18th December 2007

Crikey another week!

Well, it has been quite a few hectic days, on-going email problems at a friends, collecting Thomas from Cardiff and my PC playing up badly requiring two rebuilds in as many days. Father-in-law also had a planned hip replacement op last week for which a quick run back to the hospital today was required – all is well though!

So, nothing has been done really since my trip to Dax to get a few bits and bobs. I have a lot lined up to do now when time permits including finding a Jaguar XJS 3.54 Powerloc differential. Many bits to fit including a 17.5 gallon fuel tank, that’s getting on for 80 litres or nearly £100 of the real go faster juice. I can see the Cobra will be low mileage for some time.

There will hopefully be some progress before Xmas in which case I’ll add pictures and an update.

Oh! And Tony I haven’t forgotten, just suddenly very busy.

11th December 2007

Crikey, has it been a week since I posted. Ah well it was Nicola's birthday and I went on a visit to Dax (the kit manufacturer) plus I've had a bit of a problem with the rear brakes, after removing the back axle. I'm looking for a replacement diff now from a 1985 Jaguar XJS.

So sorry for the lack of updates (and web cam). Both will be back as soon as I've got the rear brakes all tidied up and ready to go back in.

Here's the petrol tank ;-)

Edit: Just checked the front callipers and the pistons there don't move either.

4th December 2007

Started stripping the back axle today after a bit of cleaning. I have to remember where everything goes so I can put it back together properly. One problem is getting the shims right so the rear wheels are sitting at the right angle.

This is the cars nearside and there are three shims on the outside of the disk one slightly fatter.


On the inside of the disk there's only one shim. However if the replacement differential is a different size these shims will need adjusting.







The fulcrum rod has to come out and the layout of it's washers and shims retained.







And what on earth is this green stuff coming out of the hub carrier joint !

3rd December 2007

The back axle is now out, and it was a tough job. It was relatively simple but only because I had a lot of advice on how to do it from the Cobra Replica Club. I had some difficulty with some very tight nuts and bolts but with two scissor jacks and a trolley jack it came out quite easily. I now have to clean it and take it to bits to fit a new diff (when I get hold of one).

29th November 2007

This post is more for the guys at CRC so I can get some help removing the back axle. I'm doing that because I want to change the differential ratios for something that will give a bit more acceleration.

OK, so here goes, will the axle drop if I just release the four lower ends of the springs? and either the front or back of the radius arms? Or do the fulcrum shafts have to come out too? Plus of course the prop shaft.

At the back the radius arm bolts look like they will hit the lower suspension points, at the front the bolts look like they will have to come up through the floor which means cutting it.

The top of the diff seems to be sealed to the frame with a rubber block? Is it stuck or will it come free?

28th November 2007

Just some pics of the front brake pipes, that loop will be going ;-)

28th November 2007

I had a bit of a problem with the web cam - well the PC actually so it was off air for a day or so, solved by a PSU fix in Ipswich!.

I've been looking at the brake pipes that I've fitted and decided I do need to shorten the front nearside one, so a brake pipe flange making kit is now sitting quietly in the garage waiting for it's first use.

Whilst thinking I also started looking at where the rear brake pipe will go and after a couple of excellent pictures from the CRC I now know where, so I started cleaning that part of the car and the inside! I put a tarpaulin underneath and some old carpet then set to with the pressure washer ;-) Things are beginning to look a bit better.



The engines looking a bit better too! I'm off to Dax week after next to get some specialist bits including a fuel tank. With the addition of a few pipes and a battery it might actually be close to being started. Oh! except for some exhaust pipes ;-) I'd better warn the neighbours.

24th November 2007

Finally done some damage to the Cobra and drilled some holes for the brake pipe holders, trouble is I can't a 6mm drill bit into some of them and I won't be able to when I reach the rear pipe clips down the inside of the chassis?

So if anyone knows how a drill a 6mm hole in the side of a chassis member with only a 5" gap?






I might end up enlarging the holes with a hand reamer !

Anyway I have some brake pipes in place and at least got the flexible pipes in and hos nasty twisty ones around the callipers.

21st November 2007

Several days of tinkering later and nearly all the bits I've stripped are back together. Just waiting for some new spark plugs and then I can refit the HT leads - I had to smile at the guy in the shop when he tried to give me only four spark plugs!

Anyway the brakes are now done, all clean and painted up, as is the engine so I've moved onto the brake pipes.


