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 Installing the shocks is a...  Installing the shocks is a simple bolt-on procedure using the stock hardware from the donor. The quad shock is mounted 180 degrees, with the small end of the unit toward the back. This is necessary to clear the 275/40-17 tires that will fill the rear wheelwells. Note the steel cable attached to the frame and lower shock mount; it&8217s designed to prevent the driveshaft from binding if the car gets airborne. |
 The battery is mounted outside...  The battery is mounted outside the car for safety. It&8217s positioned below the trunk floor immediately behind the differential. A battery tray is supplied complete with bolt hooks. Not only does this position aid the tire hookup, but it contributes to the overall balance and weight distribution. |
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 The entire donor pedal box...  The entire donor pedal box assembly bolts up exactly as it does in the Mustang. It’s bolted to the front of the foot box. The Mustang master cylinder is bolted in place without the booster. Since the Cobra replica is considerably lighter, boosted brakes aren’t necessary to achieve short stopping distances. Don&8217t forget to keep the Mustang flexible brake lines front and rear. |
 The clutch quadrant on the...  The clutch quadrant on the 5.0 is one of the best ideas Ford ever came up with. It constantly adjusts the clutch cable to maintain consistent pedal travel. |
 Forty-four aluminum panels...  Forty-four aluminum panels go into the construction of the replica. To install all the aluminum inner panels to the steel structures, FFR takes some cues from the aircraft industry. Bonding and riveting the panels provides a lasting structure, so FFR uses a silicone adhesive as a bond and then rivets the panels into place. |
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 Since this particular engine...  Since this particular engine will remain stock and won’t require a high-volume fuel pump, the kit’s special high-pressure fuel line and hose clamps can be used. It’s important to secure lines to the frame every few feet so it won’t work loose. The donor&8217s fuel line connectors are also used. Remember to keep the fuel lines away from the headers. |
 The shifter is a bolt-on piece...  The shifter is a bolt-on piece that mounts to the stock T-5 stalk to replicate the unique bent-forward shifter in the original car. The shifter, bolts, and knob are included with the kit. |
 Frame brackets are provided...  Frame brackets are provided to snap in the stock emergency brake cables. |
 The donor&8217s stock exhaust...  The donor&8217s stock exhaust headers can be used if the sides are swapped. This car will wear Mac equal-length shorties with 1-5/8-inch primaries. With the equal-length headers, the fit is tight, but the look and dyno performance are worth the extra price. The 3-inch flange you see here mates to the side pipes and allows complete exhaust flow. |
 The oil filter must be relocated...  The oil filter must be relocated in order for the headers to fit. FFR includes a Ford Motorsport remote filter unit with the kit to relocate the filter to a front frame member. |
 The mass air meter and bracket...  The mass air meter and bracket are bolted to the frame, and a K&N conical air filter that&8217s included in the kit replaces the restrictive Mustang airbox. |
 The finished install of the...  The finished install of the side pipe shows the massive 3-1/2-inch collector, with plenty of clearance between the hot pipes and the foot box. |
 The radiator is surrounded...  The radiator is surrounded on all sides with aluminum panels to force air through the cooler. |
 The stock radiator, overflow...  The stock radiator, overflow tank, and fan shroud are mounted at an angle to clear the low nose of the car. FFR has found that unless you&8217re creeping along in heavy traffic, the fan rarely switches on. The Cobra replica flows much more air than the donor car. |
 The stock radiator hoses are...  The stock radiator hoses are cut and lengthened with precut aluminum tubing and hose clamps provided in the kit. |
 The stock wiring harness consists...  The stock wiring harness consists of three sections; a dash harness, a computer harness, and a rear harness. Route the dash harness from the engine compartment through the precut openings in the aluminum and steel. The rubber snout of the harness presses into the hole in the foot box. |
 The computer harness passes...  The computer harness passes through a precut hole in the top of the passenger foot box. The computer is mounted to the foot box outside wall immediately in front of the dash hoop. |
 The innards of the stock steering...  The innards of the stock steering column are used to maintain the collapsible safety feature. Two pillow blocks locate the shaft for a solid mount, while the FFR adapter boss allows the use of a vintage steering wheel. |
 The stock fuel neck is cut...  The stock fuel neck is cut in half and extended to fit under the Cobra body. The vapor-sealed cap fits under a 3-1/2-inch Aston roller gas cap, so the fuel doesn’t slosh out at high g&8217s. |
 This finished chassis is ready...  This finished chassis is ready to run. Driving the chassis in this form is a good way to discover loose or missing items. It’s also easier to make repairs at this point, before the body covers things up. It isn’t a good idea, however, to do any acceleration or performance testing. KC |
Heading toward the goal of a completed Factory Five Cobra replica, we present the second buildup installment, covering the rest of the procedures necessary to finish the chassis.
In the May '97 issue of Kit Car, we began a buildup series about putting together a Factory Five Racing (FFR) Cobra replica at home. In that initial story we covered the basic chassis buildup, including the suspension, brakes, drivetrain, gas tank, and first aluminum inner panels. We continue our buildup coverage here and take the kit from a rolling chassis to a driveable chassis, including how to install the shocks, axle straps, battery, foot box, master cylinder, clutch, aluminum panels, exhaust, cooling system, wiring, and steering column.
To recap a bit, Factory Five's Cobra replica kit is designed and engineered to use a single donor car--the 5.0 Mustang. The kit sells for $9,900 and, aside from the multitude of donor car parts, comes very complete, so you need to add little to finish the vehicle.
Keep in mind that this story is intended not to serve as a build manual--FFR has a very comprehensive manual--but show the important steps involved in finishing the car.