Preparation

Engine

Gearbox\Clutch

Donor Parts

Chassis

The Build

Build by Date

Bits and Pieces

Build Schedule

Contact

Links

  
6th Mar 2010 Fuel System - Fuel tank sender puzzle!!
4th Mar 2010 Wipers finished!
3rd Mar 2010 Wiper  mechanisms fitted and problem resolved!
2nd Mar 2010 More wiper work and a Bundy problem!!
28th Feb 2010 Wipers.
27th Feb 2010 Still can't get my head around the fuel tank sender, so I'm waiting for advice!
19th Feb 2010 Correct fuel sender delivered.
10th Feb 2010 More heater and demister pipe work.
7th Feb 2010 Final fit of the windscreen. Starting to look like a car now!!
6th Feb 2010

Dashboard Part 1 - Temporary fit of the gauges.

4th Feb 2010 Ordered my seats and leatherwork today from GD. I am getting the Mk4 seats which are slightly higher than normal, which will help me with the IVA headrest issue.
31st Jan 2010 Heater and demister pipe work.
30th Jan 2010 More Windscreen work.
24th Jan 2010 Windscreen fitting.
17th Jan 2010 Cock up with the Fuel Sender!!
17th Jan 2010 Change of mind on the Dashboard layout.
10th Jan 2010 finished off fitting the fuel pump, filter and pipe work.
1st Jan 2010 Happy New Year everyone!!                   
31st Dec 09 A bit more work on fitting the fuel pump and filter.
26th Dec 09 Time to work off a bit of Turkey and sneak a few hours in the garage!! I started fitting the fuel pump assembly into the boot today.
25th Dec 09 Merry Christmas to everyone!!!
21st Dec 09 Back on line!!! I've had to get a new computer as my other one died, and I've only just got back on line! Updates on build progress to follow soon.
21st Nov 09 Thoughts turn to the dashboard.
14th Nov 09 finishing of the roll hoops.
10th Nov 09 Fun with foam!!!
8th Nov 09 More work on the Roll Hoops.
31st Oct 09 Fitting the dreaded Roll Hoops!!!
25th Oct 09 Having now got all the flashlines rubbed down, I have decided to wait till I can get the car out of the garage before any more compounding and polishing. I know its nearly Christmas but the inside of my garage will end up looking like Santa's grotto if I use the polisher much more. Farecla flies all over the place!!!  Time to start on the Roll Hoops.
20th Oct 09 I was going to start fitting the roll hoops at the weekend but fell at the first hurdle!! My right angle attachment for the drill would only take up to a 10mm bit. The hole cutting saws I have need 13mm. Because the angle attachment only accepts a 3/8" threaded chuck I couldn't find one locally at all, they were all 1/2", So I have sent for one and it should be with me tomorrow!! Watch this space!!
19th Oct 09 Not a lot of visible action this last couple of weeks. I have been rubbing down and compounding the body and having a big problem with the front nearside wing (mentioned earlier in the body section of the site).  Because of the deformity in it, the rubbing down to get it smooth has revealed lots of tiny white spots. Air bubbles I guess. I am trying to patch them by drilling them out with a small dremel attachment and then filling with Gel and rubbing down again. Not easy to show the results but will post some pics once I have done as much as I can.
6th Oct 09 fixing the Cock Up!!!
4th Oct 09 Bad Mistake.....!!!
3rd Oct 09 Rear wheels off, preparing to fit the roll hoops.
27th Sept 09 More parts collected.
27th Sept 09 Finally got some time in the garage and finished the rubbing down of the flash lines.
19th Sept 09 Working away with no time for work on the car.....very grumpy!!!
12th Sept 09 Spent this weekend rubbing down a good looking body!!!
31st Aug 09 Build Schedule updated.
21st Aug 09 Spent the best part of today putting the Pedal box back in...............!!
20th Aug 09 Holiday stopped play!! (But back in the garage this weekend!!
2nd Aug 09 Build Schedule updated.
31st July 09 Picked up dashboard and loom.
26th July 09 Securing Engine bay hydraulic hoses.
25th July 09 finishing off the plumbing.
19th July 09 Fitting the Relay's into the footwell. Not a job to look forward to!!!
18th July 09 Fitted the Battery tray, battery and engine bay studs.
12th July 09 Final body securing bolts (rear ones in the boot).
11th July 09 Fitted the Foot well extension.
5th July 09 Fitting front under tray and Oil Cooler.
4th July 09 Securing the Body to the Chassis.
30th June 09 BODY FITTED!!!
28th June 09 All jobs completed just need to gather the troops for the body fitting!!!
22nd June 09 List shrinking before body fit!!         1)  Test Hydraulics                                 2)  Drain Coolant - move radiator back 3)  Cut hole in body for the gearstick    4)  Modify transmission tunnel mounts     5)  Fit chassis rubber mounting strips    6)  Final engine bay polish.                   7)  FIT BODY!!!
20th June 09 Leak sorted (Bleeding thing!!)
14th June 09 Bleeding Leaks!!!
8th June 09

