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Gregs '65 Shelby AC Cobra Build (FFR)

by GREG M   

Start Here To Read The Build Experience

Start Here To Read The Build Experience
Welcome to my FFR MKIII Roadster build site. The purpose of this site is to...

Another view from the rear

Another view from the rear
My car on GearZ TV:...

A Car With A Full Rollbar

A Car With A Full Rollbar
My rollbar is like this full chrome style. I will make it removable...

This is what started the Cobra bug

This is what started the Cobra bug
My dad had a 1965 Sunbeam Tiger (also a Shelby modified British car)...

I can't help it. I Like Sunbeam Tigers

I can't help it. I Like Sunbeam Tigers
I just had to include one more pic of the Tiger. Even after seeing the...

Here's how most other replicas are built

Here's how most other replicas are built
I wanted to show why I purchased my replica from Factory Five Racing. Take a...

The 427 AC Cobra frame (FFR)

The 427 AC Cobra frame (FFR)
The Factory Five 427 Shelby AC Cobra tubular steel space frame. It...

A real Shelby AC Cobra frame

A real Shelby AC Cobra frame
The FFR frame started like this original Cobra frame and includes...

Another Example Of A Non FFR Frame

Another Example Of A Non FFR Frame
This is the Superformance Cobra frame. It's officially licensed by Carol...

The floor of most other replicas

The floor of most other replicas
With most of the other replicas, you get "dune buggy"...

Factory Five replica - body off

Factory Five replica - body off
Here's a completed FFR replica in go-cart stage. It's a...

The dash of the other replicas

The dash of the other replicas
Fiberglass everywhere. Take a look at the floor, dash, transmission...

Other replica's interior

Other replica's interior
It looks OK but the dash just sets in a fiberglass frame. Looks...

The Cobra Den on 10/11/04

The Cobra Den on 10/11/04
Enough of the history lesson let the fun begin! The day of the new arrival. I...

Day-1 of build

Day-1 of build
The car arrived at midnight so I didn't get much sleep. I'm looking a...

Polishing all visible aluminum panels

Polishing all visible aluminum panels
12/04, I made the decision early on to polish all the alumunim panels...

Polished trunk after rough polishing

Polished trunk after rough polishing
Directional buff marks visible. Will be removed on final buff with...

Polishing firewall off the car

Polishing firewall off the car
Polishing the firewall in the foreground, see the difference between how the...

Polished footbox with side extension

Polished footbox with side extension
My homemade aluminum footbox extension was added to get a little more...

Footbox as received before mod or polish

Footbox as received before mod or polish
Footbox and aluminim panels as shipped from FFR.

Footbox after Mod - Version1.0

Footbox after Mod - Version1.0
11/04, Gained myself 1.25" to the right side of the loud pedal....

Footbox Mod Version-2.0

Footbox Mod Version-2.0
01/05, Got snake bit on this one. Had to cut off the corner of the newly...

Drivers footbox corner finished

Drivers footbox corner finished
Footbox extension finished after cutting off the corner that was part of the...

Front Suspension-left

Front Suspension-left
Adjustable upper control arm, tubular lower control arm, Bilstein coil-over...

Gotcha-1, front lower control arm mount

Gotcha-1, front lower control arm mount
The FFR front lower control arms need the washer shown of the left...

Adjustable Upper Control Arm-left

Adjustable Upper Control Arm-left
Makes setting the caster and camber easier. NOTE: Later, when setting up the...

'94 - '95 SN95 Spindle Is The Favorite

'94 - '95 SN95 Spindle Is The Favorite
Only the '94 - '95 Mustang front spindle maintains the same Fox width...

Bump Steer Error - '95 and '96 SN95's

Bump Steer Error - '95 and '96 SN95's
How bumpsteer is affected using the Fox width 1994-95 SN95 spindles...

PBR brake and tubular lower control arm

PBR brake and tubular lower control arm
PBR dual piston front brakes with stainless braided soft line. The '94 -...

3-link Rear Suspension Upgrade

3-link Rear Suspension Upgrade
1991 Mustang GT 8.8" limited slip rearend, 11" disc brakes, Bilstein...

Rear Brake Line Connector

Rear Brake Line Connector
That little $4 brass fitting on the left is the discontinued Ford...

Home Fabricated BatteryBox and TrunkBox

Home Fabricated BatteryBox and TrunkBox
01/05, Underfloor trunk box fabricated from 0.060 plate aluminum. Adds...

Top View of Recessed Home Fabricated Box

Top View of Recessed Home Fabricated Box
I fabricated this box from .060" aluminum plate with a billet hold...

Storage Compartment Thumbscrew Mounting

Storage Compartment Thumbscrew Mounting
Opening to underfloor trunk storage. Detail of mounting block for stud...

Battery Box Hold Down Detail

Battery Box Hold Down Detail
I made a billet aluminum bar that holds the battery down and captures...

Side View Of Home Fabricated Battery Box

Side View Of Home Fabricated Battery Box
Lots of rivets and adhesive bonding make the box super rigid. Polished...

Underside Of Home Fabricated Battery Box

Underside Of Home Fabricated Battery Box
From underneath, you can see the two 1/4 20 stainless hold down rods poking...

EFI converted for carb - SEE NOTE

EFI converted for carb - SEE NOTE
01/05, I removed the old EFI fuel pump and fabricated a 3/8" metal...

Top view - electrical connector removed

Top view - electrical connector removed
I removed the plug and soldered the holes closed. I also removed the...

Front end with rough polished aluminum

Front end with rough polished aluminum
2/07/05, a nice day. Rolled the chassis out and took a few pics of the...

Front suspension, clutch & brake pedals

Front suspension, clutch & brake pedals
Pedal box from 2002 donor Mustang GT. I heated and bent the Mustang...

Master cylinder and brake lines

Master cylinder and brake lines
A view of the hard break line routing. Ford Racing proportioning valve is...

Front brake hard lines bent & installed

Front brake hard lines bent & installed
Started with a roll of 3/16" steel brake line. Cut, bent, double...

Mallory Comp 110 electric fuel pump

Mallory Comp 110 electric fuel pump
Home fabricated 1/8" thick aluminum mounting bracket and 3/8"...

Fuel pump and brass plumbing

Fuel pump and brass plumbing
I built an aluminum bracket and riveted it to the 2" downtube to...

Fram fuel filter and fuel line

Fram fuel filter and fuel line
2/12/05, I fabricated a bracket to hold the fuel filter from 1/8"...

Fuel tank from a '91 Mustang GT

Fuel tank from a '91 Mustang GT
Fuel tank is installed to check for fit. Tank was from a '91...

Final polishing a week before coating

Final polishing a week before coating
03/12/05 - Here's the labor of love. Many hours of polishing left...

A close up of polished finish

A close up of polished finish
About as shiny as you can get. I will compare the shine now and after clear...

Pedals including my home made gas pedal

Pedals including my home made gas pedal
My center-to-center pedal spacing is 4.25" between the clutch and...

Home Fabricated Gas Pedal Close Up

Home Fabricated Gas Pedal Close Up
Here's a better view of the gas pedal. What you are looking at here is a...

FMS GT40 E-cam crate engine

FMS GT40 E-cam crate engine
The Ford Racing crate GT40 302 V8 (220 duration - 0.498" lift) with X303...

Pulleys and Accessories

Pulleys and Accessories
05/02/05 - Finally obtained all the pulleys, mounts/tensioner, and...

A/C And Power Steering Bracket

A/C And Power Steering Bracket
A close-up shot of the A/C and PS bracket installed.

SVO Roller Rockers and Crane distributor

SVO Roller Rockers and Crane distributor
A nice view of what's under those polished valve covers. X303...

The Same Engine As Mine On A Dyno

The Same Engine As Mine On A Dyno
Here's a rear wheel dyno plot of the same engine, cam, carb and...

Power With The Ford E-Cam (Crane2040)

Power With The Ford E-Cam (Crane2040)
I copied this flywheel horsepower dyno chart from a magazine that...

Aluminum Polish before anodizing

Aluminum Polish before anodizing
03/21/05, I found this stuff works better for polishing aluminum if YOU DRINK...

Same panel after clear coat anodizing

Same panel after clear coat anodizing
Here's the results of soaking 15 minutes with 12V connected in a tub of...

All of the polished aluminum panels

All of the polished aluminum panels
Here are the 30+ panels all highly polished along with 13 other misc...

A/C, heater, defroster, behind dashboard

A/C, heater, defroster, behind dashboard
Quality Roadsters climate control setup. I added an extra aluminum panel to...

Fabricated Cover for Q.R. A/C System

Fabricated Cover for Q.R. A/C System
Here is the exterior of the Quality Roadsters unit. I fabricated the polished...

Lucas Wiper Motor from a '60's MG

Lucas Wiper Motor from a '60's MG
I picked this up from an MG salvage yard along with a 37" drive...

Riveting polished and coated aluminum

Riveting polished and coated aluminum
5/15/2005, first day of riveting newly coated and polished aluminum panels;...

