VINH VU's LS1 POWERED NALLE LTD. COBRA DAYTONA COUPE REPLICA

I am now working on my Cobra again and all my recent updates are on PAGE 4 and 7.

This page will be use to document my next project. The title says it all. If you don't know this Nalle Ltd. kit it is very rare. This kit doesn't exactly replicate the original Cobra but it is close enough and it catches a lot of eyes. Plus there aren't many around. You might ask where and how did I get this rare kit from well it's a long story and you can check it out at this Link.

This will be built on a 280Z chasis with the 98 C5 LS1 engine with an automatic trans. I will also plan to use the C5 instrument cluster too (Not any more I already install autometer gauges into another dash and ready to go).

This is the plan for this project. Get LS1 engine installed and running with everything completely working. Get all the fabrications done then strip the whole car down to work on the rusts repair, chasis strengthening, frame painting, parts cleanning / polishing etc.... The final stage will be painting the exterior and then put everything back.

OK here is a list of things I compiled for this car. I am sure there will be plenty of other things pop up while I am building it.

Phase 1- Engine install:
1. Custom make engine mounts and trans mount. DONE - Have to redesign the engine crossmember so that I can remove it from the bottom of the car. Something similar to the way the original crossmember bolt to the frame rails. DONE.
2. Make sure driveline is straight and everything is clear like steering shaft, exhaust header etc.. DONE
3. Relocate alternator. I ended up using a Honda Accord alternator and it fits perfectly where the original compressor was. DONE
4. Relocate AC compressor. NO AC in this car at this time. DONE
5. Get the driveshaft shorten and balance and installed.DONE
6. Route the intake to the front.DONE
7. Adapt the shifter cable to the trans. Ended up using the C5 auto shifter. DONE

Phase 2- Fuel system:
1. Fuel tank.DONE
2. Fuel pump. I am using the stock 280ZXT fuel pump for now. DONE
3. Fuel line. Using stock lines now. Will install braided hoses later. DONE
4. Fuel Filter and Pressure Regulator.DONE

Phase 3- Cooling system:
1. Build radiator supports. DONE
2. Hook up the radiator hoses.DONE
3. Block off the heater hoses from the engine. No need for heat for this car. Will be done in the body work section later. DONE
4. Build fan shroud with SS sheet metal.DONE (Might need to redo it again)
5. Mount the electric fan. DONE
6. Route the transmission oil lines to radiator. DONE

Phase 4- Exhaust system:
1. Reuse the Vette SS headers. Make sure they will clear the steering shaft and all the brake lines ...etc.DONE
2. This car will have sidepipes. I am searching for the twin glass pack just like the original Cobra as I build it. Found them from FFR web site. DONE
3. Complete the exhaust system. .DONE 3/25/07

Phase 5- ECU and wirings:
(Will use the Vette's Speedometer cluster. Changed my mind and go with Autometer gauges)
1. Find location to mount ECU and engine fuse box.DONE
2. Run and clean up all unused wires.DONE
3. Mount the Vette cluster into the Z dash..DONE 2/12/07 - Bought autometer gauges and mounted into another dash - Done 3/21/09
4. Convert Z fuel sender to Vette signal. No need to because the Z's fuel level gauge is in a separate location. All I have to do is hook up a resistor into the GM fuel sensor wire so that the IPC won't bark at me for fuel empty. DONE
5. Rewire Z ignition to Vette wires.DONE
6. Reflash the ECU. DONE
7. Get the engine started and running. DONE

Phase 6- Suspension:
1. Coil over all around. Full coil over suspension bought 10/12/06. DONE 10/25/07
2. Convert to rear disk brakes. DONE
3. Install LSD.DONE
4. Custom make rear brace for LSD. DONE
5. Upgrade front brakes. Bought AZC brakes 10/12/06. They will go on after the frame restoration.
6. Upgrade sway bars and replace all bushings. Will go on after paint.
7. Upgrade to CV axles. DONE
8. Install camber plates.DONE
9. Install coilover suspension.DONE

Phase 7- Interior:
1. Install C5 cluster into Z dash.DONE
2. Smooth out the dashboard and paint. No need to. Will be using the stock dash with all autometer gauges - DONE
3. Built the center console. (Later on)
4. Insulations and carpet. (Later on)
5. Restore the original seats and seatbelts.(Later on)
6. Restore door panels.(Later on)
7. Custom make the interior 1/4 glass panel.(Later on)

Phase 8- Body works:
1. Strip down completely fix all the rusts. DONE
2. Build front strut bars. DONE
3. Rebuild the battery tray.DONE
4. Put the front clip on the car DONE
5. Bolt the rear 1/4 panels on the car.DONE
6. Install door skins on the doors. DONE
7. Modify the cowl panel to match with the front clip. DONE
8. Modify body kit and make sure all body lines match up. DONE
9. Add fiberglass to fender arches to even out gaps. DONE
10. Custom make head light covers. Done
11. Install tail lights and side mirrors.
12. Prep the frame for painting. (On going)

13. Paint the frame.

14. Undercoat.

Phase 9- Reinstallation:
1. Rebuild and/or clean up all parts (paint, powder coat, polish) then reinstall everything back. Should be a show car when it's all done. Wish me luck.

As always I appreciate your time for stopping by. Please leave me some feedback and don't forget to bookmark this page so you can check back for my progress sometimes. Thanks

PAGE 1 - Introduction
PAGE 2 - Work in progress 1
PAGE 3 - Work in Progress 2
PAGE 4 - Work in Progress 3
PAGE 5 - New Wiring Info
PAGE 6 - Costs
PAGE 7 - Work in Progress cont