D. Brian Smith - How to Build Cobra Kit Cars & Buying Used

CarTech

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2012 by D. Brian Smith

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Edit by Paul Johnson

Layout by Monica Seiberlich

ISBN 978-1-61325-101-0

Item No. SA274

Title Page:

Backed by a Tremec TK0-500 5-speed manual transmission, the Engine Factory 351-ci Windsor V-8 mill in Mr. Waynes FFR roadster makes 425 hp. A Mass Flo fuel injection system provides free-flowing fuel for the fine Factory Five Racing ride.

Back Cover Photos

Top Left:

Theres no mistaking that sleek Cobra body. For all those destined to build a Cobra replica, your body will be delivered and look like this. Factory Five has mounted the body of the Mk4 to the chassis for safe delivery. The Stewart Transport driver and one of our intrepid builders unload the body/chassis from the truck.

Top Right:

After connecting the fan switch wire at the fan, wire and install the fan toggle switch in the dash. This is a manual switch. You can install a thermostat that automatically turns on the fan, which needs to be retrofitted. The fan comes on automatically, via the thermostat in the aluminum radiator. The fan can also be manually activated if, say, youre sitting in traffic.

Middle Left:

With the hood now fitting as it should, Jorge used the air grinder to sand off just a smidgen of the hood on the drivers side. He has 30+ years of experience working with fiberglass on boats, catamarans, and, the past 10 years on Porsche replicas at Thunder Ranch.

Middle Right:

Here is how a properly installed Simpson racing safety harness should be installed. Notice that the passenger side could use some adjustment. I wound up having to re-install the passenger side harness to get the shoulder straps to be the same length.

Bottom Left:

The panel-marking procedure includes drilling those aluminum panels that overlap each other prior to removal. Drill the passenger-side trunk wall. Look closely at this wall and you see weve also marked openings that need to be filed or trimmed. These panels fit well, but precise trimming in high spots enables them to fit perfectly, which the ultimate Cobra deserves.

Bottom Right:

Pass the shock body through the upper control arm with the shock body facing up, and hang the shock by temporarily running a long Philips screwdriver through its upper attachment holes. Do this to attach the .43-inch shock spacers that are supplied for the lower control arm in the FFR Mk4 Complete Kit.

Building a kit car, taking photography of all the work involved and writing a book about the process is quite a challenge. Without my dad, Dan Brian Smith, Sr., by my side every step of the way, the project would not have been nearly as fun and fulfilling. Indeed, I would have also taken far too long to get everything done.

From an early age Dad instilled a love of all things automotive in both my brother Kevin and me. Had it not been for him, I probably would not have such a passion for cars, and I possibly would have never embarked on creating a Factory Five Racing Mk4 Cobra roadster replica. When it comes to building cars the right way, he knows his way around a garage and is a persevering perfectionist. Thank you so much Dad for working on this project with me. We now have a Cobra replica and a book that honors the original vintage sports cars and all the replicas.

Kevin was also monumentally helpful in the creation of our FFR Mk4. He provided expert advice all the way from Suwannee, Georgia, where he and his wife Tanya live. Kevin visited us in California at several critical stages of the build and did everything from turning wrenches and riveting aluminum panels to assisting us in rescuing the car from a body and paint shop. He is also an accomplished car builder and is an adept amateur race car driver, in addition to being the marketing and public relations director for Lotus Cars U.S.A.

We relied on family and friends throughout the project, both for emotional support and for expert collaboration. My cousin Kenny Smith has several years under his belt racing first-generation Ford Broncos and campaigning off-road trucks for a couple seasons for Mickey Thompsons Racing Team. At any given moment in time, he has several of his own enthusiast car and truck projects underway. When we needed to mate the Dart aluminum 427-stroker mill to the Tremec T56 Magnum 6-speed transmission and install the drivetrain in our Mk4 chassis, his expertise helped make the installation a reality. Kenny also provided our professionally built engine and our homebuilt kit car project with first-class transport home from the engine shop and to the bodywork and paint shop, when the car was getting close to being finished. Despite having a multi-million dollar appraisal business and an earthmoving equipment rental business to run, Kenny took time out to be a guest expert Cobra builder on several occasions. He has earned the right to drive the roadster as if it were his own, as has my brother. But, we wont let Kenny take the roadster off road.

Deciding which Cobra replica to build is likely the single biggest choice you have to make; it was with us. We are so very thankful that we chose to assemble a Factory Five Racing Mk4 roadster. At the time that we were investigating all the manufacturers kits, we contacted Dave Smith, president and owner of Factory Five Racing (FFR). He let us in on a little secret, which he didnt make public until later. Dave informed us that FFR would be releasing the companys fourth-generation Cobra car replica. He explained that the all-new Mk4 body was closest to the original AC Cobra 427SC shape because a digital rendering was made of Dick Smiths record-shattering 198 mph 1966 Shelby Cobra 427SC. Equally compelling, numerous improvements were made to the chassis, the suspension, and even the interior foot boxes. What sold us was the fact that the Mk4 would be available at the same time that we needed to commence work on building our Cobra dream car. Dave, thank you so much for letting us in on your little secret. To you and your talented crew at Factory Five Racing, we greatly appreciate being able to build the most sold Cobra car replica in the world. Working with you and your team at FFR was (and is) always a pleasure.