Bill's CAV #193 Build - Canadian Made

Bill Kearley

Supporter
I think someone or many others on this forum thinks I'v lost it. What would a guy do with a brand new C6 super cobra jet automatic, built into a small block case. I do have a Factory Five MK 4 on order. Input welcome
 

Bill Kearley

Supporter
Not time yet to take the 40 out fore a burn!
 

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Bill Kearley

Supporter
After a long time to think about how to get my bits over the border I broke down and hired a towing company in southern B.C. to go and get a MK 4 Cobra kit I bought from Factory Five. I loaded every thing in Vancouver and 900 miles later, home and all is good to go for a winter project.
After a quick glance I am very happy with the quality. I will power it with a 1970 Boss 302 I rebuilt a couple years ago.
If anyone has info on headers that will fit a Boss 302 engine in a Cobra with side pipes please let me know.
 

Bill Kearley

Supporter
A couple of questions, I need help with paint codes for the CAV Gulf livery.
I'd like to start playing with this Cobra KIT but I still have things to do on the 40, Finnish the 40 or start the Cobra or a little of each keeping in mind my age and a mess I could leave behind.
 

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Bill Kearley

Supporter
Body of and all ally panels of, lots of them. Used the hoist to sling the body and lift then set on a dolly for now.
I'm about to get set up to do my own powder coating. Who has the best system?
 
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Bill Kearley

Supporter
A lot of parts hung on the MK4. I didn't like the way they do the rear brakes on the IRS so I am about to order my own calipers and make my own mounts to use Willwood calipers and MC-4 park brakes. I am using 15 inch billboards and 2015 Mustang uprights that limit brake options. Oven all most done, quite a bit of powder coating to do before getting into final assembly.
 

Neil

Supporter
Body of and all ally panels of, lots of them. Used the hoist to sling the body and lift then set on a dolly for now.
I'm about to get set up to do my own powder coating. Who has the best system?

Bill, a good alternative to powder coating your aluminum panels is to use a 2-part zinc chromate epoxy primer (from Aircraft Spruce). It cures to a hard finish that also protects the aluminum from corrosion. The best procedure is to lightly sand the panels with an orbital sander and 220 grit abrasive, wipe the panels with denatured alcohol, and brush or spray or dip the panels with a chromate conversion such as Iridite and then rinse and dry the panels. This gives you a good base for application of the epoxy primer.
 

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Bill Kearley

Supporter
Thank you for your tips Neil. taking the high tech road would be better and I know power coating is very thick and is really only good in certain applications. I used zinc on the GT40 project and was happy with it. My shop is now very crowded and I'm trying to avoid spray.
 

Bill Kearley

Supporter
A little progress. Almost finished the powder oven and booth. Just the electrics to get and install.
I will plug in the shopvac and hope I don't ingest to much pink powder.
 

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Bill Kearley

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As for the Cobra, It's normal for me to not like the way some things are done by the big engineers, so I do some things my way and kick my ass as a result sometimes. A lot of aluminum to powder coat and then we will see some progress.
 

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Bill Kearley

Supporter
A question, dose any one know who has a jig and will will build a set of headers for a Cobra using a 1970 Boss 302/ Cleveland 4v head?
 

Bill Kearley

Supporter
Dash fitted and a hinged panel under it to fit electrics. To hold the dash secure I will make a fitted glove box / junk holder from the tunnel up.
Fan shroud / mount almost ready for a finish.
 

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Bill Kearley

Supporter
After a big power bump thus a new computer we are back at er !
All the brake and fuel lines run.
Most of the ally panels powder coated and in place. I haven't decided how I want to install a barking brake yet so I'v left some of for access to the diff input flange, had some thots about building a park brake into the diff input. Very old school.
After a little time with card stock and tape ( CAD ) I bent up a one piece aluminum junk box/dash support. powder coated it and it turned out very well.
At the moment I'm making a cooling system header tank and mounting brackets. Then it will be on to rad supports
A lot of work and time is necessary to improve the cheep compromises supplied with this so called kit.
 

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Bill Kearley

Supporter
This is a warning to all. I called Stainless Header INC. and had a chat as to what I wanted. A header kit that would work on a Boss 302 / 4 V Cleveland style head in a Cobra and this is what I got, plus freight of course. Who would build a header flange like this. They blamed me for the design and left me with no choice but to pay for the return freight as well as the freight on the replacement kit. There isn't enough room on this site to explain the BS I encountered with UPS and customs trying to explain that this is replacement item.
 

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Bill Kearley

Supporter
I am my own worst enemy. This old but new Boss 302 that I wanted to make use of, along with an old C6 I rebuilt 40 years ago makes a strange combo for any car. The Boss was a slug at low RPM but in front of an automatic, STRANGE to say the least . I finely got the replacement header kit. I don't think it will be much fun. Building my own will be new to me. A little tight on no. 7 and 8. Some time and mock ups I'm sure will help.
Most of the wiring done. Not as tidy as I would have liked dew to a lack of room. I wanted to keep the engine bay as clean as possible.
Have a look at the exhaust pipe/muffler, poorly made and crooked. It will have to be cut and re welded. I hate it when one is supplied with junk when it would be a lot better for the suppliers reputation to charge a little more and have a happy customer. I have made many changes and/or not used parts supplied. Over all a strange combination of bits and pieces I've had laying around for years that I'm making use of. So feel free to criticize and make fun of me!
 

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