DuPuis Family Cobra Build

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

  1. Fiveslide

    Fiveslide Line Up and Wait

    Joined:
    Mar 27, 2019
    Messages:
    651
    Display Name:

    Display name:
    Fiveslide
    Fun fact: a semi truck has to have two horns, an air horn and, usually, an electric horn just like every other car. If your electric horn quits, one of those squeezy horns is a suitable replacement and it will pass annual inspection.

    I mounted mine to my driver's side mirror.
     
  2. SCCutler

    SCCutler Administrator Management Council Member PoA Supporter

    Joined:
    Feb 27, 2005
    Messages:
    16,812
    Location:
    Dallas
    Display Name:

    Display name:
    Spike Cutler
    Well, what the hell. Why not?

    And, in the same post as an allusion to a 1983 Ford LTD.
     
  3. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

    Joined:
    Oct 9, 2007
    Messages:
    25,904
    Location:
    Paola, KS
    Display Name:

    Display name:
    #bandozer
    It would be worth looking into things to see if anyone has (or if I think I could) retrofit an OEM style turn signal lever that has more controls built-in to it.

    The pushing a side button I think would be fine for me as a reflex since I'm used to it from other cars. While it's uncommon it's not unheard of.

    This is the setup that most people buy and it's very compact and convenient:

    http://www.norcal-cobras.com/store/russ_garage/mk3/mk3tss.html

    Yeah, my K100 had a (pathetic) electric horn and then a (loud) air horn. I liked the air horn better. :)
     
  4. Matthew

    Matthew Touchdown! Greaser!

    Joined:
    Apr 18, 2005
    Messages:
    15,935
    Location:
    kojc, kixd, k34
    Display Name:

    Display name:
    Matthew
    Whatever horn you go with, make sure it can play "la cucaracha".

    --

    What's the procedure, if any, to go through to get the finished Cobra OK'd as being street legal?
     
  5. -KLB-

    -KLB- Pre-takeoff checklist

    Joined:
    Sep 25, 2018
    Messages:
    305
    Display Name:

    Display name:
    -KLB-
    yeah, it will be difficult to compete with that. What is ironic, is that I would almost swear that the 69 Karmann Ghia that I sometimes drove had a momentary pull back contact on the turn signal stalk that operated the dimmer relay, as a simple pull back to toggle between low and hi beams.
     
  6. SoonerAviator

    SoonerAviator Final Approach PoA Supporter

    Joined:
    Jul 21, 2014
    Messages:
    5,035
    Location:
    Broken Arrow, OK
    Display Name:

    Display name:
    SoonerAviator
    Does none of the regular retrofit companies make a steering column for it (Ididit)? I know Ididit has similar styles to the one you linked and have the add-on for the high beam/FTP switch to be integrated with the turn signal or tilt stalk, but not sure if they have the exact dimensions.
     
  7. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

    Joined:
    Oct 9, 2007
    Messages:
    25,904
    Location:
    Paola, KS
    Display Name:

    Display name:
    #bandozer
    Seeing as the car has a steering column already (that comes from FFR) I don't particularly want to fiddle with a different steering column that may not fit or work as well.

    This is actually one aspect of the kit that I'm not a big fan of - the way they have you install it is using the Mustang turn signal stalk, I think mounted behind the dash and you reach under to switch it on/off. No thanks. Fine for a dedicated track car, not really for a street car.
     
  8. SoonerAviator

    SoonerAviator Final Approach PoA Supporter

    Joined:
    Jul 21, 2014
    Messages:
    5,035
    Location:
    Broken Arrow, OK
    Display Name:

    Display name:
    SoonerAviator
    I'm just surprised that your link is the "best" option, given that so many Cobra replicars have been produced. I would have thought that the turn signal/high beam/horn issue would have been addressed. What about a two position headlight switch, where the aft-position is high beams, and the mid-position is the low beams/running lights?
     
  9. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

    Joined:
    Oct 9, 2007
    Messages:
    25,904
    Location:
    Paola, KS
    Display Name:

    Display name:
    #bandozer
    I'd like that option, one's just not currently available from someone that I'm aware of.
     
  10. SoonerAviator

    SoonerAviator Final Approach PoA Supporter

    Joined:
    Jul 21, 2014
    Messages:
    5,035
    Location:
    Broken Arrow, OK
    Display Name:

    Display name:
    SoonerAviator
  11. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

    Joined:
    Oct 9, 2007
    Messages:
    25,904
    Location:
    Paola, KS
    Display Name:

    Display name:
    #bandozer
    I misunderstood what you were initially saying, I thought you were thinking about a turn signal lever on the Cobra like that.

