This blog is intended to document the build of my Gardner Douglas Mk4 Cobra; partly as IVA evidence, bit primarily to help others learn from my mistakes and/or successes.

I will endeavour to post as often as possible, with a view to entering a single post for a particular element of the build process, however inevitably some things may not be completed in one go. All posts will be tagged so it should be easy enough to find the information you seek.

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Saturday, 2 September 2017

Rigid Brake LInes

The rigid brake pipes come coiled as a kit already flared with the fittings installed, these were uncoiled and straightened by stretching them between myself and a friend.  The shorter of the two is for the front and the longer is for the rear, the kit also comes with a couple of 'T' pieces and the flexible hoses for each brake.

Front brakes
The 'T' piece was loosely bolted to the pre-installed rivnut adjacent to the lower diagonal brace mount, this was tightened fully once the pipework was complete.  Starting at the front a handheld pipe bender, I created the first bend then offered it up to make sure it was right before continuing with the next.  This process was repeated until all the bends were complete.

The pipe route is shown in the pictures below:
From 'T' piece, along lower frame and under engine mount...

...continues along lower frame then up round tube to aluminium block.

The flexible hoses are different lengths, the short one goes right and the long one goes left

Rear Brakes
The rear 'T' piece is bolted in the centre under the frame above the front diff mount, the rivnut here was a little loose so I tightened it with a spare bolt and a couple of nuts.  I used the same process of offer up, mark, bend, check, move on as I did for the front pipe, starting at 'T' piece and moving towards the alloy block.

Two shorter rigid pipes go from the 'T' piece to some brackets where they meet the flexible hoses.  The brame was drilled and tapped for the 'P' clips.

The pipe route is shown in the pictures below:

From 'T' piece along right hand upper frame rail...

...up frame rail above gearbox...

...final right angle to alloy block.

Right hand side from 'T' piece to flexible hose bracket

Left hand side from 'T' piece loops under fuel pipe, functional but not pretty, will redo this!

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