The replica car comes in what is known as a pallet kit -- usually a partially assembled vehicle "skeleton" that includes the frame, the suspension, the molded body and some of the accessories. The state of assembly or disassembly may vary somewhat according to the manufacturer you've selected. The CobraB.-replica kit that we selected for this demonstration comes with a rolling chassis, the unpainted body, and a number of components and accessories that are prefitted onto the body. The initial phase of this project involves removing the unfinished body from the frame, and then removing a number of those accessories and safely storing them away. Disassembly will ready the body for painting and the chassis for installation of the engine and drive train. To some extent the ease with which the overall project will come together relies on these initial steps. Most kits are manufactured so that no specialized tools are required for working with the body, chassis and accessories -- just ordinary automotive tools, including a complete set of wrenches, drivers and a cordless power drill. Oddly enough, the first steps in building a replica vehicle have mainly to do with disassembly. Accessories such as the dash and instrument panel (figure A), windshield, headlights, taillights and door latches (figure B) all need to be removed from the body before it can be sent out for painting, and the body must be removed from the chassis before the engine and transmission can be installed. The process of removing these and other components provides good experience for the builder of the kit car since it gives a good indication of how the parts fit together and what will be required for their final installation. Tip: As you begin the disassembly process, keep a supply of ziplock bags handy for storing smaller parts as you remove them (figure C). By labeling and storing parts in this way, you minimize the risk of losing or mixing up parts. Before even beginning disassembly, however, take a complete inventory of all of the parts that come with the vehicle -- both the ones that are preinstalled and the ones that come packed separately, such as (in our case) the carpet pieces and upholstered door panels (figure D). You can use your packing invoice (figure E) as a checklist for conducting your inventory.
A Few Things to Keep in Mind
- Building a kit car is an advanced project and one best suited for individuals with a considerable amount of experience and expertise in automotive mechanics, and some basic knowledge of electrical wiring. Even for experienced automotive do-it-yourselfers, completion of all phases of the project may require several weeks (or even months) of diligent work, not to mention an ample amount of work space and a sizable personal and financial commitment. The quality of the final product will rely, to a large extent, on the planning and preparation that takes place before the project is begun.
- As alluded to above, the process of building a kit car not simply a linear process of assembling all the pieces. In a number of stages, a process of disassembly and reassembly is required -- and in some cases that process will be repeated several times. This principle applies to working with engine components as well as elements of the body and chassis. This process of building, unbuilding and rebuilding facilitates the type of precision that will ultimately result in a finely tuned vehicle that will perform at peak specifications.
- This workshop series is intended to serve as an informative overview of the major steps involved in this ambitious project, but it should not be regarded as a comprehensive how-to manual. That level of detail can be provided only by the vehicle-manufacturer that you select and will be covered thoroughly in the assembly manual that comes with your component-vehicle kit (figure F). It is vital that all such assembly instructions be read and followed thoroughly. It is important to note that there are many steps in building this high-performance vehicle that require exacting accuracy, and that there may be critical differences from one manufacturer or model-variation to another. The steps shown in the demonstrations throughout this series are according to the recommendations of the manufacturer of our particular replica-kit and were supervised by our expert, who has built a number of vehicles from kits purchased from that manufacturer. Read and follow the assembly instructions and diagrams that come with your particular kit.
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
kitcar.com
A site devoted to high-end kit cars, from the same organization that offers cobracountry.com. Established by enthusiast Curt Scott, and maintained by Crown Communications of Santa Clarita, CA, the site contains news, articles archives, a directory specialists and manufacturers, and more.
Web site: www.kitcar.com
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