Engine bay on Memorial Day weekend 2005

Engine bay on Memorial Day weekend 2005
Polished and coated aluminum panels were riverted on the firewall,...

Memorial Day weekend 2005

Memorial Day weekend 2005
Started the wiring and filled/bled the power brakes.

Memorial Day

Memorial Day
Installed and wired the starter solenoid to the homemade polished...

Memorial Day 2005

Memorial Day 2005
Homemade engine bay filler panel and polished passenger side footbox.

Memorial Day 2005

Memorial Day 2005
A photo of the mocked up radiator. A shot of the modification to the...

Memorial Day 2005

Memorial Day 2005
A shot of the completed steering shaft, rear brake proportioning valve, brake...

Memorial Day 2005

Memorial Day 2005
Mocked up the AFCO dual core aluminum racing radiator and completed...

Memorial Day 2005

Memorial Day 2005
A shot of the homemade aluminum panel for mounting the solenoid. A...

Memorial Day 2005

Memorial Day 2005
That mess will someday be a nicely bundled wiring harness.

Memorial Day 2005

Memorial Day 2005
Radiator position is mocked up and work to fabricate an alumunium...

Memorial Day 2005

Memorial Day 2005
Fuse panel installed under dash on a homemade alumunim mounting plate....

Memorial Day 2005

Memorial Day 2005
The battery cut-off switch is installed and wired up between what will be the...

Memorial Day 2005

Memorial Day 2005
A shot of the rear and the body on the buck. Body work to start soon.

Memorial Day 2005

Memorial Day 2005
Wiring the rear of the car. Main power cables run inside the...

06/05/2005 - The engine went in today

06/05/2005 - The engine went in today
GKCobra (Gregg) and I installed the engine. It took about 3 hours from...

Engine raised to the ceiling

Engine raised to the ceiling
Almost ran out of room and hit the rafters.

Getting her lined up

Getting her lined up
It's amazing that whole load is supported by a plate bolted to the carb...

Engine is in + one week

Engine is in + one week
6/12/05 One week after I dropped the engine in. To make use of the...

Homemade upper radiator support

Homemade upper radiator support
6/12/05 completed the homemade upper radiator support. It's...

Homemade radiator fan mounting bracket

Homemade radiator fan mounting bracket
The supplied FFR fan was inadequate for a car with A/C so I had to replace it...

Homemade lower radiator support

Homemade lower radiator support
6/12/05 completed the homemade lower radiator support. The mount is made from...

6/26/05 pedal box - flexing resolved

6/26/05 pedal box - flexing resolved
After setting up the clutch, I noticed the pedal box torques to the...

6/26/05 Lucas wiper motor installed

6/26/05 Lucas wiper motor installed
Wiper motor installed nicely next to the A/C unit.

Fabricated Expansion Tank Bracket

Fabricated Expansion Tank Bracket
6/26/05 - Since I'm using the serpentine belt drive and spring...

Expansion Tank Bracket-top view

Expansion Tank Bracket-top view
Antother view.

Engine bay 7/15/05 A/C & Expansion tank

Engine bay 7/15/05 A/C & Expansion tank
Finished the custom modifications to the mid '60's big block Ford...

Expansion Tank Mods - Underside

Expansion Tank Mods - Underside
7/15/05 - I fabricated a collar to reinforce the joint where the lower pipe...

7/15/05 Expansion Tank and Headers

7/15/05 Expansion Tank and Headers
A shot of the clearances in the area of the tank.

7/15/05 Engine bay

7/15/05 Engine bay
Mounted the power steering fluid resorvoir with a custom made polished...

7/15/05 Engine bay and A/C compressor

7/15/05 Engine bay and A/C compressor
Napa crimped all the A/C hoses for $10. The coolant hose from the water...

Ignition Wires Left Side

Ignition Wires Left Side
I purchased the 9mm spiral core ignition wires from Ford Racing. I...

Ignition Wires Right Side

Ignition Wires Right Side
A view of how the wires run on the right side. The same 3.25" spacing is...

7/22/05 Throttle Cable Bracket

7/22/05 Throttle Cable Bracket
I fabricated a polished aluminum bracket to mount the stock EFI...

7/22/05 Detail of Throttle Return Spring

7/22/05 Detail of Throttle Return Spring
The throttle return spring mounts under the bracket. The cable slack is...

Fords Hydroboost Layout

Fords Hydroboost Layout
I followed this when designing the custom hose routing for the Hydroboost PS/PB.

Installing the Hydroboost hoses

Installing the Hydroboost hoses
8/8/05 - I had the hard sections of the stock power steering/brake...

Hydroboost hoses - another view

Hydroboost hoses - another view
The hoses will be secured to the frame with aluminum clips. I'm using an...

Detail of Hoses at Rack and T-fitting

Detail of Hoses at Rack and T-fitting
A view of the home fabricated bracket that holds the power steering hose from...

8/13 - Preliminary Dash Layout

8/13 - Preliminary Dash Layout
I began working the dash layout to make sure all instruments and...

Behind The Dash

Behind The Dash
8-13-05 A shot of what's going on behind the dashboard. The Quality...

Hidden AC controls -behind glovebox door

Hidden AC controls -behind glovebox door
8-13-05 AC Cobras didn't have A/C so I didn't want mine to...

Hidden AC controls - rear view

Hidden AC controls - rear view
A view of the rear of the panel and how the 3 controls were squeezed into the...

8/13/05 - Radiator, Hoses and Wiring

8/13/05 - Radiator, Hoses and Wiring
I mocked up the radiator again to check the fit of the home fabricated upper...

8/13 PVC Lower Radiator Hose Mock-up

8/13 PVC Lower Radiator Hose Mock-up
I worked out a clean design for the lower radiator hose that combines...

8/13 - Wiring Diet on Supplied harness

8/13 - Wiring Diet on Supplied harness
The supplied harness was designed for a much longer vehicle so I...

Halibrand Chrome Cobra III Wheels

Halibrand Chrome Cobra III Wheels
9/5/05 The 17 X 9 front and 17 X 10.5 rear Halibrand Cobra III...

Front Halibrand With Flat Center Cap

Front Halibrand With Flat Center Cap
Here is the front wheel before the knock-off was added. Note the PBR...

Rear Halibrand

Rear Halibrand
The rear wheel-no issues with brake clearence either. All the lugs are...

Wheels After Knockoffs and Tires Fitted

Wheels After Knockoffs and Tires Fitted
9/6/05 - Mounted the Sumitomo tires and installed the spinners...

9-07-05 The Body Work Begins

9-07-05 The Body Work Begins
Actually last weekend (all weekend!) I rolled the fender lips over nice and...

Grinding The Mold Parting Lines Down

Grinding The Mold Parting Lines Down
I used an angle grinder to knock down the mold parting lines on the...

Black Leather Hide - For Dash and Doors

Black Leather Hide - For Dash and Doors
09/23/05, I purchased a full cow hide to cover the dash and make door panels...

Mold For Rolled Rear Cockpit Edges

Mold For Rolled Rear Cockpit Edges
09/25/05. I made a mold to apply large sections of Rage Gold by...

Mold Removed

Mold Removed
I pulled off the mold and removed the tape. It makes a very uniform radius.

Rolling The Rear Cockpit Edges

Rolling The Rear Cockpit Edges
Here is the process: Sand the gelcoat with 40 grit paper and clean...

Dipsticks-not elegant but neccessary

Dipsticks-not elegant but neccessary
10/01/05 - I fabricated a new dipstick and tube because the one that...

Cutting the Aluminum Dash

Cutting the Aluminum Dash
10/16/05 The car is a year old now. This fall morning was too cool to...

Dash Layout - Final Design

Dash Layout - Final Design
10/16/05 - Completed the final dash design layout. The aluminum dash and home...

Dash Covered By 2 Layers of Leather

Dash Covered By 2 Layers of Leather
11/2/05 - Covered the dash with 2-layers of leather and installed the...

Home Fabricated Glove Box Door

Home Fabricated Glove Box Door
11/3/05 - I custom fabricated a glovebox door because I think the dash needs...

Door Viewed From Inside of Dash

Door Viewed From Inside of Dash
That red stuff on the left side isn't paint! Exacto knives are sharp. The...

Wired and Connectorized The Dash

Wired and Connectorized The Dash
11/10/05 - Completed the wiring of the dash and placed 2 connectors near the...

Detail of Lock and Stainless Pull

Detail of Lock and Stainless Pull
The lock and pull are from an RV store. I polished the pull on the...

Detail Of Washer Under Switch

Detail Of Washer Under Switch
This photo illustrates how the two layers of leather compress. It also...

Thanksgiving Day 2005 Progress pic

Thanksgiving Day 2005 Progress pic
11/24/05 - Finished installing the wiring, tested all the circuits,...

Main Wiring Behind The Dash

Main Wiring Behind The Dash
11/24/05 Completed the wiring and testing. To the left you can see the 3...