    Yes, I'd seen headlight switches like this one, and that would likely be a good option. Although I have to think about the dynamics of that. I could see it getting to where I go to turn off my high beams and accidentally turn off the headlights entirely.
     
  12. SoonerAviator

    SoonerAviator Final Approach PoA Supporter

    Joined:
    Jul 21, 2014
    Messages:
    5,035
    Location:
    Broken Arrow, OK
    Display Name:

    Display name:
    SoonerAviator
    Suppose it just depends on how strong the detent is between stations. I bet you'd only make the mistake once or twice!
     
  13. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

    Joined:
    Oct 9, 2007
    Messages:
    25,904
    Location:
    Paola, KS
    Display Name:

    Display name:
    #bandozer
    Like you said, it depends on how strong that detent is. Some switches are harder to modulate than others. The other option I've considered is a standard off/parking lights/headlights, and then have a second switch for high beams. Could even have it be a 3-position (off-momentary-on) so I could both flash high beams and turn them on.

    I need to spend some time looking at the dashboard a bit for that, as I need to determine an appropriate physical location for it, too.
     
  14. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

    Joined:
    Oct 9, 2007
    Messages:
    25,904
    Location:
    Paola, KS
    Display Name:

    Display name:
    #bandozer
    I realized I had some video that I hadn't posted to YouTube and it'd been over a month since my last video. Oops. So here's the first bit of the video:

     
  15. Sac Arrow

    Sac Arrow Touchdown! Greaser!

    Joined:
    May 11, 2010
    Messages:
    16,654
    Location:
    Oakland, CA
    Display Name:

    Display name:
    Full Send Mode
    Pretty cool video.
     
    Ted DuPuis likes this.
  16. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

    Joined:
    Oct 9, 2007
    Messages:
    25,904
    Location:
    Paola, KS
    Display Name:

    Display name:
    #bandozer
    Thanks!
     
  17. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

    Joined:
    Oct 9, 2007
    Messages:
    25,904
    Location:
    Paola, KS
    Display Name:

    Display name:
    #bandozer
    This past weekend I managed to get some work done on the Cobra, mostly on a few details. Got started making the bracket for the alternator. I need to add another portion to the bracket so that it has two bolts that mount it to the engine so that it can support the alternator belt pushing back correctly. I really need to get gas for my welder.

    I also finished up the fuel hoses that needed to get done, so that system is "done" and I could test it at any time. I suppose I have two more rivets for adel clamps to put in.

    Then I worked on the HVAC some, mostly in figuring out which fittings I needed to use where, started working on some of the hoses, and also started drilling holes for the hoses to pass through the "bird box".

    I also gave some more thought to switches etc for the dash. I've decided that what I want to do is put the wiring for the horn on the turn signal stalk, and then I'll have an ignition key (which will turn on the ECU as well as the water pump). Then there will be the headlight switch (likely a pull switch with off, marker lights, headlights, and twist to dim) and another physical switch for the high beams on and off. There's a rotary switch for the blower motor (off plus low/medium/high blower motor speeds), and then I'll have a switch for turning on the AC compressor. And given that the heated seats have their own switches which I think I'll put in the transmission tunnel area, that should be it for the dash switches. So it'll still look a bit more conventional than I was originally planning, but simpler and it'll be fine. I've also decided I'm just going to use switches I already have for now. I can put different switches in later if I feel like it. The hole sizes are pretty standard so it's not a big deal.

    As far as indicator lights go, I'm only planning on indicators for the turn signals and the high beams. Nothing else I can think of would be required.

    So I have a shopping list of things I need to buy to move things along - order the spark plug wires (the DIY ones since @3393RP sent me the assembly tool). Ignition switch, headlight switch, some other details. The big thing that I need to order, though is my AC compressor. I'm getting to where I need to mount that so that I can start figuring out where

    I did have one casualty - my angle grinder. Given that it was a cheap thing that I bought at Menard's for $20, I can't complain too much - it lasted about 4 years. I need to buy a new one, though. Gotta figure out whether to go with my standard favorite of DeWalt or something else.
     
    FormerHangie likes this.
  18. Sac Arrow

    Sac Arrow Touchdown! Greaser!

    Joined:
    May 11, 2010
    Messages:
    16,654
    Location:
    Oakland, CA
    Display Name:

    Display name:
    Full Send Mode
    Heh, I compare Ted's Jaguar to a 2017 Sentra, so....
     
