So I'm not that good at record keeping and documenting things, but I thought I'd try to do better on both scores. Ordered my kit May 1, completion date June 22, FFR had it ready a day early so was picked up by Stewart Transport on June 22 and delivered to my house June 23. Mark was my delivery driver and I can't say enough great things about him, his truck maneuvering skills, his fantastic attitude in the upper 90 degree weather here near DC on that day. Mark is really a first class guy and my delivery experience was superb.
Finished inventory Tuesday June 25, and began the build that day. A week later here begins my build entry and update.
Going to try to enter pictures.......we'll see how that goes.
I think I need to create a picture gallery, but I don't have those privileges, I don't think. Can anyone confirm that, or help me get the pictures oriented correctly.
The forum has issues with large pics (by design, to conserve bandwidth). To make sure your pics don't rotate I'd make sure that the long side of the pic doesn't exceed 2000 pixels before uploading. Then your rotation issue should go away.
Week 1 - front suspension (brakes, rotors, calipers, shocks, springs), rear suspension, 3 link (brakes, calipers, shocks, springs, panhard rod), body removed and on buck IMG_2055.jpgIMG_2057.jpg
Week 2 - only one day and now I may be stopped because interior aluminum pieces are all on back order. Harrumph. Anyway did the steering rack and pedal box and pedals, clutch, brake, accelerator. Will see what I can work on in the mean time.
Received cockpit aluminum and put in outside below door panels, and rear tunnel panel and 3/4 rear pieces. Blowing through 1/8 drill bits, but I remember that from my Lotus 7 build long ago. Sharp drills speed the process. Put in the fuel line. Is going to be carbureted and modest HP so single line sufficed. Floors are in and most of the aluminum around the drivers pedals. Some bits are "cleco-ed" in for now. Wheels came so need to buy tires. I mount and balance my own tires so will enjoy that. Waiting on brake line tee fittings to run brake lines.
I'm surprised how cramped the pedal box is. When I ran the Lotus 7 at the track I used wrestling shoes which are much cheaper than fancy race car shoes and may have to do the same here. Had to do some significant accelerator pedal bending to get it to stop hitting the aluminum and flipped the pad/pedal piece so more of it is below the pivot. I think it will work, if not I can work up another approach. Are you guys able to keep the silicone off your hands or do you end up with it all over the rivet tool and every thing else?
So I have an insurance question. It occurred to me that it isn't a moving car and so wouldn't likely be insured as such and probably will fall under home owner's insurance during the present build phase? I'll need to check that and would hate to have it damaged somehow in the garage and not be covered. You guys address that one in your experience.
Anyway tee fittings arrive tomorrow and then onward. Need to make final tire decision too. Probably 235/60r15 front and 275/60r15 rear.
Week 1 - front suspension (brakes, rotors, calipers, shocks, springs), rear suspension, 3 link (brakes, calipers, shocks, springs, panhard rod), body removed and on buck IMG_2055.jpgIMG_2057.jpg
Do the 289’s all come in black gel coat? Looks like you’re making good progress!
Regarding silicone getting on your hands, I use these when working in the garage, they’re tough, chemical resistant and I can even use my phone touch screen with them on;
Finished up wiring and test fit of the gauges in the dash. Lots of wires, will need to pay attention to that. Trunk panels and rear cockpit panel in place. Manual talks next about drive train. Uh oh........mine isn't due until October. I'll likely shift to body work on the buck and try to make progress there. Very enjoyable project. Lots of rivets and very fun. Really well thought out by FFR I think having done a scratch build myself long ago. IMG_2102.jpgIMG_2107.jpgIMG_2108.jpgIMG_2109.jpg
Engine arrived Wednesday, 9/4 and I installed it yesterday day 9/7. Ended up installing it solo using a 2 ton HB hoist. Glad I had the longer reach. Almost hit a snag when trying to get the shift/transmission end past the firewall tunnel cross frame member. Thought I was going to have to wait for my wife to return until I concocted a solution using a ratchet strap that I looped over the top of the transmission and fed around the car frame allowing me to put downward pressure on the transmission end and it slid through and into place. Took ~ 1 hour. Transmission mount was a challenge as I needed to slot the mount some to accommodate the tail housing bolts. All worked out in the end. Back in business now and moving ahead on other items on the build list.
I would say you are fast. My 289 shows up this week. I have all the drive train here or on their way. I doubt I will be dropping the engine in just 3 months like you have accomplished. Well done!
