted or powder-coated. In our case, a powder-coating was used, creating a more durable finish that is resistant to chips and scratches. The coating is applied by an electrostatic process, in which the metal surface is sprayed with powder particles of opposing electrical charges. Once the coating is applied, the parts are then baked to ensure a very durable bond.
Body Construction
The vehicle body is made from fiberglass. Although some manufacturers simply spray the fiberglass into a mold, in our case fiberglass mats are actually installed into the mold in layers. This process ensures a lighter, more rigid and more durable structure.
The mats are first saturated with resin (which acts as an adhesive as well as a hardener), then carefully laid in place in the mold (figure D). Once each mat is placed, any excess fiberglass is trimmed away. Additional layers are applied -- in some areas as much as seven layers thick. A roller is used to remove any air bubbles, ensuring a smooth surface.
The body-mold itself can be rotated to allow access into more difficult areas such as wheel-wells and fenders. Great care must be used when placing the mats into these areas so that they will follow the curves and contours of the mold without wrinkling. When the fiberglass has cured, all the edges are sanded to ensure a smooth, clean release of the structure from the mold (figure E). This mold comes off in three separate pieces, leaving two seams -- one across the front fender and one across the rear quarter.
The fully formed body has a fair amount of flex in it, so it is then lowered onto an underbody, which will make the entire structure more rigid (figure F). The two main components, the body and underbody, are joined together with a process similar to that used to create the body. Resin-soaked mats are used to secure the components together. A jig, similar to the one used to hold the frame-pieces in place, is used to provide support for the body structure and line everything up correctly, while the resin causes the two portions to adhere.
Once the body is fully formed, it can be placed on a frame, where holes can be cut to accommodate various accessories like headlights and taillights and small holes can be drilled for the mounting screws that secure the accessories. Once all of the holes are in place, accessories such as the windshield (figure G), taillights, headlights, fuel-fill cap and optional rollbar can be installed. If a rollbar is installed, it is bolted directly to the frame to ensure a safe, secure fit.
Suspension System
Once the frame is finished and powder-coated, it is ready to receive the suspension system and rear differential. In the case of our Cobra replica, a high-end donor-vehicle rear suspension is installed. The independent rear-suspension (figure H) is wheeled into place and then secured in place with bolts. This system utilizes dual rear shocks and springs, and in-board disc brakes (figure I).
Once the rear suspension has been installed, the custom-designed front suspension can be moved into position ( figure J) and installed. The adjustable system is bolted into position on the front frame-rail.
Fully adjustable shocks and springs (figure K) are also a feature on this kit. The suspension is of the double-wishbone variety.
With the front and rear suspension installed, the steering column is put into place for the rack-and-pinion steering, the steering-shaft bearing is placed over the column, and the front sway-bar is attached and tightened down (figure L).
Aside from the high-quality craftsmanship that goes into this particular component vehicle, it is actually delivered to the buyer as a "rolling chassis," simplifying much of the process for the do-it-yourselfer.
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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