DuPuis Family Cobra Build

Discussion in 'Hangar Talk' started by Ted DuPuis, Aug 3, 2018.

  1. Kenny Phillips

    Kenny Phillips Pattern Altitude

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    I appreciate that, but I was more commenting on how that picture looked. I'll bet you could sneak that into someone's build blog and it would go unchallenged!
     
  2. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

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    Ahh, ok. That makes sense, and having never built (or been around) a -10, I didn't get the reference. :)
     
  3. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

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    Made a bit of progress on the Cobra this evening. I finished drilling the holes for the panels for the heater core and AC condenser, and then I drilled the holes for the panels in the left side trunk panel.

    I'm getting to the point where I'm about to run out of panels. I have 5 more panels remaining (all in the trunk). After that there are some smaller panels, but those all come much later in the build process. So really, I'm getting to the point where I'm going to have to start pulling some parts out of the parts car soon and/or buying some other parts that I'll need to put on the thing. Really, the things I need to be working on next are pulling the rear end and pedalbox out of the parts car so that I can get working on that. I'm also running very thin on clecos, but given that I'm almost done drilling aluminum panels, I think I'll survive with what I have.

    However one thing that's come to mind as a tool I need, and that's something that's good for cutting holes in the aluminum. I have to cut a retangularish hole in the firewall panel for the HVAC, and then I also am thinking I'm going to cut a hole in the rear seat panel to provide some access to the forward trunk area. I have a jig saw but I don't feel like that would do the job very precisely. Any recommendations for an appropriate tool to consider?

    If I were to follow the instructions, I would be using the Mustang wiring harness. I don't want to do that because 1) it's 25 years old and going to be brittle/broken if I remove it and 2) it's got a lot of functions I don't need/won't use. So I'm planning on making my own wiring harness. The electrical system is going to be pretty simple. Circuits will be for the EFI, fuel pump, ignition, lights (probably a couple different circuits to split up the lights), starter relay, HVAC, and heated seats. I'm planning on putting a master battery cutoff as those are recommended for the cars as a general safety/anti-theft precaution. There won't be anything that needs a "keep-alive" circuit anyway. I think what I'm likely going to do is find some marine switch and fuse panels. Something like this looks pretty appealing, having circuit breakers and fuse panel in one - make things simpler:

    https://www.amazon.com/VETOMILE-Wat...F8KC59ZAF73&psc=1&refRID=03E437665F8KC59ZAF73

    For some of the higher amperage things I might have to put in a relay and then a separate fuse, but I think mostly that'd probably do the trick. I'm somewhat debating when I want to start work on the electrical system, but I think that probably will come pretty far down the road. I at least want to get the car rolling and steering and run the brake and fuel lines before I get into the electrical system. If nothing else, I think that will make it more apparent where the wiring needs to/should go.

    One of the problems I'm having at this point is that I'm running out of the things to do that can be done in a shorter block of time and am more at the point where the things that I'm going to do will require a dedicated day, or at least dedicated morning/afternoon to do well. Fortunately the weather is getting warmer and it's staying light later.
     
  4. SoonerAviator

    SoonerAviator En-Route PoA Supporter

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    How big of a rectangular hole are we talking about? If nothing too expansive, a Dremmel with a cutoff wheel ought to do it pretty easily. You could clean up the corners with snips or file if needed.
     
  5. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

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    The big one is maybe 12”x6”. The Dremel idea came to mind.
     
  6. Tarheelpilot

    Tarheelpilot Ejection Handle Pulled

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    Does painless make a harness you could use as a base?
     
  7. SCCutler

    SCCutler Administrator Management Council Member PoA Supporter

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    Comanche 400. Hubba.
     
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  8. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

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    I've looked at their products, but really anything I've seen of theirs is really more than I'm looking for in terms of capability/wiring, and not particularly cheap for what you get. I think their stuff makes more sense if you're wiring a normal car that has more "normal car" things like power windows and locks.

    I may change my mind, but when I take a look at the various pre-fabbed options and what they actually provide, it seems like it makes more sense to buy a plug-n-play EFI setup, not so much for the main wiring harness.
     
  9. Tarheelpilot

    Tarheelpilot Ejection Handle Pulled

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    I have come to the same conclusion about their pricing over the years. Nice products but I never could pull the trigger.
     
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  10. FormerHangie

    FormerHangie Pattern Altitude

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    I have a RotoZip saw, and I see that there is a metal cutting bit available for it. I've never tried it on metal, but I can testify to its effectiveness on wood and especially sheetrock. The challenge in cutting with a RotoZip is that its rotation makes cutting extremely easy in one direction, maybe a little too easy. My experience with reciprocating saws on sheet metal isn't positive, they tend to beat the edges up pretty badly.

    Have you considered one of those nibbler attachments for your drill? They appear to do a pretty decent job.
     
  11. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

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    That RotoZip looks like that could be a good potential option, thanks. I'd want to try on a scrap piece first probably. I'm not familiar with the nibbler drill attachments, that could be another option, any links to ones you'd recommend?
     
  12. jesse

    jesse Administrator Management Council Member

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    I would just cut it with a cutoff wheel on a dremel. It will make VERY quick work of aluminum and is easy to control accurately if you trace the line.