Top View of Relays and Wiring

Top View of Relays and Wiring
11/24/05 - A top view. The blinker assembly fits on the steering...

Wiring In The Footbox With The MSD Box

Wiring In The Footbox With The MSD Box
11/24/05 - A view of the wiring inside the footbox and the top of the fuseblock.

Wiper 2-speed And Parking Diagram

Wiper 2-speed And Parking Diagram
Here's the electrical diagram I used to make the wiper system run in 2...

Dash Support Tubes

Dash Support Tubes
12/10/05 - Fabricated a pair of brackets and dash support tubes. The FFR does...

Dash Support Tubes

Dash Support Tubes
A close up view of the home fabricated brackets and how they attach to the...

Dash Support Tubes and Speedo Input

Dash Support Tubes and Speedo Input
A shot of how the tube lines up with the input to the reverser gear on the...

Fabricated New Emergency Brake Bracket

Fabricated New Emergency Brake Bracket
1/21/06 - The worst thing about the FFR replica is the location and...

Ebrake Bracket With Lever

Ebrake Bracket With Lever
1/21/06 - Note how the ebrake lever is accessible even when it's...

Modifications To The Lever

Modifications To The Lever
I found this information on another builder's site but it was...

Ebrake Clearance With Seat Installed

Ebrake Clearance With Seat Installed
Here's a shot of the ebrake with the seat installed. It fits...

Ebrake - Top View

Ebrake - Top View
An overhead shot here. I will fabricate a leather boot to dress the...

Ebrake Cable Installed

Ebrake Cable Installed
I cut the stock balance T-bar down reducing it's spread and...

Top View Of the Ebrake cables

Top View Of the Ebrake cables
There is plenty of clearance between the cables and the driveshaft and each...

New Style FFR Ebrake Boot Installed

New Style FFR Ebrake Boot Installed
Since I relocated the ebrake lever to the side of the transmission tunnel, I...

Finished The Cockpit Aluminum

Finished The Cockpit Aluminum
2/3/05 - Completed riveting all of the cockpit aluminum panels. Test...

Cockpit and Dash Layout - ALUMINUM!

Cockpit and Dash Layout - ALUMINUM!
These cockpit shots illustrate just how well built the Factory Five...

Hidden A/C Controls & Fire Extinguisher

Hidden A/C Controls & Fire Extinguisher
The A/C controls are hidden inside the glovebox on their own leather panel. I...

Rear of The Cockpit

Rear of The Cockpit
A shot of the rear aluminum wall and the home fabricated storage compartment....

Rear of The Cockpit

Rear of The Cockpit
A view from the other side.

Paint Scheme Inspired By Nature

Paint Scheme Inspired By Nature
2/09/06 - Our first snowfall of the season inspired a paint scheme. On a side...

Adding Bump Stops To Bilstein Shocks

Adding Bump Stops To Bilstein Shocks
3/03/06 - There has been some evidence that these shock can fail if...

Bump Stop Installed On the Shaft

Bump Stop Installed On the Shaft
The rubber part fits very tightly on the shaft. There is no way it will ever...

Unmodified VS Modified Rubber Part

Unmodified VS Modified Rubber Part
The modified piece is on the right.

Re-Assembled Shock

Re-Assembled Shock
A view with the shock re-assembled.

Shock Fully Compressed Against Stop

Shock Fully Compressed Against Stop
I removed the coil spring and jacked up the lower control arm to check for...

Body Mounted Back On The Frame

Body Mounted Back On The Frame
3/5/05 - I mounted the body back on the frame after being off for the last 16...

Hood Trimmed and Centered To Body

Hood Trimmed and Centered To Body
3/11/06 I trimmed the hood edges to set the required 3/16" gap. The hoop...

Trunk Fitted and Centered

Trunk Fitted and Centered
3/18/06 - Fitted trunk lid and set 3/16" gaps. The trunk was off...

Drivers Door - Test Fit

Drivers Door - Test Fit
I test fit the door and I was very surprised to see it acually lined...

Molded a Trunk Lid Seal To The Body

Molded a Trunk Lid Seal To The Body
4/1/06 - I needed to place spacers under the trunk lid to adjust the...

Close-up Of The Molded Trunk Edge Seal

Close-up Of The Molded Trunk Edge Seal
Here's another view. The seal is 1/4" away from the body, is...

Making The Seal With Rage Gold

Making The Seal With Rage Gold
I used some 1/4" wide foam weatherstrip to set the distance from...

Making A Perfect 3/16" gap , Step - 1

Making A Perfect 3/16" gap , Step - 1
4/15/06 - The first step is to clearance the hood edges to about...

Step -2

Step -2
Apply 3/16" self adhesive foam weather stripping to the hood opening.

Step - 3

Step - 3
Place the hood back on being carefull to keep the proper alignment.

Step - 4

Step - 4
Force body filler into the gap between the hood edge and the weather...

Step - 5

Step - 5
Remove the weather stripping and sand the ridge off the hood edge. You should...

Molded A Fiberglass Scoop Extension

Molded A Fiberglass Scoop Extension
5/1/06 - I'm extending the hood 1.5" under the scoop. This mess is a...

Re-do Of The Rolled Dash Cowl Edge

Re-do Of The Rolled Dash Cowl Edge
I rolled the dash cowl edge on the buck and may have molded in a curve...

Installed All The Fender Splash Panels

Installed All The Fender Splash Panels
5/2/06 - Trimmed and fitted all of the inner fender splash panels....

Fitted The Doors And Hood

Fitted The Doors And Hood
I fitted the doors and hood. It took several days to accomplish this....

Finally A Roller

Finally A Roller
5/08/06 - For the first time in 18 months the car is sitting on the...

Side View

Side View
The doors need to be fared into the body sides and the gaps set. Exhaust and...

Side View-2

Side View-2

Front View

Front View
I spent days aligning the hood and scoop. And days getting the hood to close...

Hood Alignment OR "Misalignment"

Hood Alignment OR "Misalignment"
An Overhead shot of the hood fit and how close I got the hood scoop to being...

Placement Of Wiper Boxes On Body

Placement Of Wiper Boxes On Body
I used this layout to drill the holes for the windhield wiper boxes....

The Ralph Nader Bumper Installed

The Ralph Nader Bumper Installed
05/11/06 - Installed a bumper inspired by Ralph Nader. Actually...

Rolled The Door Into the Dash Cowl

Rolled The Door Into the Dash Cowl
06/04/06 - Completed rolling and fitting both doors, the rear cowl and...

Rolled The Door Into The Rear Cowl

Rolled The Door Into The Rear Cowl
Here's the rolled edge transition from the driver's door into...

Body Filler On Driver's Door

Body Filler On Driver's Door
Here's what it took to blend the driver's side door edges into...

Passenger Door Body Filler

Passenger Door Body Filler
Here's the passenger door. It fit better than the driver's side.

Home Fabricated Billet Door Strike Mount

Home Fabricated Billet Door Strike Mount
6/11/06 - The FFR supplied tab on the door frame did not line up with...

Cut Off The Original Hood Scoop

Cut Off The Original Hood Scoop
6/17/06 - I cut off the hood scoop in preparation for installing a new...

Added The New Bolt-on FFR Scoop

Added The New Bolt-on FFR Scoop
6/22/06 - Here's the new FFR scoop trimmed and aligned within...

Close Up Of The New Scoop

Close Up Of The New Scoop
I will be extending the hood by 1.5" into and under the scoop for a more...

Hood Centering Pin And Bracket

Hood Centering Pin And Bracket
06/25/06 - The hood had a tendancy to move from side-to-side near the...

Hood Centering Pin

Hood Centering Pin
Here's the adjustable hood pin mount.

Pin and Bracket Engagement

Pin and Bracket Engagement
Closing the hood shows how the parts align.

Rolled Fender Edges

Rolled Fender Edges
I did these a few months ago but wanted to include a photo of the...

Rolled Fender Edges

Rolled Fender Edges
Here's a shot of the lower end of the rear passenger fender. I...

Home Fabricated Lower Radiator Hose

Home Fabricated Lower Radiator Hose
7/23/06 - I took a break from the body work and prepared for the first...

Lower Radiator Hose

Lower Radiator Hose
Another shot showing the hose as it turns toward the radiator. I built...

Lower Radiator Hose

Lower Radiator Hose
And yet another view. The power steering line is temporarily pieced...

Upper Radiator Hose

Upper Radiator Hose
In this shot you can see the home fabricated aluminum tube and hose....

Oversized Cooling Fan

Oversized Cooling Fan
I tossed the wimpy FFR supplied fan for a larger temperature...

A/C Condensor And New Body Support Bar

A/C Condensor And New Body Support Bar
Another shot of the home fabricated billet body support bar. I bonded...

The Dash Cowl Is Crooked As Supplied

The Dash Cowl Is Crooked As Supplied
8/1/06 - This is not my car but mine was exactly like this one. Notice the...

Oak Dash Cowl Shim Blocks

Oak Dash Cowl Shim Blocks
I made three blocks from oak and screwed them to the dash hoop. I then ground...

