Pauls Project Dax Thread - Here we go!

[CobraPaul]

Hey Chris,

I just researched some local exhaust fabricators to be honest. Dominic came recommended and was only 4 miles from my house so I was comfortable with being able to see the project as it progressed. He had the car for a total of about 2.5 weeks in all; and I am very pleased with his craftsmanship. It wasn't cheap, but it was cheaper than new headers directly from Dax. In addition, I was not confident that new headers would just bolt on; being a kit car there was every possibility that the new headers would have needed adjustment anyway, so again more expensive.

I collected the car this evening and drove it for the first time with the new exhausts. Obviously sounds different and may take a little time to bed in.

My old exhausts have been sold already, just pending payment and collection, and this money back will certainly help fund the customisation work Dom has done for me!

I intend on getting the full exhaust system cerakoted satin black, but I may need to do that after getting some miles in.


As for engine rebuild; several rings were seized and the block was re-honed and so i am hopeful now running much better. A dyno tune and run will certainly be the test; again after things have bedded in.

[Chris]

Hi Paul ,
you are progressing well although with a few unexpected hiccups on the way but you are sticking with it .
The piston ring for a start was a bit unlucky but that's sometimes how it is .
I like your stainless headers, there's a lot of work involved with that, did you use someone local to yourself ?
The reason that I ask is that my headers that are of mild steel are nearly thirty years old !
They are ok at present and would be looking at stainless replacements, there is I think in my location a
company called Pipe Craft that still does this kind of work ?
I am looking for a bit of feed back from yourself with regards to yours, how did you measure up or did you
take the old ones to where you purchased them ?
My thoughts are that I would prefer not to leave my Cob in someone's workshop for long periods of time !
Going back to your DAX you should have a good chance of getting out and driving fairly soon ?

Chris.

[CobraPaul]

Wow - I've not updated this thread in nearly a year, so I guess it's time I did! I've not been slouching, that's for sure.  I'll just bullet-point the list of things I've likely not included in the latest posts:

- New Heated seats from Ash Trim - Nottingham
- New Momo steering wheel and quick release hub (Hub shown previously)
- Installed a Fire Safety stick
- Built/fabricated some boot dividers to help with storing items in the boot
- New MDF boot floor
- Replaced the rear fog and reverse light with individual, superbright LEDs
- Relocated the manual choke cable to make it easier to install/remove the dashboard
- Installed an upgraded lower steering column bearing
- Upgraded the spark plug leads to MSD
- Installed shock absorber protectors
- Installed a new gear stick, knob and gaiter
- Installed a new radiator fan - 16" SPAL
- Installed a new alternator bracket - adjustable and easier maintenance
- Installed a new 95 degree radiator switch
- Replaced upper radiator hoses and improved routing across engine bay
- Installed new throttle cable bracket and return spring setup
- Complete engine strip down and rebuild; resolving issues with piston rings
- Full carb strip down, clean and reinstall
- New side pipes and custom exhaust header fabrication (in progress)

I won't write too much else, other than I think my total investment into the car is ~ £33k now. I've still got the bodywork and interior carpets to sort, but nearly there!
Photos will speak louder than words, so here is a selection of photos showing the work over the last year.

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[CobraPaul]

Thanks for the heads up the 5000 model, will presume also a higher lift ?
Will see what comes up in auctions etc .
Chris.

Presumption incorrect actually. The newer versions lift higher. But are also different dimensions so you need to check.
I spent a long time researching but my model lifts high enough to slide underneath on some wheels so it's good enough for me

[Chris]

My QuickJacks are the larger but older version - 5000 model not 3500. 3500 is very limiting in terms of length and weight, and these JUST squeeze between the wheels.
Picked my set up for a LOT less than new price second hand.

Thanks for the heads up the 5000 model, will presume also a higher lift ?
Will see what comes up in auctions etc .
Chris.

[CobraPaul]

Looks like things are moving along ok, although progrees has stopped due to parts shortage, not much you can do about that .
With luck you shouldn't have to wait too long to use the beast and the weather looks like it's in our favour for a few more weeks fingers crossed ?
With regards to you headlights/led solution, just be aware that you could fail the test if they don't conform to regs and could even be illegal.
I'm sure that you have looked at the pit falls with this, I'm defiantly not trying to put a damper on your progress .
And by the way your quick jacks have got me thinking again, Costco do a set delivered for thirteen hundred quid !
They do look like a reasonable solution for our Cobra's with just over 1.5 ton limit, no good for most electric cars !
 
Chris.

My QuickJacks are the larger but older version - 5000 model not 3500. 3500 is very limiting in terms of length and weight, and these JUST squeeze between the wheels.
Picked my set up for a LOT less than new price second hand.

[Chris]

Looks like things are moving along ok, although progrees has stopped due to parts shortage, not much you can do about that .
With luck you shouldn't have to wait too long to use the beast and the weather looks like it's in our favour for a few more weeks fingers crossed ?
With regards to you headlights/led solution, just be aware that you could fail the test if they don't conform to regs and could even be illegal.
I'm sure that you have looked at the pit falls with this, I'm defiantly not trying to put a damper on your progress .
And by the way your quick jacks have got me thinking again, Costco do a set delivered for thirteen hundred quid !
They do look like a reasonable solution for our Cobra's with just over 1.5 ton limit, no good for most electric cars !
 
