MadaboutKitcars

My first post, although been admiring all the fascinating work on here for a couple of years now. It amazes me at the patience, passion and skill that exists in this forum.

Building a car has always been a dream of mine. Conventional kit cars, whilst my goal, is a lot of work, and I think a step too far for my limited skill set (and garage!). That's where I want to be some day, but when I saw the Kobra kit, it seemed like a great way to enter the world of kit cars.

I met with Richard Noon, Nubodi, in late 2016, where I saw the Kobra kit for the first time. Soon after, I had bought myself a BMW Z3 2.0L, 2000, off eBay for £700, and the kit was delivered (November 2016). In hind sight, I should have waited to Spring 2017 - but I was a 'kid in a sweet shop'.



The Z3 had lacquer pealing in several places, hence the price I guess. Other than that, it was mechanically sound and even came with an MOT.

I made a start on removing the panels ...



I have a double garage, but it has the usual family bikes, lawnmower, bits and bobs crammed into it. It has 2 separate garage doors with a pillar in between. I quickly realised how much of a pain this was. Bottom line, I had little space.

Remove the rear wings. I was impressed by the condition underneath.



Boot, lights and bumper removed ...



Here you can see the space I had to work with. Need a bigger garage!



Finally the front stripped. To get the garage door to close, the front of the car touches the front bench. Not ideal.

Make a start on the new body now, starting with the side wings. I wanted the classic look, with AC Cobra louvred vents, so I remove the section and prep.



Vent panel removed ...

More prep to remove the seams.



Starting to take shape ...



Fitted to the car ...

clinkadink - Welcome to the forum.

Looking forward to you filling us in on all the work you have done.

Without giving the game away too much, are you finished now?

Good luck, Paul.

PS
Did you really say my double garage is too small?

The Z3 mirrors are mounted towards the middle of the door. Yet the original cobra they mounted a lot further forward. I removed the mirrors and filled the holes.



I am using U-Pol B fibre glass filler (mainly) and body filler for the fine stuff. My skills are starting to be tested hwell:



Certainly past the point of no return ...



Repeat on the drivers side ...

Thanks Paul. No, not finished yet. But the bulk of the work has been completed. I should have added the build to the forum in 'real time'. Although, like Netflix, folks can now 'binge watch' a build without waiting weeks

Lol - yes, double garage is small. I even floored out the garage attic half way through the build and chucked a load of stuff up there. Still not enough space to swing a cat.

Start work on relocating the fuel cap. I used Car Builders Solutions for all the bits.

1. 90 Degree 50mm I.D. Fuel Fill Hose, £28.80
2. Heavy Duty Flexible 50mm I.D. Fuel Fill Hose 1 Yard Length, £45.60
3. 3 1/2" BSP Aston Polished Alloy Fuel Cap Kit, £240.00
4. Stainless Steel Hose Clip 60-80mm Sold Singly x 2, £3.00
5. 51mm Beaded Aluminium Hose Joiner, £11.40
6. Classic Bullet Mirror Chrome Plated Brass 100mm x 2, £38.40

Time for the Aston Martin fuel cap. It weighs a ton! I have to insert the fuel cap recess (seperate optional GRP panel provided in the kit).



But first, I fit the rear end of the Kobra.



Start cutting hole for the new fuel cap recess ...



Then fill, sand [repeat] ...

A bit of spray filler ...



More filling, sanding and then primer.



The cap is just resting in its recess at present, its not fixed ... and will face the other way.

Start working on the doors. I must admit, I struggled get the old mirror holes completely flat. It took several attempts until I got it to an acceptable standard.



At this stage, I invested in air tools and proper compressor. Until now, I was using typical DIY tools (which I am sure will still do the job).



Loads still to do obviously, but coming along. Trying to pay extra attention to the gaps between the panels.

Yay! All the lights have arrived.



I used ebay mainly to source the parts. The shopping list was provided by Richard Noon, Nubodi. Fair dos, it was a life saver. @Richard, thanks

In case anyone needs the shopping list, you can access it here.

Time to offer up the bonnet. Need a bit more space, so drive her out of the garage. I take the opportunity to take a few photos of how the kit is fitting at this stage. Its about 4 weeks into the build, mainly weekends and the odd evening.

With the bonnet in place, and some minor adjustments to the original BMW bonnet hinges, I notice how bad the gaps are between the bonnet and the doors.





I am still trying to get the hang of filling and sanding. This whole build has obviously been a learnining curve. I cannot count the times where I pack up each night, chuffed with the work done that day ... only to return the next morning and think "that's naff" ... and redo it.

I down tools in December 2016, its -2 degrees in the garage. Sadly, I do not recommence until July 2017. No excuses, I am lazy. I have many old school reports ... "Chris has the potential, but is easily distracted".

The boot lid goes on ...

At this point, I notice the height/curveture of the left rear arch is flatter than the right. I decide to build it up (and hope for the best) ...

Back to door gaps. Fill, sand, curse ... repeat ...

Spent a lot of time on the gaps. I am sure this is true of all builds, but being the first one, I didn't appreciate how much attention is required. But if I don't do it, it will haunt me for ever more (even if no-one else spots it).

July 2017, this is how it looks. 9 months since the start of the build, but probably, 2 months of that is working on the car.

Time to start on the lights. Exciting bit, as by now, I am tired of filling/sanding, and need to recharge my enthusiasm

Wiring the lights into the original BMW Z3 wiring loom may sound a little daunting to some. All I used was a multi meter and tested each pin of the original connector block, when switching the lights on/off, or pressing the brake pedal. Once I saw 12v on the meter, I knew I had the right wire and connected them to the new lights, using heat shrink or waterproof connector blocks.

My advice to any other new builders is to carefully plan this stage; double check all your connections before you make any cuts, sketch out a diagram if it helps (I did), and consider whether the item you are connecting will need to be removed at a later stage of the build or operation.

The battery light on the car came on. I then found the alternator had packed in. I also noticed (a little late, granted) that the belt was in poor condition. I replaced both, and the light went out.

Fitting the number plate lamp and lock. Taking shape.

Back to the bonnet, need to cut out the air scoop. First drill loads of holes ...



I used a mini hack saw to remove the rest ...



Then filed down and sanded the rest ...



Happy with the result so far ...

Next, the overriders. I purchased from Brasscraft. All the bits, including tube, bolts, for both front and back came to £252.

I had to make a mount for the front overriders to bolt to. These were fibre glassed in from inside the bonnet.

Next fit the overriders to the rear. No need to make mounting plates. The bolts slide through the body and onto the rear BMW chasis.

I tried to demonstrate this in the diagram below.



One on, one to go ...

This is where I realised I made a 'newbie error'. The body was by no means prepped to an acceptable standard, so I had to remove all the lights and fittings.

I gave the body another rub down with 600 and then 1200 grit wet and dry. Then applied a layer of filler spray. Not sure if this is 'accepted practise', but I find it does help smooth out and remove those minor imperfections.





The body is now looking flatter ... if not a little too yellow for my liking.



After another rub down with 600 / 1200 grit ...



I applied the grey primer, much easier on the eye ...