My Dash Cowl Is Even Now

My Dash Cowl Is Even Now
Notice the driver's side now looks almost exactly like the...

Extended The Hood Back Under The Scoop

Extended The Hood Back Under The Scoop
8/11/06 - I had an earler photo of a fiberglass part I made to extend...

Fuel Filler Neck

Fuel Filler Neck
08/15/06 - Here's my setup for the fuel neck. The small tube and...

Front Nose Oil Cooler

Front Nose Oil Cooler
I installed a Mocal oil cooler for cooling the power steering fluid....

Home Fabricated Seat Mounts

Home Fabricated Seat Mounts
08/16/06 - I experimented with various seating positions and settled...

View Of The Completed Seat Installation

View Of The Completed Seat Installation
Here's a view of the seat mount covered in the FFR supplied door...

First Start And First Ride!!!!

First Start And First Ride!!!!
On 8/16/06, I started the engine and it ran amazingly well. There were...

Cobra Laundry - Parts After Featherfill

Cobra Laundry - Parts After Featherfill
9/10/06 - Primed the hood, doors, trunk, and hood scoop with...

Radiator Cover and Splash Pan

Radiator Cover and Splash Pan
10/01/06 - It was rainy all weekend. I spent time in the garage...

Engine Radiator Cover & Brake Cover

Engine Radiator Cover & Brake Cover
A shot of the radiator cover and to the left, a shot of the polished aluminum...

Hydroboost Brake Shield

Hydroboost Brake Shield
Another view of the shield.

Shield - Drivers Side View

Shield - Drivers Side View
I fastened the shield with screws so that in the event of a master cylinder...

Body Ready For Featherfill G2 Priming

Body Ready For Featherfill G2 Priming
10/8/06 - The body work is done and it's ready for the first coat of high...

The Body Is Primed

The Body Is Primed
Here it is with 3 coats of FFG2. Attention to detail payed off. I...

Spraying The Guide Coat On FFG2

Spraying The Guide Coat On FFG2
10/15/06 - Sprayed the second application (3 coats) of FFG2. This photo was...

Block Sanding Tools - Purchased/homemade

Block Sanding Tools - Purchased/homemade
Here's the complement or tools I used to block the body. Some were...

Cobra Work In Fall 06

Cobra Work In Fall 06
10/29/06 - I spent the day block sanding the passenger side of the body and...

Fall 06 And Some Shiny Aluminum Parts

Fall 06 And Some Shiny Aluminum Parts
Man that aluminum sure does shine! I fabricated an extension on the...

Waiting For A Go-cart Ride (with videos)

Waiting For A Go-cart Ride (with videos)
I've been registered with the DMV for a 2 months now. I take her...

Dead Pedal Modification To Footbox

Dead Pedal Modification To Footbox
11/11/06 - Fabricated a box to extend the drivers footbox for a dead pedal....

Dead Pedal And Pedal Spacing

Dead Pedal And Pedal Spacing
Here's an inside view of the pedals. I counter sunk stainless flat head...

Completed The Cockpit Insulation

Completed The Cockpit Insulation
11/19/06 - This is a shot of the insulated cockpit. I used a closed cell foam...

Another Shot Of The Insulation

Another Shot Of The Insulation
I'm making the transmission cover removable so there's a seam in the...

An Overhead View

An Overhead View
So nice and shiny, it's almost a shame to cover it with carpet.

Another Overhead View

Another Overhead View
Tomorrow I start the carpet installation.

Tranny Tunnel Saddle Carpet Surging

Tranny Tunnel Saddle Carpet Surging
11/20/06 - Started the carpet install by laying out each piece in the...

Trimming Back The Carpet's Edge

Trimming Back The Carpet's Edge
I used am electric hair trimmer to cut the pile back evenly from the edge by...

Marking The Leather Trim For Cutting

Marking The Leather Trim For Cutting
Outline the carpet edge on the backside of the leather using tape and a pen.

Mark Two More Guide Lines

Mark Two More Guide Lines
The middle line was the edge of the carpet. Make one inboard line and one...

Cut The Leather Out Using The Lines

Cut The Leather Out Using The Lines
Cut on the inboard and outboard lines. Then place the leather piece on the...

Apply Weatherstrip Adhesive

Apply Weatherstrip Adhesive
Apply the adhesive to the top edge of the carpet and to the reverse...

Place The Leather On The Carpet

Place The Leather On The Carpet
After the cement has dried for 5 minutes assemble the two pieces.

Gluing The Backside Of The Carpet

Gluing The Backside Of The Carpet
After the top side has dried for 1 hour, flip the work over and add cement to...

Fold The backside Over

Fold The backside Over
Complete the reverse side by carefully folding it over and adding...

Completed Leather Trimmerd Carpet

Completed Leather Trimmerd Carpet
Here's a view of the rear section completed. The entire process...

Removeable Transmission Cover

Removeable Transmission Cover
The tranny cover is secured along each side with stainless sheet metal screws...

Carpet Installed Drivers Side View

Carpet Installed Drivers Side View
12/10/06 - All of the carpet was glued down with 3M spray trim adhesive and...

Carpet Installed Overhead View

Carpet Installed Overhead View
Note the leather surging on the tranny "saddle" carpet. Only...

Carpet Installed Passenger Side View

Carpet Installed Passenger Side View
The e-brake relocation I made worked out real nice with the "new...

Carpet Installed Rear View

Carpet Installed Rear View
A view of the carpet, the rear glovebox, and the polished aluminum...

Carpet And Pedals

Carpet And Pedals
Here's a shot of the pedal arrangement. It's hard to see but I...

Installed The Vintage Wiper System

Installed The Vintage Wiper System
1/6/07 - Installed the vintage '65 MG wiper setup. I made and...

Final Wet Sanding Of The Body

Final Wet Sanding Of The Body
1/13/07 - Completed the final wet sanding with 600 grit paper. It...

Wet Sanding

Wet Sanding
Here's a view of the rolled dash edge and the front end.

Wet Sanding The Front DS Fender

Wet Sanding The Front DS Fender
Here's a shot down the side of the car. To check the straightness,...

Wet Sanding The Rear

Wet Sanding The Rear
A shot of the rear end. You can't tell it but I moved the license...

Wet Sanding The Rear Rolled Edge

Wet Sanding The Rear Rolled Edge
This shot shows the rear rolled edge.

Modifying The MSD Box Mounting Scheme

Modifying The MSD Box Mounting Scheme
1/21/07 - To facilitate removal, I removed the MSD6AL module from the rubber...

Leather Covered Hinges And Support Wire

Leather Covered Hinges And Support Wire
1/22/07 - I covered the otherwise plane steel hinges with leather, added...

Final Assembly Of The Trunk Aluminum

Final Assembly Of The Trunk Aluminum
1/25/07 - Installed all the trunk alumuninum panels that I polished...

Chassis And Body Ready For Installation

Chassis And Body Ready For Installation
1/27/07 - Prepared the chassis to accept the body by removing the side pipes,...

Moving The Body

Moving The Body
I enlisted the help of some neighbors and fellow FFR builder FORDCSX, working...

Slowly Lowering It Into Position

Slowly Lowering It Into Position
The nose was massaged into place and then the back was dropped down.

Double Checking The Oil Cooler Fit

Double Checking The Oil Cooler Fit
This was the first time the oil cooler and the front radiator aluminum...

Massaging The Back Over The Bulb Seal

Massaging The Back Over The Bulb Seal
This was the most difficult part of fitting the body. The next and...

Drip Tube Interference

Drip Tube Interference
I installed some small brass drip tubes in the front corner of the...

Seating The Windshield Wipers

Seating The Windshield Wipers
As the body was lowered, the wiper wheel boxes were positioned and pulled...

The Body Is On

The Body Is On
Removing the body support brace after the body was seated.

Going Back Into The Shop

Going Back Into The Shop
The car went back in. Over the next few days I installed all the...

My Blue Choice - Lexus Indigo Ink Pearl

My Blue Choice - Lexus Indigo Ink Pearl
Here's my color choice. It's a dark blue pearl-metallic that...

Taking The Car To The Painter

Taking The Car To The Painter
2/23/07 - The body work is completed to the point where it can be...

Body Wiped Down And Ready For Sealer

Body Wiped Down And Ready For Sealer
The car as delivered. It's wiped down and tack'ed off and...

Applying The Sealer

Applying The Sealer
The painter shooting the 2K sealer. Note the hood is setting on the...

A Shot Of The Car In Sealer In The Booth

A Shot Of The Car In Sealer In The Booth
First we applied a 2-part urethane sealer to keep the body work and...

Indigo Base Coat Application

Indigo Base Coat Application
In this shot, the silver is already sprayed on the center of the car and the...

Transformation Completed

Transformation Completed
A shot after the last clear coat was completed.