Thanks rkl20678. I retired in May so have more time than some. However, I am returning to part-time consulting for my former employer next Monday. Winter in the garage will slow things for sure. I'm not a fan of cold weather so I'm trying to accomplish as much as possible before then.
So I have an insurance question. It occurred to me that it isn't a moving car and so wouldn't likely be insured as such and probably will fall under home owner's insurance during the present build phase? I'll need to check that and would hate to have it damaged somehow in the garage and not be covered. You guys address that one in your experience.IMG_2084.jpgIMG_2087.jpgIMG_2092.jpgIMG_2093.jpg
Good evening, Fred... did you ever find the answer to your question regarding insurance coverage while your Cobra is being built? If not, let me know... both my wife and daughter are property claims representatives for one of the major insurance carriers. If they were both not sleeping, I would find out and post the answer now...
I never did. Once the build started I was too excited and it kind of slipped through the cracks. It would be good to know I think.
I spoke with my daughter about the situation... my complete kit is being delivered in a couple of weeks, so I was curious too... She stated that since the vehicle is not complete or registered to drive on public roads it would be considered a "collection of parts". She is 99% sure it would be covered by homeowners should something happen prior to it being legal to drive. She sent an email to one of their defense lawyers to find out for sure and will let me know what they say when she receives a reply. We are in Virginia so, of course, it may be different in Maryland. She suggested reaching out to your agent that handles your homeowners insurance to see what they say... If you call your agent on the phone to discuss the situation and are advised it will be covered under your homeowners insurance follow up the conversation with an email to memorialize what was said and your understanding of the content of the conversation. Include in the email "if I have misunderstood the content of our conversation, please provide written clarification as soon as possible so I may seek other forms of coverage". If you have not received a response from your agent within 3-4 days of sending the initial email send a follow up email stating that since you have not received a response you are assuming you have correctly understood the content of your conversation on the specific date and that your Cobra, while being built and prior to be legal to drive on public roads, is covered by your homeowners insurance for any loss.
Good information. I'll chat with my insurance rep and see what they say. Thanks for checking into it with your daughter. Good luck with the kit and the build when you receive it. You in NOVA or elsewhere? I have kids/grandkids in the Richmond area. VA is a good state.
Good information. I'll chat with my insurance rep and see what they say. Thanks for checking into it with your daughter. Good luck with the kit and the build when you receive it. You in NOVA or elsewhere? I have kids/grandkids in the Richmond area. VA is a good state.
I spoke to my daughter this afternoon after she spoke with one of the "coverage specialists" in her office. There is no clear answer as it is very subjective. She advised that she used the example of a garage fire occurring and destroying the contents of the garage. Components not yet installed would be covered under the homeowners' policy, that part is definite, while components installed on the vehicle would be covered under auto insurance. She then raised the issue that, until the vehicle is issued a VIN number, it is not insurable under an auto policy. She also raised the question, when do the components become a "vehicle"? The person she spoke to did not have an answer. My daughter worked in an agent's office while in college... in addition to her prior suggestion of reaching out to your agent she suggested contacting one of the specialty insurers such as Haggerty. I wish I had a clear directive as this definitely seems to be a grey area...
Thanks again StangRacer for more info. Seems I assume much of the risk here, but I guess that's par for the course. In a sense when we buy insurance, such as life insurance, we're betting on an early death making the premiums a good deal. Insurers bet you'll live........and they spread their risk across a larger pool and we/I do. I'll do a little research myself and am now more aware of the risk. Thanks again.
We have an insurer in Australia that specialises only in enthusiasts cars and bikes. Their premium s are more than fair, as they recognise our vehicles aren't daily drives. At any time, we can advise them that our car is 'laid up' for repair, build or restoration. In my case, I advised that I had just received the kit and power train. Being specialist They totally understood what that was about. My premium dropped to around 25%, whilst maintaining an agreed value. These guys are great. They also sponsor many charity events. I don't think you would get too many insurers that car / bike guys are really proud to say they are with, me included.
Maybe you can find an insurer that offers a lower premium for the build stage?
