AKSPORTSCARS #17

Hello all!

Tomorrow I will be taking delivery of my AK SPORTSCARS AK40, "SGT". I ordered the coyote modified chassis as I will be running the 04 Cobra engine ( bored .020 over) tossed the cast iron block for an aluminum one and will be pushing 13-15lbs of boost, 47lb injectors, bolted up to a G86.20 6 speed. The transmission will have 3.00 ring and pinion gears and .62 6th gear and LSD for improved drive-ability.

Holley Terminator X EFI

I chose to go with RHD, obtained one of Jimmymac's casted pedal boxes by pure luck. Though I am sure it has gone through a lot of peoples hands from him to me. Build the clutch and brake pedal, still need to make the gas pedal.

Really do not wanting to list everything out all at once as far as what I am utilizing, but I shall blast the first post with random pictures to wet the beak.

Many unhappy wife hours ahead!
 

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Neil

Supporter
Hello all!

Tomorrow I will be taking delivery of my AK SPORTSCARS AK40, "SGT". I ordered the coyote modified chassis as I will be running the 04 Cobra engine ( bored .020 over) tossed the cast iron block for an aluminum one and will be pushing 13-15lbs of boost, 47lb injectors, bolted up to a G86.20 6 speed. The transmission will have 3.00 ring and pinion gears and .62 6th gear and LSD for improved drive-ability.

Holley Terminator X EFI

I chose to go with RHD, obtained one of Jimmymac's casted pedal boxes by pure luck. Though I am sure it has gone through a lot of peoples hands from him to me. Build the clutch and brake pedal, still need to make the gas pedal.

Really do not wanting to list everything out all at once as far as what I am utilizing, but I shall blast the first post with random pictures to wet the beak.

Many unhappy wife hours ahead!
"Many unhappy wife hours ahead!"
Don't sacrifice one for the other.
 
Nice collection of parts Douglas. Congrats on your upcoming build.

Regards Brian
I cannot seem to find pictures of some items, but Demister, headlights, fog lights, tail lights, latches and hinges not shown, researching and allocating MGD, Renault, Mini, and various other items that had same parts usage definitely took time.
 
Car was delivered late. But all arrived well and the whole process from ordering to delivery was 4 months. Once I get things organized in the garage, the build will begin and pictures will follow. First task will be mounting the engine/transmission...
 
Hey Neal! Congrats on starting your build! Many fun hours ahead!! The engine is beautiful...

What city in Ohio are near? I am about 40% through a RCR40 in Columbus.
 
Hey Neal! Congrats on starting your build! Many fun hours ahead!! The engine is beautiful...

What city in Ohio are near? I am about 40% through a RCR40 in Columbus.

Nick,

Closest big city is Canton, I am just south of that.

I already took a hiatus on the build as I am waiting for some tubing to arrive. Already cutting out tubing to fit the engine. The front accessory side actually isn't the issue, that all fits fine with plenty of room, but the back of the heads needs more room as the AK frame tapers inward towards the back of the engine where the transmission crossover mount is at. I am leaving the uprights for the transmission crossover mounts the same, no issue there, but the brace from the tubing parallel(ish) to the engine needs widened. I will post up pictures of before and after once I get it all welded up.

Very poor quality drawing below ....
 

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Very little progress has happened on the build as work in the house has taken priority. But today I widened the engine compartment a few inches in the backside of the compartment for the wide girl modular engine. Not completely done with the bracing but felt like calling it a day.

I also a bad at remembering to take before and after pictures.
Before:
20240218_163156.jpg

After
20240218_163204.jpg
 
Small update, realized I am an idiot and should never have gone with the G86.20, even with the gearing changes I have. It will not work as the transmission is requiring me to raise the engine wayy.... to high.

I have moved on and placed the long awaiting order on a Quaife QBE62G from AK. AK gets a small discount on them because of the volume used. I know most people if any reading this build are waiting to see the engine fitted. But that is literally all based on having a transmission for axle alignment first....

On the AK frame that I widened just slightly in the engine compartment, the engine back and forth to centerline of axle on the porsche trans with KEN spacer, had plenty of room, so based on measurements of the ZFQ with bellhousing I will gain a few inches up front of the engine, so... sweet.

I will continue to built it up everywhere else until the transmission arrives, when the wife says I can. :)
 

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Did a little rework today. I am using a ProAlloy radiator. And the support on the AK are setup for one different than my setup, I could have just welded up a support going straight off the front upright supports, yet decided nah. Lets just make it my own. I know SGT #70 went above and beyond and make his as close to original setup as possible, I did not. I retained a lot of AKs supports and moved around others.

I will be later adding on to the supports when my condenser and intercooler show up, condenser has been on back order for a while....
 

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Did a little work,... after work...today. radiator, condenser and intercooler fitted, and it all fits with room to spare under the from clam. Which is good.

Still need to cut adjustable slots in the brackets for the intercooler and reduced their sizes a little. This way I have adjustability with each part and I will be using that radiator foam stuff and aircraft baffling rubber to aid in airflow direction control.
 

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While back ago I was test fitting the engine and the harbor freight engine hoist I have used for years collapsed on me. I got a gantry now to save myself any scares again. Luckily the engine was spared anything aside cosmetic damage. But the frame became a teeter totter and bent up the back frame about 1/4 of an inch, smooshed in the tubing on top where angled round tube went up from the now center of my splice reinforcement plates. Got tired of working and called it for the day. Just need to add the angled tubes and this bad memory will be over with.

20240330_211515.jpg
 
Did a little tinkering today before going into work. With the space frame chassis I did not like the sharp edge that you get in the cockpit. So with inspiration from how the monocoque is designed; I removed .75" from the tubing and welded in a pie of some 1.5" tubing that i split apart. Only one side down and one to go. Obviously the square side is still the remaining passside to do.
 

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Very, very slow progress at the moment. Still waiting on Quaife transmission so I can properly locate engine mounts. So pretty much no frame progress has not happened. I am at the moment making a larger tunnel. Needs to be taller since I am going to make original style hammock/web support seats, and need the metal to attach the angled supports on.

Got my steering wheel badge made up as you might have seen on another forum. 3d printed in clear resin and painted reverse side.
The machining didn't go as planned on the bezel, but I am happy with it.
20240428_183342.jpg

Got in a adapter pulley for the dry sump system finished up. Just waiting to finish up the modified metco idler bracket to fit around the oil pump. Also need a longer cogged belt for that.
20240506_192430.jpg


Slow and steady progress for now on odds and ends.
 
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Malcolm

Supporter
Hi Douglas

Good luck with your build! Waht gear ratio and final drive did you select for the quaife box?
 
Hi Douglas

Good luck with your build! Waht gear ratio and final drive did you select for the quaife box?
Sorry for the late reply, 3.500 final drive.

Finally got all my brackets made up or modified for the dry sump pump mounting. Not an easy feat if you have read Petes build on putting a 4.6 dohc in thw frame. Every dry sump manufacturer besides Aviaid told me what I wanted to do was not possible if I was to retain the air conditioning. But here we are all mounted up.
 

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