12 Hours Later At 2:30 AM

12 Hours Later At 2:30 AM
After 12 hours of continuous work and taping, the blue and silver...

Back Home With The New Paint Job

Back Home With The New Paint Job
2/24/07 - Here's the car after drying for 10 hours. it still needs to be...

Hood And Rear Quarter Panel

Hood And Rear Quarter Panel
Here's a shot of the paint and hood scoop. I also striped the...

Parts In The Sun

Parts In The Sun
The indigo ink pearl paint is dark in the shade but really pops in the sun.

Stripe Layout On The Trunk Lid

Stripe Layout On The Trunk Lid
I moved the license plate lamp mount over by 3/8" toward the...

Closeup Of The Paint Color On Stripe

Closeup Of The Paint Color On Stripe
This shot shows the texture of pearl indigo and the metalic silver. It...

After 5 Days Of Curing In The Sun

After 5 Days Of Curing In The Sun
3/2/07 - I placed the hood and trunk on for a first look at the stripe...

Master Cylinder Cover - Hydroboost Hoses

Master Cylinder Cover - Hydroboost Hoses
3/3/07 - Fabricated a cover for the end of the hydroboost master brake...

Passenger Side Engine Bay Filler Panel

Passenger Side Engine Bay Filler Panel
3/3/07 - I fabricated a lower panel to conceal the fiberglass body from view,...

Wet Sanding And Compounding

Wet Sanding And Compounding
3/15/07 - began the long and carefull task of wet sanding the clear coat. My...

3M Perfect-it 3000 Rubbing Compond

3M Perfect-it 3000 Rubbing Compond
Another shot of how much difference there is before/after compounding....

Compounded Finish On A Door

Compounded Finish On A Door
Here is the finish after wet sanding and compounding with 3000. There is...

Engine Bay Rubber Filler Panels

Engine Bay Rubber Filler Panels
4/7/07 - Fabricated some rubber filler panels to close off the engine...

Completed The Sanding And Buffing

Completed The Sanding And Buffing
4/8/07 - My process: After wet sanding with 1200/2000 and then again with...

A Close-up Of The Hood And Stripes

A Close-up Of The Hood And Stripes
The process continued - Next I hand applied the Utrafina SE. It worked...

A view Of The Rear And Stripes

A view Of The Rear And Stripes

Reflection Of The Paint

Reflection Of The Paint
You can see how smooth the overall finish is in this photo. Those who have an...

Drivers Side Additional Splash Panel

Drivers Side Additional Splash Panel
4/10/07 - Rainy evening, so I fabricated a panel to conceal the side of the...

Splash Panels In The Fender Well

Splash Panels In The Fender Well
This view shows the complete panel setup. Also note the angled box on...

Splash Panel On The Passenger Side

Splash Panel On The Passenger Side
I carried the idea over to the passenger side as well. It was a little more...

Last Shot Of Chassis Before Body Goes On

Last Shot Of Chassis Before Body Goes On
4/22/07 - Completed the fender well black out treatment. Also installed the...

Fender Well And New Panel Blacked Out

Fender Well And New Panel Blacked Out
I used Plasticoat bed liner paint and 3M ruberized spray under coat to...

Passenger Side

Passenger Side
Note the extra insulation on the footbox and the additional engine bay filler...

Rear Wheel Well.

Rear Wheel Well.
Continued the black out treatment on the rear.

Painted The FMS Air Cleaner Logo

Painted The FMS Air Cleaner Logo
4/24/07 - Painted the recessed logo on the top of the billet aluminum air...

An Aluminum Screen For The Radiator

An Aluminum Screen For The Radiator
Made up a standard window aluminum screen with parts from Lowes. I also...

Self Supporting Roll Bar Covers

Self Supporting Roll Bar Covers
4/25/07 - Fabricated a set of spring loaded and hinged support brackets to...

Hinged Support In Action

Hinged Support In Action
As the rollbar enters the bezel, the support folds out of the way.

Rollbar Cover Installed

Rollbar Cover Installed
This cover was just for this demonstration but you get the idea. The...

Finalized Rollbar Filler Blanks

Finalized Rollbar Filler Blanks
Here's a shot of the final design for the 1/8" polished...

Door Details

Door Details
Of note: The door latch assy, weatherstrip on door and leather trim interface...

Seat Belt Rubber Gaskets

Seat Belt Rubber Gaskets
I made a rubber gasket to place behind each seat belt bezel. The...

A Simple Fix For The Sagging Tank Cover

A Simple Fix For The Sagging Tank Cover
Many donor Mustang tank covers pull away and down from the fuel tank at the...

Painted Body Installation

Painted Body Installation
4/29/07 - Installed the painted body on the chassis. Friends and neighbors...

Fitting The Nose Over The Aluminum

Fitting The Nose Over The Aluminum
Carefully lowering the front to clear the nose aluminum.

Pulling The Windshield Wipers Through

Pulling The Windshield Wipers Through

Champagne Toast

Champagne Toast
We toasted the occasion!

Measuring Ride Height

Measuring Ride Height
I use this aluminum threaded block and its brass bolt to check the...

The FastTrax Camber/Caster Tool

The FastTrax Camber/Caster Tool
I use this tool to adjust the camber and caster of the front wheels. It cost...

Camber Set To -1 Deg

Camber Set To -1 Deg
A shot of the tool's gauge and how it diplays camber with a bubble scale....

My Method Of Toe Steering Adjustment

My Method Of Toe Steering Adjustment
I tape 2 pieces of paper to the floor at the front wheels on each...

Toe Adjustment Part-2

Toe Adjustment Part-2
Once the toe lines are scribed on the paper, I measure out in front...

A Shot Under The Scoop

A Shot Under The Scoop
Here's a shot of how things lined up and how the hood looks...

Overhead Shot Of Scoop And Mounting

Overhead Shot Of Scoop And Mounting
I used 27 Stainless button head screws spaced at 2" centers.

Detail Of The Underside

Detail Of The Underside
I cut off the moulded-in scoop and rolled the ragged edges of the hole in the...

Another View Of The Rolled Hood Edge

Another View Of The Rolled Hood Edge
A close up view of the rolled edge. I accomplished this by placing...

Detail Of Driver's Side Hood Hinge

Detail Of Driver's Side Hood Hinge
A shot of the driver's side hood hinge setup. The shoulder bolts...

Driver's Side Hood Hinge (inside view)

Driver's Side Hood Hinge (inside view)
A shot of the driver's side hinge taken from the inside of the...

Hood Hinges Top View

Hood Hinges Top View
A shot of both hinges.

Passenger Side Hood Hinge

Passenger Side Hood Hinge
A shot of the passenger side hood hinge

Side Vent Louvers Installed

Side Vent Louvers Installed
These are from Finishline and are mounted inside the body cutout with...

Underdoor Aluminum Trim Pieces

Underdoor Aluminum Trim Pieces
5/12/2007 - Here's a shot of the 1/2" X 1/2" aluminum...

Door Panel And Carpet Edge Trim

Door Panel And Carpet Edge Trim
These door panels were made on a masonite base with 1/8" foam...

Carpet Detail On Passenger Side

Carpet Detail On Passenger Side
I covered all exposed frame tubes and installed carpet to just below the door...

Carpet Detail On Drivers Side

Carpet Detail On Drivers Side
Like the passenger side the carpet covers all the frame tubes and a...

Detail Of Home Fabricated Strike Mount

Detail Of Home Fabricated Strike Mount
The strike plate is shown installed here. Two stainless bolts pass...

Door Latch And Strike Details

Door Latch And Strike Details
Door mechanism installed on passenger door. The strike is mounted to the home...

Rolled Dash Edge Overhang

Rolled Dash Edge Overhang
Here's a shot of the overhang on the rolled dash edge and the...

Home Fabricated Leather Spats

Home Fabricated Leather Spats
I knew the wide front tires would sling rocks against the rear fender...

Spat And Added Aluminum Inside Fender

Spat And Added Aluminum Inside Fender
Here's a detail of how the spat is folded under and held in place...

Mounted Hood Latch

Mounted Hood Latch
Here's how the hood latch looks mounted through the hood. I used a...

Front Overrider Mount And Grommets

Front Overrider Mount And Grommets
The chrome overriders are mounted using 7/16" stainless threaded rod and...

Rear Overriders

Rear Overriders
I mounted the rear overriders much the same as the fronts except they tighten...

Detail Of Overrider Threaded Rod Mount

Detail Of Overrider Threaded Rod Mount
I used threaded rods, nuts and washers to mount the overriders. I prefer this...

Trunk Aluminum And Threaded Rod

Trunk Aluminum And Threaded Rod
This view from underneath the trunk further illustrates the mounting...

Radot Mirror Mount Modification

Radot Mirror Mount Modification
I cut about 1/2" off the bottom of the Finishline Radot mirror...

Radot Mirror Mounted To Windshield Frame

Radot Mirror Mounted To Windshield Frame
I purchased the mount and mirrors from Finishline. The mount was cut...

Rear Detail Of Mounting The Mirror

Rear Detail Of Mounting The Mirror
I drilled the new holes in the frame so that I could use the top...

