How to Build an AC Cobra Replica

I have always dreamt over the cobra replicas so 4 years ago I bit the bullet and chose my kit, I went for a Gardner Douglas Mk4 Euro, lots of reasons why I chose the GD but the main selling point for me was every part of the chassis is new, rather than an old Jag. Anyway, hope you enjoy my brief guide and hopefully inspire a few more cobras on the road.

Supplies

You don't need a full garage worth of tools. But lots of time and patience.

Step 1: Collecting the Body.

The GD euro build sequence is the body first then the chassis, so off with the trailer to collect the body and start work. A build trolley doesn't just help with moving the body around but also puts the car at a nice height to work on.

Step 2: Flash-lines Flash-lines and More Flash-lines

although the car will be painted, spending the time on the flash-lines now will mean a lot less work in the paint shop. I found scraping with a blade as a negative angle did a good job at removing the bulk and then start sanding, you can see the before and after.

Step 3: Starting to Plan Out the Wiring Loom

The more you think about the wiring in a car the more you realise how many systems there are.

I will be using classic style LED headlights so although still looking classic, will be a bit more than candles in jam jars.

Step 4: More Bodywork Work..

So mainly cutting holes and fitting panels, even after cutting more holes than can count each one is still a nervous task. Measure twice cut once!! I'm not spending too much time on the panel gaps at the moment as it will all be removed for paint, just getting them roughly in the right place.

Step 5: Mocking Out the Dash Board

So I used Inventor to place decals in all the correct places, then printed this out 1:1 so the spacing was correct. Now just to drill all the holes and wrap in the cream leather.

Step 6: ENGINE!!!!!

I started with a 350 Small block Chevy, the whole engine has been stripped down, and only the main block casting retained. Its had the cylinder bores bored to 60 thou, and I will be putting a stoker crank in so it will end up as a 6.3L or 388CDI.

I have sourced a fuel injection compatible intake manifold, Hopefully it will look like classic downdrafts while having the reliability of fuel injection. A mega-squirt ECU will be controlling the fuel and spark.

Step 7: A Bit of CNC With Fusion 360

So I bought a small Denford novamill, ripped out the electronics and got it running GRBL on a arduino. Its proving its worth cutting out stainless plated for lights, cover brackets ect..

Step 8: Chassis Time

Collecting the chassis can be easily done on a roof rack, well withing the load limits, and very little aero drag.
Its then just like a giant lego kit, nice 4 pot ap racing calipers should mean it stops as well as it goes.

Then it was time to hoist the engine in, its a tight fit but after a bit of time its sitting on its mounts.

Step 9: Fluids

Trying to work out the routing of all the coolant pipes, there is just about enough room for the header tank to the the highest piece in the system.

Step 10: 1st Ever Start

A momentous occasion in any car build, the first start. The British weather was against me but noting a tarpaulin wouldn't solve.

Another run with it, still a load of tuning to be don't but the idle is nice now.

Step 11: Final Body Prep Before Paint

Again, a bit like the flash-lines, the more effort put in now will show after paint, so take time ans keep working away, I used 400 grit wet and dry. A long a tedious task.

Step 12: A Little Bit of Paint Makes a Big Difference!

Some photos from the paint shop, red primer so stone chips are hopefully less visible. Then Aston martin Diavolo Red main body colour, with BMW storm grey stripes. The stripes are actually tapered so they look parallel from a distance.

Step 13: Reuniting the Body to the Chassis.

Now the body has been fully painted, its back on the chassis to be built back up again.

Step 14: Interior

One by one the pieces of interior are going in, again not rocket science just nice and steady with the carpets, you only have 1 chance to cut them.

Step 15: Finished, I Think

I imagine there will be a lifetime of tinkering, but as far as being road worthy then she is finished. Thank you for taking the time to read all of this and hope you found it useful or just enjoyed it.

Comments

[10ft]

First of all, I love the build and do not see anything I would do different. I would like to know if you have a schematic of the wiring you installed. I am working on another project but have no plan for wiring and would love to see what you did. Thanks for your write up and the photos, keep up living your dreams.

Thanks for your reply.

[richard.stubley]

Hi, sorry I made it all up as I went along. I do have some sketches I did of each loom but I don't think they would be much use.
From doing this loom my advice would be to break it down into sections. I did a rear section, rear lights boot lights, fuel tank.
Then an dash loom, and so on. Then it was just the task of joining them all up. The wring loom was probably the single most time consuming part, but doing all yourself means you can do things like waterproof connectors and nicer loom coverings.

Good luck! I hope your project goes well.

[NoelM57]

Hi Richard,
just come across your Cobra build and it looks stunning. I've just started a Pilgrim Sumo Cobra. I was wondering if you had the file used for the dash/clocks layout. i thought the rear reflector/fog light backing plate attached to overriders was a neat thing to do. How did you attach to overrider and do you have a template for measurements?

[NeilRG]

Great scope of work instructable. I built a plastic model of a Cobra decades ago. The only transferrable skill is a little bit of patience.

[KevinM597]

Where did you buy the kit

[richard.stubley]

Gardner Douglas sports cars (UK)
https://www.gdcars.com/

[KevinM597]

Thank you and this car looks absolutely amazing I've always wanted a car like this.

[jeffbot]

Again, just how much did this cost, trying to get and idea for creating this beauty?
Jeff

[richard.stubley]

I didn't keep exact costs as that can sometimes spoil the project. No matter your budget you can make a project you are proud of at the specification you want. As I posted before, Ive seen amazing examples for 20k upto 80 and beyond.

[gcai_fwb]

Damn! shorted out the keyboard from drooling :)
Lovely job - spectacular car !

[richard.stubley]

Haha, thank you. Hoped you enjoyed the read.

[Uncadoo]

Originally, I had some choice words for the guy who put a Chevy engine (CHEVY??? REALLY??) in a Ford product and then put the steering wheel on the wrong side. After all, I come from a "Ford family" for a couple of generations.
Then I remembered that: 1). The Cobra was essentially a kit car when it began. 2). It was a BRITISH car when it began. And 3). Carrol Shelby would hock his wares at any car company that would listen. So as long as you didn't do anything truly sacrilegious like putting a Rover engine in it or a V-Dub engine, who am I to complain?
Besides, the builder had a reason for choosing the Chevy 350, and it wasn't just to piss off all of the Ford people.
Also, anyone who would complain about this without having built their own AND having built it "the right way" can go pound sand!
IMHO

[richard.stubley]

Cheers, thanks for the support. Kits cars are individual thats the best part about them.

[rmelchiori]

Great job! How about a video so we can hear it roar?

[richard.stubley]

Just put an MP4 for you to download on the "1st engine start" post.

[aviatrz]

I would like to know what I can expect to spend on a project like this?

[richard.stubley]

How long is a piece of string? (Twice as long as half of it) It is so dependant on the kit you choose and options just grow from there. You can build a cobra anything from 20K up to 80k and beyond. Your best speaking to a local kit manurfacturer and see the options the provide.

[jimoliveira]

Beautiful looking Cobra. I had the same colour on mine, except my stripes were gold.
My next project will be a coupe. Need a roof. :)

[richard.stubley]

Definatly, you can get really nice hard tops for the cobra kits.

[Geoff Garford]

Really well done article,and car like the look of the carb trumpet s , I also have a Cobra ,had it since 1999 and still love it! Enjoy regards Geoff