Project 1965 Roadster

Casey Design's First Roadster (Cobra) project. This project included several suspension and engine modifications.


Attached Pages: 

Project Intercooler - Phase 2

Phase 2 complete! WOW!!!

Project Intercooler - Phase 1

It all starts with ambient fresh air.

New Roadster Dash Installed...Finally

It's been a super busy year thanks to all the great fellow builders out there helping promote Casey Design. It was time to finally take a vacation to install my own modular dash. Check it out.

Bring on the rain

I promised never to do it again! I kept to my promise by only doing it three more times before breaking down and purchasing a top. Any Roadster owner will tell you they are not worth it since you still get wet, but it sure is better than getting soaked. It also adds a nice vintage look. Did I mention, make sure you get RainX. I never plan to install wipers, so that is a must.

Boost

The pipe is now fully functional after some machining to correct a manufacturer defect from Kenne Bell. This installation took much longer than expected since I could not locate the original bracket. The intent was to use the supplied one for temporary use until I made the one seen here. Not a great day considering I had a race the following day. Since these pictures were taken, the bracket has been modified to limit belt slippage.

Got Paint?

I was going to go with flat black and gloss black stripes, but the painter convinced me to be more traditional. I'm happy I did. These are some shots before, during, and after paint prep.

Get Ready For Boost

Kenne Bell superchargers are not great at pulling air and I figured I'd help out. This setup works well for both naturally aspirated and supercharged applications. And this is a 95mm mass air meter used in combination with 42# injectors. This setup does not create as much power as with 24# injectors and appropriate meter, but good enough.

New Engine

What do you get when you sink way too much cash into an engine. Details are secret, but estimates say just about 600HP and tons of torque at the crank. That is supercharged of course.

Body On

The body goes on fairly easy, even by yourself when you use pulleys mounted to the ceiling. Don't think once you put it on you will never take it off again.

Wiring and Stuff

This has changed a little since a second piggy back computer was added.

Panel Shots

Most panels have beads rolled in them to help stiffen and reduce vibration. I only had to recreate the drivers footbox since I didn't want plugged holes and the inside edge did not line up properly. The photo shows the installation of FFMetal's firewall, which is .60 thick and moves the firewall in towards the engine bay by 1.5". This adds depth to the engine bay and substance to the firewall itself.

Rolling Chassis

This stage only took a month to get to while only working on it, on the weekends.

Ford Motor Sport 345HP (Dead)

Nice fit, too bad I had to take it out only six months later due to motor problems.

Custom Roadster Parts

These are just a few of the parts I made to hold various items. If you don't like what is available, make them yourself.

The Kit Arrives!

After many years of dreaming along with many months of research, the wait has ended. My kit was ordered several months back and finally delivered. Was it worth the wait? You tell me.