Chris.

[CobraPaul]

Ok, so it's been 3 months since my last proper update, and a lot has gone on since then!

Back in July the car went to Thunder Road Speedshop for a full check-over and MOT as I wanted to get a professional check over of the car before driving on the road. The car was with them for a little under 2 months, whilst there were considerable jobs undertaken like a strip down of the carb, engine tuning and a new alternator due to intermittent charging issue with the old one. Tracking down a few leaks and a new sump gasket has helped resolve those, although there is still a small leak from the rear main seal. However, a clean MOT and my first proper drive on the road! Unfortunately the engine isn't 100%, but I need to get some miles under the belt for further tuning.

August saw some new LED bulbs for the headlights. Unfortunately the cheap LED units from online had a really poor beam pattern so instead opted for some top quality LED bulbs inside standard units. I also replaced the Aston-style fuel cap for a black flush aero cap and as a result, had to include a breather vent on the fuel filer hose as there isn't one in the aero cap. I much prefer this style of filler and it'll work much better with the final finish I'm going for.
Another cosmetic change was the removal of the large single roll bar for a single 3-legged rollbar behind the driver. I managed to locate a roll hoop second hand (it'll be powder coated black later) and I've made my own brackets to fit. This included a custom section of bent steel for the middle leg and I made my own mount so that the inside leg can be bolted through the fiberglass floor and into a spreader plate underneath. This is very strong now, although isn't structural.

September included the start of some "silentcoat" sound deadening; I've put some in each door and then filled the doors with expanding foam for a more "solid" feel and sound. This has worked very well.
An "oil fooler" has also been fitted in the front; an oil cooler that hasn't been plumbed in. It's unlikely this will need to be functional, but it wouldn't be too difficult to connect up if I needed to. However, this was just a cosmetic addition for the time being.
Being tall and long in the leg, I'm spending a lot of time trying to get the seating position correct. I need to get the seat as far back in the cabin as possible and for those that know the Dax chassis, you'll know how limited the space is for the base of the seat. I'm still working on this and need some replacement seats anyway. In the meantime, I've purchased a Momo steering wheel boss, an NRG quick release hub, and am now pending the purchase of a new steering wheel. This wasn't an expected plan, but given there are no quick-release options for moto-lita wheels or bosses, had to be done. Having a removable wheel will make it MUCH easier for me to get in and out.
I also decided to fit some connectors for the headlight units as this will make it much easier to completely remove the headlight bowls for the inevitable paint job and any maintenance work.

Over these 3 months I've also spent a LOT of hours on the bodywork. I've been filling holes, using wet and dry to get the fiberglass mould ridges removed and she's now nearly ready for a Bodyshop o take it to the next stage. I've put on a temporary sticky front number plate to tidy up the front end until paint/wrap.

I've got a few jobs due to finish soon, including the installation of a firewall bearing for the column (instead of the friction-fit) Sierra item, but delivery has been delayed. I also have some new MSD spark wires that I'm going to route under the headers which should keep them protected from the head better.
I've also not been happy with the look of the rear LED/fog light combo, so I'm replacing these with 2 high-powered LEDs which will be fitted in the same location. I think these will be much more discrete.

So a very busy time so far, but getting closer to the final stages of bodywork and interior!
P.S I also bought a set of second hand quickjack hydraulic car lifts. This makes it MUCH easier to get under the car and do that necessary maintenance!

LED Bulbs


Oil Cooler


Fuel Cap


Doors and Expanding Foam


Quick Release:


Bracket In Progress








Roll Hoop Before and After
   





Wiring Quick-release



Quickjacks

[CobraPaul]

Definitely drive it now . Usually October is the last month before we start to see salt going down.

She currently can't move as I'm working on the steering column. A delivery has been delayed meaning she's been stuck in the garage for longer than expected!

[JON1D]

Mostly, yes - Altho it's not particularly comfortable to drive with these seats in! I'll have to grin and bear it for a while

Definitely drive it now . Usually October is the last month before we start to see salt going down.

[CobraPaul]

Sorry I haven't updated this thread in a while. Will update soon, promise! A lot has gone on and I need some time to format my post

[CobraPaul]

...your list can all wait till the winter. Now is the time for driving!

Mostly, yes - Altho it's not particularly comfortable to drive with these seats in! I'll have to grin and bear it for a while

[KevinW]

...your list can all wait till the winter. Now is the time for driving!

[CobraPaul]

I have a huge to-do list, but at least she is back on the road for the time being.
To Do List, at a high-level:

- New full bucket seats (including guides for harnesses)
- New aero fuel cap
- Single roll hoop behind drivers seat
- Tidy all of the bodywork
- Adjustments to bonnet, boot and doors
- Chin spoiler
- Powdercoat all hardware black
- Cerakote side pipes
- Wrap headers
- Full body wrap
- Full interior carpets etc

[CobraPaul]

Fair enough then! I think she looks a lot better in the photos than real life and a considerable number of bodywork blemishes and jobs to do. Not entirely sure I'm up to or capable of sorting them but I'll address that later.

Some of these pics show the car from a few weeks ago vs now. The keen eye will spot an entire lack of interior and a gelcoat finish which needs a lot of time spent on it before it can be wrapped.


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