List getting smaller before body fit!!1)  Test Hydraulics                               2)  Drain Coolant - move radiator back 3)  Cut hole in body for the gearstick    4)  Modify transmission tunnel mounts      5)  Fit chassis rubber mounting strips    6)  Final engine bay polish.                   7)  FIT BODY!!!

8th June 09 Hydraulics testing.
3rd June 09 Fitting the Pedal Box
31st May 09 Good weather stopped play! (although I did manage to sneak an hour to fit the fluid reservoirs!).
27th May 09 Foot well extension and wheel arch cavity covers.
24th May 09 Main Body Loom: Stage 2.
23rd May 09 Main Body Loom: Stage 1.
3rd May 09 Heater fitted.
30th Apr 09 Latest batch of parts collected:  Finally picked up the pedal box and a few other bits today. That's the pot empty now, better start saving for the next batch of parts!!!
17th Apr 09 Latest parts order. Spoke to Andy at GD today about my latest parts order. Its been held up for a while due to the workload at GD. There are a few bits and pieces in the order (battery tray, hydraulic reservoirs etc) but the main one is the adjustable pedal box. Andy say it should be ready (along with the other bits of the order) next week.
17th Apr 09 Fitting the Heater.
12th Apr 09 Modifying the Heater.
10th Apr 09 Final coat of paint in the engine bay, and putting on a rubber coat!!!
4th Apr 09 Painting the engine bay.
27th Mar 09 Engine bay preparation.
17th Mar 09 Sorting the engine bay Flash Lines and Joins.
16th Mar 09 Parts Order delay. Spoke to Andy at GD today to find out how long my parts order would be, which included the adjustable pedal box. Andy said it would be another couple of weeks at least  because they were up to their eye's in it trying to finish some cars for SVA. It's no big problem as I have plenty to do at the moment!!!
4th Mar 09 First look at the Main Body Wiring Loom............Gulp!!!!
1st Mar 09 Ordered Adjustable Pedal Box. Ordered adjustable pedal box from GD. Together with Battery frame and the Alloy Front Under Tray. Andy says about two weeks which is fine as I got skiing on Saturday for a week!!
22nd Feb 09 Body Shell arrives!!!!!!!!
12th Feb 09 Body Shell Update: Spoke to Andy today and he confirms the body will be ready weekend commencing 21st Feb. He is away on the Saturday so we have agreed I can pick it up on Sunday 22nd. Watch this space!!
6th Feb 09 Body Shell Update: Spoke to Andy at GD and things are running behind with my body shell. He says I will almost certainly have it for the weekend commencing 21st Feb. So...........fingers crossed for then!!
31st Jan 09 Preparing for the Body: Fitted the tunnel cover plate.
24th Jan 09 Clutch Hydraulic Hose fitted.
15th Jan 09 Body Shell update.
13th Jan 09 Throttle cable bracket from the States.
10th Jan 09 More wiring.
1st Jan 09 Happy New Year!!
26th Dec 08 Got the permanent engine bay loom fitted today. Needed to get some cold fresh air in the garage after eating and drinking for England yesterday!!
16th Dec 08 Body Shell update. Spoke to Andy at GD today. My Body Shell will be started second week in January and ready for collection approximately ten days later. That's fine by me, as it gives me time to save a bit more and also make sure the garage and necessary bits are ready. Just need to organise some transport and some able bodied men!!
1st Dec 08 Finished "fiddling" with the engine.......for now!!
29th Nov 08 Change of heart with the "Fuel King"!!
23rd Nov 08 Fitted a "Fuel King" pressure regulator.
16th Nov 08 A bit of woodwork.
24h Oct 08 MK4 Body ordered!!
6th Oct 08 Up and running again.
1st Oct 08 Head gasket woe's.
27th Sept 08 So, having decided to get GD to compound and polish the engine bay, but me to do the rest of the body, and having also prepared a list of things I need to order at the same time as the body, my finances tell me I will be ready to order the body in December. Need to talk to Andy as if I want it before Christmas I may need to order earlier as I'm not sure what the lead time is..............watch this space!!!
26th Sept 08 Build Update. Apart from the slightly smokey engine (which will hopefully settle itself), and some oil seepage (seems to be seeping from the head gaskets but more investigation necessary), I have just about finished the engine/chassis stage (fingers crossed!!) and ready for the body. Time to sort the finances out!!!
14th Sept 08 Fitted new Alternator.
13th Sept 08 Not much happening at the moment. I've run the engine a couple of times now and it sounds very sweet. No lifter noise now. Still a little bit of smoke but hoping that will go as the engine beds in.
30th Aug 08 Back from Holiday and raring to get back in the garage!! I have added a couple of "YouTube" video links of my engine start up, just click on this link.
14th Aug 08 Off on holiday so won't be posting for a while. Think I would have cancelled the holiday if the engine hadn't started!! Now I can go with a big grin on my face!! Watch this space ..................
11th Aug 08 Engine Started!!!
9th Aug 08 Rain stopped play!!! Weather was lousy this afternoon so I wasn't able to go for the first start. Watch this space!!
7th Aug 08 Engine start this weekend, weather permitting!!!
3rd Aug 08 Unfinished job on the brakes.
2nd Aug 08 Put oil in the Diff (Valvoline 80W-90), engine (Valvoline VR1 racing) and gearbox (Castrol SMX-S). I filled the oil cooler and associated pipes and also filled the oil filter. Once I get hold of a temporary fuel  tank I will be ready to go for the first engine start next weekend!!
28th July 08 Final bit of the cooling system (for now!!!).
25th July 08 Temporary wiring diagram
20th July 08 Wiring for the first engine start.
19th July 08 The crankshaft pulley bolt is finally tightened!
19th July 08 One step nearer to engine start - temporary dashboard finished.
17th July 08 Gauges and senders arrive from ETB.
12th July 08 Handbrake v Crankshaft pulley bolt!!
6th July 08 Rethink on the Oil system (Again!!).
4th July 08 Wiring for first start.
27th June 08 Radiator fixed and fan finally fitted!!!
25th June 08 Pacet electric fan arrives but disaster is just around the corner!!
14th June 08 Fram filter temporarily fitted ready for first engine start.
13th June 08 More Fuel System parts.
9th June 08 Fuel System
20th Apr 08 Exhaust finished!!
19th Apr 08 More Exhaust fitting.
13th Apr 08 Exhaust system.
30th Mar 08 More hose work.
28th Mar 08