  19. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

    Joined:
    Oct 9, 2007
    Messages:
    25,904
    Location:
    Paola, KS
    Display Name:

    Display name:
    #bandozer
    Technically it's my wife's Jaguar. Which means you have to deal with insulting her car, not mine.

    I don't envy anyone in the position of insulting my wife or anything she owns.
     
  20. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

    Joined:
    Oct 9, 2007
    Messages:
    25,904
    Location:
    Paola, KS
    Display Name:

    Display name:
    #bandozer
    Well, I was going to go with a set of custom Taylor wires, and then they went and annoyed me.

    Last month I'd messaged them about what I wanted. They gave me a price. I followed up wanting to buy the wires, no response. So then I call them up. Guy says he can't sell me what I need (the race wires with EDIS ends) and that I'd have to do it myself. Then when I remind him he said they could do it he looks at it, says the price is now close to $200 shipped.

    Ok, I can figure out something else better.

    So I've started out by ordering a set of Ford Racing 9mm 4.6L 2-valve spark plug wires. The real key with this is that they're for an EDIS-equipped engine (which is what the 2-valve 4.6s were prior to the introduction of coil-on-plug, at which point there were no more spark plug wires). This gives me wires that will at least connect to the EDIS coils correctly.

    What I do from there will depend on what I see once the wires show up. The 4.6L has spark plugs buried deep within the heads and so the boots are quite long. I have a feeling the spark plug boots won't work for me as-is, and of course these are cut to length so they will probably be the wrong length. But it gives me a starting point and gets me what I need to start for the coil packs. And that set is $75 shipped.

    What I can then do if I need (which I probably will) is order a universal plug wire set of 9mm Ford Racing wires (for about $50 shipped) and then mutilate the two sets of wires to make Frankenwires to make ignition work on the Cobra.

    And that's a lot cheaper than the $200 shipped that Taylor quoted me, with less hassle. Sounds good to me.
     
  21. geezer

    geezer Pre-takeoff checklist

    Joined:
    Aug 8, 2019
    Messages:
    219
    Display Name:

    Display name:
    Kruse'n
    Do you plan to have windshield wipers? I think they are mandatory for street legal. Thought of them while reading the list of switches you are planning. Turn signal stalk is a common place to hide the wiper switch. The progress is impressive so far.
     
    Ted DuPuis likes this.
  22. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

    Joined:
    Oct 9, 2007
    Messages:
    25,904
    Location:
    Paola, KS
    Display Name:

    Display name:
    #bandozer
    I will have windshield wipers, and ordered that option from Factory Five when I bought the kit. Yes, that will be a consideration, and I should actually look at mounting the wiper motor before too long so that I can have that constraint in place when running certain hoses and wires.

    What a lot of people do is they'll simply put in a manual wiper to pass the inspection. I figured I wanted real wipers as I'll get caught in the rain at some point.
     
  23. Ted DuPuis

    Ted DuPuis Administrator Management Council Member

    Joined:
    Oct 9, 2007
    Messages:
    25,904
    Location:
    Paola, KS
    Display Name:

    Display name:
    #bandozer
    A friend of mine who has a lathe is helping out with the task of modifying a distributor to simply be an oil pump drive for the engine. This way I don't have both coils and a distributor (either with or without cap) just sitting there and looking like an afterthought.

    I bought a freshly rebuilt 351W distributor to send to him to start working with. I do have a diameter restriction to consider because of the intake manifold, so we're looking at that. But one consideration was how to cap off the modified distributor so that it looks like an intentional piece. My friend did some digging and found an old Ford dust cap, similar to this one:

    [​IMG]

    Which he bought. The one he found is in more "used" condition (and looks it) but I think will look a lot more purposeful and intentional, having the Ford logo and such. I'm looking forward to the finished product on that.

    I also went ahead and ordered a bunch of crank sensors to hopefully find the right one that will fit, so hopefully I can have that figured out before long.

    Once my friend finishes up the distributor work and sends that to me, the motor will be in a state where all physical items are in place to make it run, it'll just be a matter of electrical work.

    This is definitely the "90% down, 90% to go" phase of things...
     
  24. FormerHangie

    FormerHangie En-Route

    Joined:
    Oct 28, 2013
    Messages:
    2,915
    Location:
    Roswell, GA
    Display Name:

    Display name:
    FormerHangie
    A bespoke part for your bespoke car, gotta love it.
     
    Ted DuPuis likes this.