Wiper Arm Angle Adjustment

Wiper Arm Angle Adjustment
As supplied the British wiper arms don't lay flat along the bottom of the...

Easy Fill Fuel Cap

Easy Fill Fuel Cap
A shot of the Lemans style aluminum fuel filler. Under the cover...

Trunk Prop Rod

Trunk Prop Rod
I fabricated this trunk prop rod from 1/4" steel rod purchased...

Prop Rod In Use

Prop Rod In Use
Here's a shot of the rod in action. The top fits over the ball stud...

Cades Cove In The Smokys

Cades Cove In The Smokys
This was our first extended ride. We took it up into the Smoky...

First Car Show

First Car Show
05/18/07 - I took it to the local Friday night car show in Maryville,...

Car Show Side View

Car Show Side View
The Friday evening car show at the Maryville Mall was just starting to...

Another Side View

Another Side View
Oh Yeah.

Polished Trunk

Polished Trunk
Deb and a few friends came early and admired all the nice cars.

Interior View

Interior View
I like the windshield support rod and the asjustable rear view mirror....

Interior

Interior
Another view from the passenger side.

A Shot Of The Completed Engine Bay

A Shot Of The Completed Engine Bay

Another View

Another View

I Took This Photo From The Roof

I Took This Photo From The Roof
The stripes came out very well aligned. Note the rollbar bezel covers.

A Classic Car At A Classic Gas Station

A Classic Car At A Classic Gas Station
Fuel was still .25 a gallon here - in the Twilight Zone! I had the...

All Smiles

All Smiles
06/19/2007 - My wifes nephew after a Cobra ride.

A Road Test Of A Real '65 427 Cobra

A Road Test Of A Real '65 427 Cobra
This is a test on the real thing. Note 0-60 in 5 seconds. An FFR with...

July 1, 2007 - Covered Bridge, IN

July 1, 2007 - Covered Bridge, IN
This was part of our 875 mile trip from TN, to KY, OH, IN. The car behaved...

4th of July 2007

4th of July 2007
I prepared the car for a small town Independence Day parade in Greendale, IN....

A Trip To The Superformance Dealer

A Trip To The Superformance Dealer
We stopped by Ross, OH and checked out this Superformance show room....

Next To A Real 1963 AC FIA 289 Cobra

Next To A Real 1963 AC FIA 289 Cobra
8/4/07 - I met a group of Knoxville Cobra guys at Hooters in Alcoa. I had the...

Tail Of The Dragon Run In TN and NC

Tail Of The Dragon Run In TN and NC
8/18/07 - I ran the Tail of the Dragon from TN into NC at Fontana. The...

Taking A Corner Hard On The Dragon

Taking A Corner Hard On The Dragon
This photo was taken by one of the many pro photographers who inhabit...

Leaving The Corner And Hard On The Gas

Leaving The Corner And Hard On The Gas
Leaving the corner, I smoothly accellerate. In the background, a real...

Another Corner

Another Corner
Now, a pro's shot of me turning hard right.

Cruising The Dragon Along Fontana Lake

Cruising The Dragon Along Fontana Lake
Here's a shot of the group traveling North on US129, The Dragon,...

A Shot Of The Group On The TN Side

A Shot Of The Group On The TN Side
We posed for a group photo after completing a two-way run of the...

Final Stop On The Dragon

Final Stop On The Dragon
Every participant had his/her photo taken to share with the FFCobra.com forum...

Tuning The Carb With The LM-1 A/F Meter

Tuning The Carb With The LM-1 A/F Meter
8/23/07 - Some time back I replaced the Edlebrock 1406 carb with the 1806 AVS...

Close-up Of The LM-1 Data Logger

Close-up Of The LM-1 Data Logger
This meter provides instantaneous A/F ratio readouts while driving and...

LM-1 RPM Converter

LM-1 RPM Converter
The LM-1 works with an optional RPM converter shown velcro'd here....

A/F Plot Of The Edelbrock AVS 1806 Carb

A/F Plot Of The Edelbrock AVS 1806 Carb
The first carb I tried on the car was and EDL 1406. It had a huge bog...

Plot Of The 1806 Running Primaries Only

Plot Of The 1806 Running Primaries Only
To prove the secondaries were causing the wild AF swings, I removed...

O2 Sensor Exhaust Bung In The Collector

O2 Sensor Exhaust Bung In The Collector
Before I had the sidepipes ceramic coated, I welded in an exhaust bung...

Changing Jets And Rods

Changing Jets And Rods
Based on my A/F measurements, I need to go 2 stages leaner on cruise and WOT...

Step-1

Step-1
Open and slide over the step-up spring cover to expose the piston, rod and...

Step-2

Step-2
Carefully remove the piston, rod and spring from the carb. Repeat for both...

Step-3

Step-3
Remove the Torx screws that hold the top half of the carb onto the base. Also...

Here's The Carb Topless

Here's The Carb Topless
A shot inside the fuel bowels.

Primary And Secondary Jets

Primary And Secondary Jets
The primary jet is on the right and the secondary jet is on the left....

Holley 570 AF Plot After A Few Mods

Holley 570 AF Plot After A Few Mods
This plot is a run on the Holley Avenger 570. Note the absence of AF...

Changes Made To The Holley 570 Carb

Changes Made To The Holley 570 Carb
The only change I made to metering block was to drill out the small...

A Sparkplug After Installing The Holley

A Sparkplug After Installing The Holley
This plug is the original plug that came in the FMS302-E GT-40 engine. It has...

Holley Avenger 570 Installed

Holley Avenger 570 Installed
Here's the Holley 570 carb installed. I was able to use the fuel...

Thottle Connection And Breather

Thottle Connection And Breather
The throttte cable mount setup I designed for the old EDL carb worked...

Air/Fuel Ratio Plot With The Holley 570

Air/Fuel Ratio Plot With The Holley 570
This was taken during a 1st - 4th gear easy accelleration run up to 55...

A/F Ratio For A Steady Cruise In 4th

A/F Ratio For A Steady Cruise In 4th
This plot shows the A/F is maintained at the ideal 14.7 ratio during...

WOT 1st - 3rd Gears And Then A Cruise

WOT 1st - 3rd Gears And Then A Cruise
This plot shows a 5 mph rolling start in 1st gear uphill entering the...

Secret Vacuum Gauge

Secret Vacuum Gauge
I installed a small vacuum gauge from McMaster Carr in the ashtray. Since I...

Winter In TN

Winter In TN
2/10/08 - Fueling her up at the corner gas station for a winter's day drive.

An Engine Oil Spectro Analysis

An Engine Oil Spectro Analysis
I sent a sample of the engine oil in for a lab analysis. The oil had...

A 50 Deg Winter Day Cruise On The Hiway

A 50 Deg Winter Day Cruise On The Hiway
2/13/08 - In the winter, you have to take advantage of any 50 degree day....

Rod And Run Car Show In Halls TN

Rod And Run Car Show In Halls TN
4/12/08 - entered a local car show. Took a plaque for TOP 25 Best...

Spring Foliage Drive In Knoxville

Spring Foliage Drive In Knoxville
4/15/08 - We took a drive though one of the better areas of town to see the...

Tulip Reflections

Tulip Reflections
The flowers reflected very well in the side of the car.

Indigo Paint And Nature

Indigo Paint And Nature
The Indigo Ink Pearl paint really pops against the natual Spring colors.

Pink And Indigo

Pink And Indigo
What a beautiful tree!

Finally Installed The Full Rollbar

Finally Installed The Full Rollbar
5/04/08 - After one year on the road and going "barless" the...

Full Chrome Rollbar Rear View

Full Chrome Rollbar Rear View
The full rollbar was an option offered by FFR for a while. I initially...

Rollbar Rear View

Rollbar Rear View
A shot from behind.

Smoky Mountain British Car Show

Smoky Mountain British Car Show
5/10/08 - Took the first place award for Cobra category at the 21st annual...

My Car And Allen From SC AKA Biker's Car

My Car And Allen From SC AKA Biker's Car
8-16-08 The Southeast Cobra guys did a Dragon run that I had to miss....

Foothills Parkway

Foothills Parkway
9/07/08 - Rob in the #27 real Cobra and I ran Foothills parkway...

Trick Video Camera Mount

Trick Video Camera Mount
A forum member loaned me his camera mount for the rollbar. It worked...

Tail Of The Dragon Run 2008

Tail Of The Dragon Run 2008
9/20/2008 - 13 months ago we ran the Dragon. This year we did it again with a...

A Closer Shot

A Closer Shot

My Car

My Car
A shot of the car and video camera mount at the end of the Dragon run.

A Pro Shot Taken On The Dragon

A Pro Shot Taken On The Dragon
I was taking up the rear of the group so I could get some good video...

Fall Cruise - Smoky Montains TN

Fall Cruise - Smoky Montains TN
11/01/08 - We took a long cruise through the Great Smoky Mountain...