Coolant Hoses: Received a consignment from PSH (Performance Silicon Hoses).

22nd Mar 08 Fitted the shortened Rover remote gearchange housing.
16th Mar 08 Fitting the Alternator.
15th Mar 08 Starter Motor.
2nd Mar 08 Cylinder Head bolts.
1st Mar 08 Starter motor woe's!
25th Feb 08 Headers - out with the grinder!!
24th Feb 08 Fitting headers, but nothing ever goes smoothly!!!
16th Feb 08 Rethink on the oil pipework!
12th Feb 08 More oil pipework.
6th Feb 08 Right and wrong remote filter head.
3rd Feb 08 Fitting the oil system pipe work and parts.
2nd Feb 08 Fitted coil and ballast resistor.
25th Jan 08 Exhaust system arrives!
25th Jan 08 Picked up the Propshaft from GD.
25h Jan 08 Cooling System: I picked up the radiator and header tank from GD Today.
19th Jan 08 Engine bay brackets.
19th Jan 08 Fitting the Carburettor.
15th Jan 08 Carburettor arrives.
8th Jan 08 Ordered radiator, header tank, drive shaft and exhaust system from GD. Ordered Holley Carb and Cobra air filter, oil cooler  and various other parts for oil system (oil Cooler, thermostat, remote filter mounting etc) from Merlin Motorsport and other suppliers.......................Hell, I need a drink after spending all that!!!!!
5th Jan 08 Sorting the oil system.
2nd Jan 08 Finishing off front and rear rigid brake pipes.
1st Jan 08 Happy New Year everyone!!
27th Dec 07 Engine in, at last!!!
25th Dec 07 Merry Christmas Everyone!!
23rd Dec 07 A bit of brake pipe work.
16th Dec 07 Into the daylight!!!
9th Dec 07 Wheels on! Now it's starting to look like a car (if you have a good imagination!!).
8th Dec 07

Baffled by "Bump Steer"!

