Building A Backdraft Racing Roadster

At the Backdraft facility, the 2x4-inch rectangular tube chassis are cut and welded from scratch in a frame jig.

Backdraft Racing (BDR) is a relative newcomer to the Cobra replica arena. Though the company was officially founded in January 2002, development of the Roadster replica, the Mark I, began in December 2000 and was first publicly shown in October 2001. The company's 53,000-square-foot manufacturing facility in Durban, South Africa, has already produced several hundred Roadsters and accordingly has earned hundreds of ecstatic customers throughout the world.

To accommodate a global market, BDR's cars are either lefthand or righthand drive. The all-independent front and rear suspensions are BMW 3-series units as standard, and are upgradeable to high-performance M3 underpinnings. Going with BMW suspensions enables the chassis to be serviced at any BMW dealer or authorized shop. Using these mass-produced, proven components also facilitates race car handling with a very comfortable ride for street or even daily driving. At 92 inches, the vehicle's wheelbase is two inches longer than the original article to enable a driver up to 6 feet 4 inches tall.

Here, a technician bends an aluminum windshield frame in the bending device.

Tony Martin in Durban, South Africa, and Reg Dodd in Boynton Beach, Florida, orchestrate the super well-oiled machine that is Backdraft Racing. Both Tony and Reg are high-profile racecar drivers. Tony has won the Daytona 24 Hours, Formula Ford, and Formula Atlantic titles. He oversees the entire production process at the Durban factory. Tony campaigns BDR Roadsters at the major South African races throughout the year. Reg has a great deal of experience racing both in South Africa and in the U.S. He was the South African champion two years in a row. He oversees the Boynton Beach facility and is responsible for the company's sales, marketing, and product testing efforts. In terms of product testing, he still has his hand in racing the BDR cars. In fact, he drove a navy blue Roadster at the first ever KIT CAR Performance Day, and achieved some impressive numbers.

We'll provide the Roadster's test results in an upcoming issue of KC. For now, let's take a close look at what goes into these special Cobra recreations. Thanks again to all the folks at Backdraft for providing these photos.

Bdr Roadster Dimensions
Body Style: Two-door Roadster
Wheelbase: 92"
Length: 153.5"
Height: 45.3"
Width: 67.5"
Rear Track: 65"
Ground Clearance: Adjustable
Front Wheels: 15x8-inch
Rear Wheels: 15x10-inch
Tires: BFGoodrich radials
Fuel Tank: 18 gallons

Handmade, as is the rest of the car, the aluminum fuel tanks hold 18 gallons.	To assure the engine header pipes are the proper dimensions, they're welded together in special dies depending upon which engine size the customer will install.	All the various body panels are molded in the fiberglass shop. Here, left and right doors are being made.
	Technicians 'glass the different body components together in the fiberglass shop.	The water-cooling tanks are manufactured out of stainless steel. Here, a technician assures the opening in the top of the tank is the correct width.
After assembling the body onto the chassis, it is sanded and smoothed. Then the body panels are fitted with the gaps aligned before moving to the paint shop.	A vehicle is sanded and prepared for painting after its primer coats are sprayed on.	In the last stage of production on the assembly line, bodies are attached to the frames and the accessories/wiring harnesses are installed in the cars.
The Roadster body receives its primer coats in the spray booth.	Inside the spray booth, a car that's just had its topcoat applied awaits the application of the clearcoats.	The upholstery shop is where all the leather, vinyl, and wool-comprised interiors are cut and stitched before the Roadster cockpits are installed.
	Backdraft Racing Roadsters are available in a variety of colors. Simply tell them what you want, and they'll write up an order for your dream BDR Roadster.	Backdraft Racing Roadster $28,900Fully assembled and painted turnkey-minus car supplied with 15-inch wheels and BFGoodrich radials.Customer-supplied engine/transmission.
		Including the instrument cluster, the full interior is installed prior to the vehicles being delivered to various parts of the globe.