The Old Bilstein Shock Installed

The Old Bilstein Shock Installed
11-8-08 - Here's a shot at 8,500 miles of the old Bilstein shock....

New Front Shocks - Bilstein VS Koni

New Front Shocks - Bilstein VS Koni
I installed the new front Koni shocks today. The original Bilstein...

Clearance Between Spring And Sleeve

Clearance Between Spring And Sleeve
Note the large distance between the sleeve and the spring on this Koni shock....

Koni Shock Rebound Adjustment

Koni Shock Rebound Adjustment
To adjust the damping (rebound), pry the cap up as shown. Press and hold the...

New Koni Installed & Checked For Binding

New Koni Installed & Checked For Binding
I installed the new Koni shock and compressed it fully to check for possible...

275 Tire/Suspension Limit

275 Tire/Suspension Limit
I'm running 275/17/40 tires on the front. I wanted to see what...

Koni Shock At Tire Limit

Koni Shock At Tire Limit
This shot shows the 1.25" distance between the bump stop and tube...

Rear Koni Install & Modifed Bracket

Rear Koni Install & Modifed Bracket
11/11/08 - Before the rear Koni shock on the driver's side could...

3/4" Tube Rough Cut

3/4" Tube Rough Cut
Here's the tube end removed before I cleaned it up with a file and...

Clearance With Bracket Trimmed

Clearance With Bracket Trimmed
Note the acceptable clearance now. The modification is painted black...

Rear Koni Installation Completed

Rear Koni Installation Completed
The driver's side is done. The axle limit strap is not connected to the...

Passenger Side Rear Koni At Ride Height

Passenger Side Rear Koni At Ride Height
Here's shot of the passenger side Koni showing the clearance between the...

Passenger Side Rear Koni At Ride Height

Passenger Side Rear Koni At Ride Height
Note the ample clearance between the Koni and the brake caliper and e-brake...

Driver Side Rear Koni At Ride Height

Driver Side Rear Koni At Ride Height
Here's a shot of the drivers side Koni at ride height. The 3-link is...

Driver's Side Rear Koni At Ride Height

Driver's Side Rear Koni At Ride Height
Note the bumpstop in the top of the shock. At a 4.75" ride height,...

Me & Don (Vorcy) Planning A New Build

Me & Don (Vorcy) Planning A New Build
2/26/09 - Don and the local Cobra Knoxville Team are planning his new Cobra...

At Fontana Dam North Carolina

At Fontana Dam North Carolina
3/22/09 - Photo taken on the first long drive in early Spring from...

Condition Inside Engine At 9,500 miles

Condition Inside Engine At 9,500 miles
4/12/09 - I dropped the oil pan to replace the one-piece gasket due to a very...

Cylinder Wall Condition

Cylinder Wall Condition
The honing marks are still very visible and the wall is shiny with no...

Testing The Posi-track Rear End

Testing The Posi-track Rear End
07/6/09 - Wanted to make sure the posi-track was working. 340 HP, 2250...

Twin Sons Of Different Mothers

Twin Sons Of Different Mothers
8/13/2009 - My car's negative paint scheme in the car on the...

Rear View

Rear View
8/29/09 Took a photo at the park on a nice evening drive.

Fall Run In Search Of Leaves

Fall Run In Search Of Leaves
10/25/09 - My car on the left followed by Brian's car on the Cherohala...
article published 1/21/2005
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SharkHide prep and performace
Todd, Thanks for the Kudos. I first cleaned the panels with lacquer thinner. Then cleaned them with diluted Simple Green and rinsed with water.

The thinner removes the oils and silicon, and the Simple Green removes the organic compounds.

The finish is holding up extremely well. Be sure to use at least 3 coats and don't splash any solvents on it.
— GREG M, August 14, 2009

Greg, I LOVED your site!! Great insights and some wonderful pictures that have already helped me as I build my MKIII. Two questions on the polished panels: 1) Sharkhide instructions indicate that all polish should be stripped before coating. Did you apply directly over the Mothers polish or did you clean them first? 2) How is the finish holding up?

thx Todd
— Todd, August 14, 2009

Thanks for looking!
Build site statistics as of 5/7/09:

848,292 photos viewed, 42,338 visitors
— GREG M, May 7, 2009

You are welcome, Shelby Micke
Good luck on your build. You will have a real attention getter on the roads in Sweden.
— GREG M, December 29, 2008
Thank's from Stockholm, Sweden.
Hi I want to send You a million thank's for the very informative site, and all the photos.

I'm building a ac Cobra replica myself, but it's not bought from a company. I used a form that's made of a real -66 Cobra and made the shell in fibreglass myself.

I have now, in a week or two, made the frame drawings from pictures of different companys frames.

My intentions are to take the Ac Cobra S/C 1966 into the 21:st century. I'v bought a brand new 1998 Mustang Cobra DOHC 32V engine, 100% complete from air filter to the exaust system. It also includes a T-45 5 speed manual gearbox, and a 8,8" axle. I will mount the rear axle in Art Morrisons Triangulated 4 bar system and in front Art Morrisons Mustang II front.

I will use the ABS function and are thinking of trying to also build in a anti spinn function.

Thank's again for all the nice pic's You have on Your site, it's really inspirational.

Best regards Shelby Micke
— Shelby Micke, December 27, 2008

Website is still up and running!
Worldisround may have worked out it's financial issues. The site is still up and running! As of today, this buildsite has been hit 33,358 times and 652,827 photos have been viewed.
— GREG M, October 23, 2008
upretirementman
Do like I did... Copy every single item, the thumbnail, the small, the largest photo and be sure to get the text for each photo too. then burn a DVD with everything on it.
— Paul Coones, June 11, 2008
Miranda
It was nice meeting you. Thanks for checking out the biuld site and leaving the comment. I hope you can reach your dream of building a car of your own. If you have any questions, just ask. Go to www.ffcobra.com and select "65 roadster forum" for 17,000 people who share our interest. I'm Greg_M on there as well.
— GREG M, June 9, 2008
Hello again!! We met at Sweetwater Hospital! (the enthusiast)Thank you so much for sharing your website with me. I have spent the last 2 DAYS looking over your pictures and reading your progress. I literally felt myself getting excited for you when the body was finally ready for paint! She is LOVELY. It's been my dream since I was a little girl to have one of my own and maybe one day I'll be emailing you for tips regarding my own build!!
— Miranda, May 30, 2008
Thanks John,
John, By day I am an Electronics Engineer specializing in MRI medical scanners, superconducting magnets and cryogen systems. I have always been detail oriented and like almost anything technical.
— GREG M, May 26, 2008
Greg, I waws wondering what kind of work you do for a Day Job? Your attention to detail is great. Im a jeweler so im very much intersted in in the fine detail to the car. Im hoping to start a Build soon.
— John, May 26, 2008
This Might Be Goodbye For Me
Thanks everyone for your many positive comments over the last 4 years. It's been an honor to have so many of you view the site. As of today, more that 27,000 people have visited and looked at 495,000 photos from this site. AMAZING! Worldisround is closing down and unless I can find a new home for the buildsite it will be no longer.

Greg_M
— GREG M, April 29, 2008

Absolutely awesome detail during your build. Perfect selection of components!

Best of luck with your Cobra. Hopefully, I will be so lucky to build one this nice!
— Greg D, March 15, 2008

I just spent the morning looking through the pictures of your build. This is one of the best documented builds I have seen and one of the nicest cars. There is lots of good information and helpful hints. I plan a build in Jan. 08. Thanks for posting a great and informative site.

Eddie
— Eddie Haas, December 18, 2007

Hi Robert, RE cavitation
Thanks for checking out the buildsite. I'm pleased you were able to decide on the FFR Roadster. You won't be disappointed. Having 2 bodies is a novel idea and one that makes since if you are showing/racing the car.

The stock Mustang has a 1.25" top radiator hose and a 1.5" lower radiator hose. I installed a 4-core radiator and all the hoses are upgraded to 1.75", top/bottom. I have run the car in 100 degree weather on long trips in city/highway traffic with the AC running and have NEVER had the temp go over 200 deg with a 195 deg thermostat installed. The only reason it went to 200 deg is because that's where I have the thermostat set on the electric fan. So I suppose cavitation is not a problem or at least has no adverse affect on engine cooling if it's present.
— Greg_M, October 28, 2007

Inspirational indeed!
I hadn't heard about FFR until yesterday. Then I found your site today. What kind of performance car to buy/restore? That is no longer a question after perusing your build diary. My wife sealed it when she suggested building one chassis and two skins. One with major paint and show for summer and one with a tougher less elegant finish and a removable hard-top to drive in the grumpy seasons. As for the guys at Superformance, I'm supposing that they aren't savvy enough to know what a real Cobra looks like anyway as you seem to have had to let them in on the actual nature of the car or they are just insanely jealous. One way or the other they don't seem to actually appreciate a really fine automobile. Your craftsmanship and attention to detail are exemplary. One curiosity, are you having any issues with cavitation being generated in your coolant by the right angle plumbing in that bottom radiator tube?
— Robert Hathaway, October 27, 2007
Paint Info
Chris, Thanks for leaving a great comment! The paint codes are: Viper Silver Metallic Clearcoat CODE A9 Lexus Indigo Ink Pearlcoat CODE 8P4 I added this info in the photos as well. The paint was PPG Deltron DBU base coat and PPG Concept clear. The sealer was 2K urethane.
— GREG M, October 12, 2007
Lexus Indigo Ink Pearl Metallic
Stunning - and I'm absolutely in love with the colour. Greg, my FFR Mark III is "almost" complete, and the shell is going in for bodywork and paint over the winter. I was wondering if you had the paint codes and paint manufacturer's name for that amazing blue and the stripes.
— Chris Burchell, October 11, 2007
WOW What a site.What a sight! Fantastic effort, fantastic achievement. Inspirational.
— patrick h, September 14, 2007
I Love Your Site
Greg, I just spent 2+ hours looking at your photos and descriptions and all I can say is WOW! You have done an amazing job on your car. I've saved a bunch of photos in a file so I can use some of your ideas. You should be proud!