2nd Dec 07 Toe in and steering geometry set.........eventually!!!
21st Nov 07 First fit of the steering rack.
18th Nov 07 Front end brake lines in.
6th Nov 07 Picked the steering rack up from GD!!
4th Nov 07 Finally finish fitting the front hubs and setting the caster and camber. Thank God for that!!!
4th Nov 07 Start to install Rigid Fuel Line.
29th Oct 07 Calliper problem resolved!!
27th Oct 07 It was all going so well!!! Problems with fitting the front callipers.
18th Oct 07 Treated the Chassis with Dinitrol ML.
18th Oct 07 Moving on to the front.
10th Oct 07 Cock up at the front!!
8th Oct 07 Rear axle finally sorted!!
2nd Oct 07 Trying to sort the rear axle shimming and line of thrust out.
23rd Sept 07 One step forward and one step back!!!
18th Sept 07 Setting camber on rear axle.
15th Sept 07 Initial build and configuration of the rear axle.
6th Sept 07 Chassis J0258 collected!!
5th Sept 07 Pick up Chassis tomorrow!!!
1st Sept 07 Working on the Rear axle parts, in preparation for Chassis.
30th Aug 07 Andy from GD rang. Chassis is in for powder coating and should be ready next week!!
18th Aug 07 Bell housing fixed using a Helicoil.
17th Aug 07 Chassis being built next week!!
14th Aug 07 Gearbox/bell housing problems.
11th Aug 07 Fitted Gearbox to the engine.
8th Aug 07 Fitted the thrust bearing and clutch mechanism to the gearbox/bell housing.
1st Aug 07 Frustrated!! GD are on shutdown until the 13th so its going to be a few weeks yet until I get my Chassis!!
29th July 07 I spend the afternoon setting the shims on the rear disks.
27th July 07

My Diff  Finally arrives back! (at last!).

27th July 07 New clutch and flywheel arrive from JRV8.
23rd July 07

Ordered Flywheel and three part clutch kit from JRV8.

22nd July 07

Back from Holiday and "playing" in the garage. Waiting for the Diff and Chassis to come!!

9th July 07

Away on holiday for just over a week, starting tomorrow, so no updates on the site for a while.

6th July 07 Finally send my Diff to Wards!!!
29th June 07

The saga of City Link continues!!! Diff still not picked up!!

27th June 07

Back from working in Italy, box with Diff in still not picked up!! Couriers say the box is to heavy!! Chatting to Eddie at Ward's!!

22nd June 07 Ordered Chassis!!
22nd June 07

Courier never turned up!! City Link eh!!! Trying again Monday.

21st June 07 Courier (City Link) never turned up!! Trying again Friday!
20th June 07

The courier booked to pick up my Diff to deliver to  Wards for recon.

8th June 07

Booked an appointment at Gardner Douglas for the 22nd June to have a factory tour and to book my Chassis (exited)!!!

1st June 07 Reconditioned Hubs and Brake Callipers arrive from Ward's.
24th May 07 Finally get the engine off the stand ready for the gearbox to be fitted.
21st May 07 Spoke to Eddie at Ward's today, my Hubs and Callipers won't be ready till next week now!
15th May 07

Still waiting for my hubs and brake callipers from Wards!!

7th May 07 Acquired build wheels.

                                                                       

ddd

 

 

Latest News

This Website is firstly intended as a permanent record to catalogue the events, from start to finish, of my GD Cobra build. If by publishing the "diary" it gives information, pleasure, or just an interesting interlude to like minded enthusiasts, then I will feel more  than satisfied that my time has not been wasted!!

The diary dates for each of the sections ("Donor Parts", "Engine" etc) may not run concurrently but are there just as a record of when that particular part or component was tackled! Click on the "Build by Date" button on the left to see progress catalogued in date order.

Please come back regularly to see the progress, I normally update every week. If anyone would like to contact me about the project please feel free to e-mail me.

April 2006

I have been intending to build a Kit Car of some kind for many years but one thing after another has always got in the way. Another birthday came round in December and I thought "right, enough good intentions, and enough dreaming, 2006 will be the start of what will be (I hope!) a satisfying and exciting project". No idea how long it will take but I don't care, I'm just excited to be under way!

I wasn't sure what I wanted to build having often fancied a Caterham and other similar kits. A trip to Oulton Park Kit Car Show changed all that after I saw the array of beautiful Cobra's there on display!

I was smitten but had to decide which kit. My main Criteria was that I was going to do this over a longish period, engine build first, then Chassis followed finally by the body. I have a large but not Double garage and have no room to store the body shell. I needed a kit that I could buy the body shell, only when I was ready to fit it, even if that was two years down the line. I also wanted a Cobra with underslung exhausts, purely because I like the look of them, rather that the side pipes. The only kit that ticked all my boxed was GD and after looking at some examples at Oulton Park my mind was made up. 

First and foremost I had to sort my Garage out, make a bit of space and then find a suitable engine!!

 

 

 

 

 

                                                                                                             

 

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