    I’ve cut everything from plastic to wood to aluminum to steel with a dremel. It’ll cut anything if you’ve got enough wheels...steel goes through them fast but I’ve cut through some pretty thick ****.
     
  13. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

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    That'd probably the simplest option since I already have cutoff wheels for my Dremel. But... then I don't get to spend money on another tool.
     
  14. Matthew

    Matthew Touchdown! Greaser!

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    Is the firewall panel already mounted?

    If not: Is it flat? How thick is it?

    I know a guy with a laser.
     
  15. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

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    No.

    Yes.

    Not very thick... I'm not sure the exact thickness but it's fairly flimsy.

    Is it a shark?

    [​IMG]
     
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  16. Matthew

    Matthew Touchdown! Greaser!

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    [​IMG]

    ^^^ This isn't it, but it's similar. I'll check on it, we use it a lot for Lexan and a few other materials. I'll see if it's the right beam and wattage for aluminum and what thickness it can cut. I'm pretty sure we'll need to put together a .DXF file or similar for the holes you need. The XY gantry is just a plotter with a laser instead of a pen. Getting the holes placed properly would be the trick. You only get one try. In the image above, the parts and associated holes are cut in a sheet, so the holes are already aligned with the parts because they are all the same drawing. Adding holes to an existing part is a little trickier because you have to get everything properly oriented first.

    edit:

    The guy I need to talk to is stuck in MSP.

    My guess - yeah, we can do it, but it's probably going to be more trouble than getting a Dremel or Rotozip.
     
    Last edited: Apr 12, 2019 at 3:40 PM
  17. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

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    That would be my guess as well. Plus the piece is painted, which probably is bad with a laser.

    Appreciate the thought, but I'll figure out a RotoZip, Dremel, etc. I think.
     
  18. Matthew

    Matthew Touchdown! Greaser!

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    It would char the paint around the edges regardless of which cut side is up. I'd probably have to make a jig to hold it, do test cuts on paper for placement, then put the panel in the jig and let 'er rip. I could program it to etch your signature on it too, for the "Banhammer Signature Edition".
     
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  19. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

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    Now THAT could be cool... maybe somewhere along the lines we could find a place to put in a fun little personalization for the Cobra if it wouldn't be much trouble.
     
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  20. Matthew

    Matthew Touchdown! Greaser!

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    I can probably etch that on a small piece you could attach somewhere. You want an etching of your picture? That might personalize it too much!
     
  21. PaulS

    PaulS Final Approach

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    You need a nibbler tool, I believe that's what my buddy used when he built his. You can get electric or hand operated. Just drill a hole and go to town.

    [​IMG]
     
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  22. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

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    That’s it! I used one of those at some point years ago.
     
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  23. FormerHangie

    FormerHangie Pattern Altitude

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    I don't have any personal experience with nibblers. There was a thread a while back where someone was asking about which hand nibbler to get, and it got me investigating them. I wish I'd known there was such a thing back in my racing days, it would have saved a lot of time if we'd had one.
     
  24. -KLB-

    -KLB- Pre-takeoff checklist

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    Wait, this doesn’t currently have ignition issues?

    There are air powered nibblers that make quick work of holes like that. Be aware that all nibblers, especially the air ones make a bunch of razor sharp crescents (especially if cutting steel) that will pierce shoe soles and hitch rides to lots of places to atttack bare feet. So use them someplace you can hopefully contain the mess, and clean it up right away.
     
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  25. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

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    Well the engine doesn’t run and there is no engine therefore there is no ignition system so it kinda has ignition issues. :)
     
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  26. MIFlyer

    MIFlyer Line Up and Wait PoA Supporter

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    You probably want a fun radio and console phone charger?


    Sent from my iPad using Tapatalk
     
  27. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

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    I’ve decided no radio for this car. Lots of people put them in, but general consensus is you can’t hear it while driving anyway. Our Harleys have radios and we can hear those fine, but reality is these days I’m more of a “turn the radio off and enjoy the drive” type. I figure I can use ear buds and my phone if I want to listen to tunes. Maybe not entirely legal but I’ll be using ear plugs of some sort when driving much of the time I suspect. No reason to make the tinnitus worse any faster than necessary.

    I do figure I’ll put in a USB charger and cup holders. Some of the marine switch panels I’ve looked at have USB chargers built in, so that seems a logical step.
     
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  28. SoonerAviator

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    I own both a Dremmel and a Rotozip, as well as pneumatic cutoff tools. For fine cuts less than a foot, the Dremmel is much easier to control and it won’t get away from you. The Rotozip makes quicker work of things and can handle thicker materials, but if it snags or hangs up it can make a mess of things. Pneumatic cutoff wheels are more easily handled than the Rotozip, but don’t have the consistency in wheel speed or torque. Choose wisely.

    Nibblers are fine, especially the pneumatic type, but for a rectangular 12x6 hole I’d pass on them. If you have more complex shapes they’re a better option.
     
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  29. Matthew

    Matthew Touchdown! Greaser!

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    I found a parts car for you:


    50BC3475-2CE6-498A-BF89-69DF37477D9D.jpeg
     
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  30. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

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    Perfect! I was wanting velocity stacks...