First problem with the brake pipes is that the set I have seem to be rather too long so I've asked for some advice from those very nice people at the Cobra Replica Club. And the master cylinder is missing a manual, so I have no idea which pipe fits in which hole. I'm sure someone will know.


I also had to raise the car on it's stands so I could get underneath to start drilling the chassis for the brake pipe holders.

16th November 2007

Did a bit of painting today, some more successful than others ;-). Callipers will now be visible, cylinder heads will be bright and rocker covers are sparkly black.


When it's all dry, or 'cured' as these paints say, the front can all go back together. Still waiting for my right angled gadget to drill the brake pipe clip holes. But that's looking like the next job on the list, not that there is a list or anything just a gut feel of what needs to be done next or, in some cases, what would be more interesting to do next.

15th November 2007

Refitted the first disk today, but can't finish until the calliper paint arrives which it did in the post after lunch. A very gooey paint that cures over several days so may be a while yet. I decided the engine needs some paint too.

I found the location for the dipstick thanks to several photos on the Cobra forums.

I had a long chat with a friend (Tim) about where things go on the Cobra and discovered his build manual is a lot more informative than mine. I now know where the brake fluid reservoir goes and why, as well as how to fit the steering column although I need some bits from Dax to complete that.

I found the Sierra switches and whilst cleaning them broke the hazard light switch !! Painting tomorrow I think.

14th November 2007

Both front brakes are now in bits, cleaned and ready top go back together. Just waiting for some caliper paint to brighten things up a bit. New discs are here as are the pads. I've got a Dremel right angled attachment coming so I can drill the chassis to fit the brake pipe holders.


Just found a really good web site for Jaguar bits a lot cheaper than local motor factors. www.britishparts.co.uk thanks to the CobraClub for that.

Wondering whether to put the disc shields back on, most people seem to leave them off.

12th November 2007

Started stripping the nearside front suspension in preparation for the new discs so that I can complete the brake system.

However don't use cheap tools when undoing possibly the tightest nuts on the car, disc to hub nuts!

Ah well, another trip to the tool shop.

Strangely I was only using this socket as my main socket set goes 5-15 17-20 ish there is no 16mm socket! The new one worked though so I'm just waiting for new discs to arrive and things can get back together then on to the off side front suspension.

At least it looks a bit better even if it is only half done, amazing what a duster and a bit of paint can do.

If anyone is passing and has a right angled drill, I'm going to need one soon to attach the brake pipe clips inside the chassis beam. I suspect this should have been done before the gearbox and body were fitted ;-)

The weekend

I need to take a rest today but the engine is looking a bit cleaner don't you think? and I've been checking out where all those pipes and cables go!

There's quite a bit lacking with the brakes, the front disks need to to be replaced, the callipers cleaned and painted - probably bright yellow - some new pads fitted then the pipework installed. Finally filled up with brake fluid, bled and tested. At that point, if I need to get it out of the garage I can stop it rolling off down the drive ;-)

It could also do with some steering! I'll need some bits from Dax for that so I can see a trip coming up. Nicola will have to come along otherwise I'll end up buying everything that's needed to finish it off.

Still considering the colour red or blue?

Other resources I've made available are the web cam and my selection of photos.

9th November 2007

Thomas' birthday.

Some 20 odd years ago when I was struggling to buy cars that were fast enough, the thought of a kit car started, but as usual things got carried away and the basic Caterham 7 style for five grand turned quickly into a twenty grand Cobra monster, so the idea was shelved for later years.

Well those later years have arrived and with the opportunity to retire early (some would say not early enough) it was decided to sell the Prodirve Impreza and use the proceeds to get a utility vehicle and the first parts of the kit. The utility vehicle turned out to be a Mitsubishi L200 and the kit turned out to be a part built Dax Tojeiro.

See Dax's Home page for details of the Tojeiro.

The part built car has the Dax ladder chassis, the body and most of the mechanical parts including a Chevy 350 engine Tremec gearbox, twin clutch and Powerloc diff. Running gear is from a Jaguar XJS.

It still needs all the plumbing for brakes fuel and water, electrics, interior, doors bonnet and boot, hood and painting. (Pleas note use of UK names for bonnet, hood and boot). But first it needs cleaning.

8th November 2007

Time to start centralising the information on the cobra build. I'll start putting progress reports and the odd picture here. Plus I'll add a brief history at some point.

To start with, this is what I want to end up with.


And this what I'm starting with.