Take care, John OH
— John Jones, August 28, 2007

Thanks Jim
If you are looking for vehicle that offers the most fun on wheels, this car is for you. I've owned bikes, boats, and cars and I can say without hesitation this is the most rewarding toy I have ever owned.
— Greg M, August 24, 2007
Awesome Site!
Your build site is the best I've seen! The pictures and descriptions are great. The level of effort you're putting into the roadster serves as an inspiration to those of us thinking about doing this build. Thanks!
— Jim (Dargo), August 24, 2007
Thanks Andrew(s)
Are you the same two Andrews? Anyway I used the lines that came with the kit and also bought a few short pre-flared lines and couplers from Advance. I buffed everything to look like stainless and coated with SharkHide.
— Greg M, June 16, 2007
Brake lines
Great build Greg, I really like the look of the fix brake lines. Where did you source you tube and fittings. Regards Andrew
— Andrew Hocking, June 15, 2007
Superb Build
Its a credit to how much effort you have put in. Your car is one of the nicest I have seen. I'm starting a big build push on mine in a couple of weeks, I'll be happy if it looks half as good.

Great job, congratulations
— Andrew, June 14, 2007

Greg
Just wonderful! You are sure to win every prize at every event you enter it in! Thanks for the wonder photos too! Congratulations on every aspect of your build!

Paul ( upretirmentman )
— Paul Coones, May 21, 2007

Expansion tank source
Ken - I picked it up on Ebay for $40. It needed extensive re-plumbing and a custom mount to fit my application.
— Greg M, March 28, 2007
Was wondering where you acquired the Black Expansion Tank for your Cooling System on the right side of your engine compartment. I have been looking for one and have not had any luck.
— ken kemper, March 27, 2007
Reply to Stan
Stan, Thanks for the comments. I would be glad to speak with you. You can reach me gsmarsh@comcast.net
— Greg M, March 2, 2007
Build question
Greg,

Would it be possible to get your e-mail address, I have a few questions. E-mail me if you can, thanks.

Stan
— Stan Knight, March 2, 2007

Amazing build
I just went through every picture and narrative, I can't believe you have the time to document it as well as you have while building it. Great color, very impressed with your attention to detail, you must be very proud of it. I'm dying to start building one. Good luck. Stan
— Stan Knight, March 1, 2007
Greg
That's a very beautiful color! Good Choice.

Paul
— Paul Coones, January 28, 2007

Great Build Site
Greg, you should do the installation manual for F5! Great site, Congrats. Jeff B.
— Jeff Bordenave, December 14, 2006
Thanks Paul
Paul, It may have looked easy but it was tedious and actually took 5 full days to install the insulation and the carpet. I still have to make some floor mats out of extra carpet pieces and trim them with leather. It never ends...
— GREG M, December 13, 2006
upretirementman
Greg

Thanks so much for updating us on your carpet installation! I saved all the photos for future reference on my Cobra Simulator. You make it look so easy too! Looking forward to the door panels, etc! It looks very nice. Good Job!
— Paul Coones, December 13, 2006

Greg

How are you doing installing the carpets? When can we expect to see the photos? We all are looking forward to your progress!

Paul
— upretirementman, December 6, 2006

Reply to Albert
Hey, you caught me! Yes I am an ex-Houstonian. Thanks for the comments. I really appreciate any comments from FFR builders. You guys know what it takes to build one of these cars.
— GREG M, November 12, 2006
Great job. I am gonna save this for future reference. Fine job on the aluminum. You must be from Texas (Shiner beer). I live in Victoria, Texas and am building a Mark III now. Thanks for the pictures.
— Albert Johnson, November 12, 2006
Response to Paul, RE: photos
Paul,

I'm using a 7 year old Sony DSC-S70 3 mega pixel digital camera. It has an amazing macro zoom mode. All of the photos maintain the "full size" as original if you select view full size photo. You can save the photos directly from the site. Thanks for the complement!
— GREG M, November 8, 2006

upretirementman
Greg, your photos are wonderful. What camera are you using to get such detail? What format are the ones on your website? And size? Do you have the original ones available if one should ask for a particular one to be emailed to us?
— Paul Coones, November 5, 2006
FFR Fanatic
Thanks Dennis - I'm glad the site has some value for others. There are a few gotchas in the build. I look at the kit as a starting point for a really great car. It's what you put into it that determines what your final result will look and drive like. The manual is useless in my opiniom. If it weren't for the FFR Forum, I would much farther behind. You can always email me at gsmarsh@comcast.net for any questions. Good Luck!
— Greg_M, June 13, 2006
Great build site
Your site reinforces what I aleady know about FFR and the Smith Bros. The attention to detail and personal touches evident in your build pics and narrative are a solid paradigm for prospective builders like me, and I'm convinced the Smiths should make you their poster boy. There is a solitay reference to a "Gotcha," however, with the front suspension, and I'm curious if there were others that might be worth mentioning before I order my MKIII kit. I recognize that it is probably an aggregate of "little" gotchas rather than great engineering that frustrate and short-circuit some FFR builds, and I don't want to fall victim to that. Any help you might provide would be most appreciated.
— Dennis, June 12, 2006
Reply to Max
Thanks Max! I'm Greg_M on the FFR Cobra forum so you can always send me a private mail anytime. Good luck with your build! Greg
— Greg_M, March 28, 2006
Greg, I love your work on the car and your documentation! I will certainly be using some of your ideas and techniques for my own MKIII build starting May '06. Wish I could see this in person. Perhaps I could contact you with questions, in the future? Thanks, Max
— Max K, March 28, 2006
Alternator-reply
The 2G and 3G alternators work fine. Just buy the 3-wire D-connector from NAPA, add the main output wire, and a field wire and you're good to go.
— Greg_M, January 2, 2006
three wire alternator
I'm building a roadster similar to yours, the level of craftmanship in your project has given me a target to shoot for. Were you able to wire the three wire alternator? ff5 guys say it won"t work. Please let me know 425-508-4468 happy new year
— dave, December 31, 2005
Very Nice Site and Photos
Thanks for posting some of the best build photos I have seen recently. I picked up some good ideas from them. Good luck on the build and keep up the great work! Mike-AZ
— Mike, November 12, 2005
Hey Tuff in TX Watch talking about girls: Greg sent me this site, and I am a girl. I enjoy looking at his progress. Yes we like to ride in them, but some of us like to see the process that it takes to take that ride. (HA) Greg, you are doing an awsome job. I will keep checking your web site now that I have the address to see your progress. I cannot wait to see you and Deb riding in it on the road.
— Julie, October 17, 2005
Steve McQueen
Is this the car Steve McQueen drove in Buillitt (the best car chase movie ever)? Anyway, Deb sent me the link to your site and although chicks may not like to put together cool cars, we sure like to ride in em! What an awesome project! Tom says hey!
— Tiff in Texas, September 28, 2005
Response to Mike Mazoway
Mike, Yes the kit is everything I expected. The nature of the FFR kit lends itself to all kinds of home fabricated upgrades that make each build unique. I spend at least 3 times as much time mocking up new ideas and planning ahead than I do actually building. As far as what would I do different? Not sure yet-so far nothing. Greg
— Greg_M, July 31, 2005
Wonderful site. Lots of good info for someone like me who is considering taking the plunge. The real questions are a) did the kit live up to your expectations? and b) what would you do differently if you were to do it again. Response would be appreciated. Mike
— Mike Mazoway, July 30, 2005
Nice job! I can't wait till you pull up outside and ask if I'm interested in a ride. Sorry it took so long to get here. I can only imagine what the body will look like with the detail you used on what is normally unseen.
— Rick M, June 10, 2005
Greg - Just visited your site. Very impressed with your work! I am scheduled to attend the Motts College build school 7/19 and am currently sourcing/planning parts, etc. You should be very proud of your start! - Ken
— Ken Moon, June 2, 2005
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