Best of luck,
Nige
Mk.4 FFR supplied Right hand drive
Received 12/2012 completed 12/2019
Gen1 Coyote / TKO600 / IRS
Lots of mods to make compliant for Australian design rules
Successful first start today. Temporary side pipe mounts as others suggested. Connecting J pipes to headers needed some extra work as the threads on the headers were a little rough and I had to tap them to get the studs to screw in. Luckily I had a M12 X 1.75 tap and didn't have to run to the store. So that was a success, but none of the gauges register..........harrumph. They light up so are receiving power, but don't register what they are there for. I'll need to figure that one out. These are the basic gauges one gets with the 289 full kit, first on the list "16009 - 289 style GPS Gauges (mph)". Was a little weird that none worked, but maybe that's good as a single solution could solve them all. Get that sorted then on to tire purchase and take it for a spin.
Update is gauges now work........I had connected the wrong brown wire at the ignition switch. I've run through 2 full 20 minute heat cycle checks. All's well, no leaks. I did melt the clutch cable. Bummer but ordered a replacement and will be sure to move it further from the headers. Pleased with progress so far.
Remedied the clutch with a new Ford cable and the Forte clutch cable spacer and a firewall adjuster so that is sorted. I mounted the tires and took it for the maiden voyage. First go kart from one of my driveways to the other and back. Brakes need attention as some air still in the lines, but that milestone is in the rear view mirrors..........don't have those attached yet........so in the history books.
Onward to finish up the chassis and rolling bits then to mount the body.
Rolling chassis is completed. Purchased a pressure bleeder and brakes are now excellent. Requires a fair amount of pedal pressure but will likely improve after bedding the pads in. Finished up driver foot box and adjusted ride height and a few other details. Ready to try fitting body. Will need my wife to help, not sure just when, but that's next...........cheers - Fred IMG_2345.jpgIMG_2346.jpg
Body is on, still some pushing and shoving, but it's close to being right. Rear quick jacks are another story. Wish I knew of the "Kleiner mod" earlier in the build, but I'm glad I know it now and when the body comes off I'll make that change. Seems a shame FFR doesn't weld some nuts to the frame for this purpose, but alas that's what we have. Driver's side pipe is a little close to the body so I ordered some Breeze spacers to move it out a little and achieve better fitment. For what it's worth I needed to trim the furthest rear flat aluminum and some of the rear trunk side aluminum to get the body to settle in. It is a snug fit, but seems to be going in the right direction. Removed bulb seal across the back of the cockpit too as body was really tight there. Installed fuel filler cap yesterday and now onto the doors, hood and trunk. - Fred IMG_2352.jpg
Successful first start today. Temporary side pipe mounts as others suggested. Connecting J pipes to headers needed some extra work as the threads on the headers were a little rough and I had to tap them to get the studs to screw in. Luckily I had a M12 X 1.75 tap and didn't have to run to the store. So that was a success, but none of the gauges register..........harrumph. They light up so are receiving power, but don't register what they are there for. I'll need to figure that one out. These are the basic gauges one gets with the 289 full kit, first on the list "16009 - 289 style GPS Gauges (mph)". Was a little weird that none worked, but maybe that's good as a single solution could solve them all. Get that sorted then on to tire purchase and take it for a spin.
Harumph!!! Harumph!!! Didn't want that to be left hanging any longer...
Harumph indeed. I in my confusion attached the wrong brown wire to the ignition system. Gauges lit up because I connected them to the lighting system which I wrongly interpreted as receiving power. Once I sorted the ignition brown wires all the gauges came on. All systems go.
Hood is on and latches. I was able to attach the hood hinges without getting under the car. I really don't like being under the car any more than necessary so I reached in through the head light hole and through the front grill area and managed to get it mounted. Am messing with the doors and door latches now. Also put Breeze exhaust spacers in to push the drivers side pipe out for better alignment. Attached a pic of the hood latches and it at idle. I am really enjoying this build.........most of it. Doors aren't the easiest. IMG_2383.jpghttps://www.youtube.com/shorts/Y7aKbHRD39k
My wife captured the first drive with the body on. Still no trunk lid. Going to tackle the windshield and trunk lid this week. I think I may go the temporary body paint approach to cover it and then get it registered, enjoy it and work up the final paint decisions next summer. At least that's how I'm thinking now. I do want to get it on the road and take it through the shake down process.
Mk.4 FFR supplied Right hand drive
Received 12/2012 completed 12/2019
Gen1 Coyote / TKO600 / IRS
Lots of mods to make compliant for Australian design rules
Thanks: 
Likes: 
Reply With Quote
Originally Posted by FRM
