My 94 Cobra to 03 cobra conversion

[wldtang]

I don't know of another conversion such as this. Many similar but not exactly like this.
My 94 cobra has went through many changes over the past couple of years. I have finally settled on one setup. At least for now.
This is a major conversion.

The car is getting everything swapped over to 03 stuff.
Motor
trans
complete wiring harness
dash shell
brake system
pedals
steering column
fuel system
a/c system
coolant system

Mods will be:
Steggy stage 5 Ported eaton
Accufab plenum port to steggy
2.76 upper / 2lb lower pulley
60 lb inj
SCT 2800 maf
longtubes
x pipe
catback
JLT CAI
Accufab TB and plenum
4 piece idlers
egr delete
SCT Xcal II tuner
Spec stage 3+ clutch
Fore top hat
GT pumps
dual FPDM's

First I started stripping the car down. Everything needed to come out.
I installed a PA Racing tubular K. Next I will be installing 03 A arms, sway bar, steering rack. I will re-use my spindles and brakes.

I then stripped the interior.

Pulled the dash and converted it. I wanted to keep most of the 94 look. Mostly because of the color. True black. Not charcoal like the 03-04's.
I swapped my dash pad and heating ducts over to the 03 metal frame and installed all of the 03 wiring.. Installed the 03 cluster.

03 pad after removed from the shell

03 dash shell with pad removed

94 dash before it is stripped

94 stripped shell and harness. Pad was relocated to new 03 dash frame

94 dash converted to 03 internals converted

I had to change the pass side air bag connector.
From Brown

to Black

Updated: 12-28-07
Removed the abs module and front brake lines.
Removed remaining harness in engine bay
Test fitted the hydroboost. I need to drill one alignment hole.
Removed 94 horn and installed 03 horn

12-30-07
Trimmed the brake hole opening for the hydro boost and drilled the alignment hole. It now fits.

Installed the 03 pedal assy.

Hope to move the lower rad. mounts this week.

1-6-08
Finished bolting up the PA Racing K member and installed the 03 cobra front sway bar. I will complete the front suspension once I install the steeda X2 balljoints on the 03 A arms.

Installed the dash assy and pedal assy. Wire connectors all mated up.

Broke my *&#@ windshield trying to tight the top three dash bolts. Ratch slipped and hit the windshield and crack. Guess I get to buy another one.

Need to get my suspension completed so I can move the car for engine bay paint. Once that is complete, assy should move faster.

Got my stage 5 steggy ported eaton back today.
Stage 5 port
front drive rebuild
2.76 pulley install
accufab plenum port to my eaton
What a beaute.

Fore top Hat - just need some GT pumps now.

Finished my front suspension.
Bolted up the K member
Installed Steeda X2 balljoints in the 03 cobra control arms
Install 03 struts. Retained my 94 cobra spindles,, brake caliper, abs sensors, and soft brake lines.
Also switched the 03 cobra front sway bar.
I am using the 03 cobra front rotors. Just need to get them shaved to clean up.
I also need to order a MM service 6 kit so I can put a boot over the strut rod.

1/19/2008
Ordered a Fore hat about a month ago from Lethal.
Ordered a new sending unit and dual GT pumps from Tousley Ford.
Today I decided to assy the hat.
All went very well. The only problem I had was when taking the stock filter off of the new GT pump, I broke the small tab that helps hold on the sock.
The fore supplied sock seems to fit very tight on the pump so I should be ok.

Update 3-16-08

Finished patching the pass side fender apron (from the power pipe when I had the S trim on the 302). Rolled the car outside and scrubbed the engine bay with Simple Green. Wow does that stuff work. Changed out the wiper motor and linkage assy.
The 94 wiper motor uses a different connector than the 01+ motor. I just change the whole assy since I had it.

I also adjusted the hood hinges so the 96-98 cobra hood lines up.

Next up, engine bay painting.

 

[wldtang]

Update 1-31-08
Got my longtubes. Nice.

Update: 2-2-08

Finished installing the mach 460 rear deck harness and ran a 10 ga. wire from the trunk to engine bay. This will feed the GT pumps in the fore hat.
Installed the rear side panels, speaker deck cover and rear seat. Also installed the mounting bracket for the 3 plugs behind the drivers kick panel.


installed the 03 stereo and bezel. However I need to get a different stereo. My harness connectors are different than what this stereo requires. Anyone interested in this head unit?

I need to paint the bezel to match the dash. I also need to find a way to flush mount the screws on the side of the bracket I made.

started back on my project.
Turned the car around in my garage so I could start some welding.
1. Started patching the fender opening where a power pipe used to be when the S trim was on.

2. Started removing the lower radiator mounts to make them about 1 inch wider on each side for the 03 cobra radiator.

3. Started making my Dual FPDM. Bought three pigtail harnesses from ford. made my own mounting bracket for the FPDM's. Should be starting wiring up the FPDM's later this week. Look over the nasty looking weld in the first pic.

Hope to have all of the welding done this weekend so I can start painting the engine bay. After the paint is done, look out because the build will really speed up.

update 3-12-08

Removed my lower radiator mounts. Plan to weld them back in place tomorrow. They needed to be moved about 1" to the outside.

Had to make a spot to mount the upper rad. mount on the drivers side. The 94-5 cars has that mount on the side of rad. The 03-04's have it on top like the pass side.

Next, I had to drill holes to mount the over flow bottle. 96+ cars should not have to worry about this as they already use the overflow bottle.

I plan to take some pics this weekend once everything is welded in place.

update: 3-13-08
welded in the lower radiator mounts

drilled hole and welded nut to bolt down drivers side upper radiator mount.

drilled hole for bolts and clips to mount the overflow bottle

mounted radiator, fan and overflow bottle. Still need to mount overflow bottle support rod.

 

[Javi]

Awesome swap D. cant wait to see it running


keep us update :thumb:

 

[Matt94GT]

wow thats my dream setup man, nice work!! just a question tho why all that work for the dash? just the odomoter mostly?

 

[wldtang]

wow thats my dream setup man, nice work!! just a question tho why all that work for the dash? just the odomoter mostly?

I wanted to retain the black dash. The 03-04's has a charcoal color. My interior is in great shape and did not want to change all of it out.

Basically I just changed the dash pad. The cluster bolts right into place. Keep in mind all of the car wiring has been changed.

 

[Brian95SVT]

you are makin so many peoples dreams right now
i hope you know that!

beautiful swap so far, keep it up and please keep postin pics!!

 

[wldtang]

you are makin so many peoples dreams right now
i hope you know that!

beautiful swap so far, keep it up and please keep postin pics!!

The engine bay will be looking great in a couple of weeks. New paint and then the massive 03 motor goes in. I can't wait to post those pics.

 

[1996mustangGT]

nice man!
definately subscribing to this one :thumb:
your my flipin hero for doin all that/this work yourself :dancing6:

 

[Javi]

nice man!
definately subscribing to this one :thumb:
your my flipin hero for doin all that/this work yourself :dancing6:

see i told you D.

 

[wldtang]

nice man!
definately subscribing to this one :thumb:
your my flipin hero for doin all that/this work yourself :dancing6:

see i told you D.

Cool. I hope people can get get some good information from this thread. The swap is going fairly easy. I am just taking my time and doing research along the way.

 

[AaRoN]

Awesome build :thumb:

Looks like it's coming along nicely :thumb: :thumb:

 

[scarface]

wow...thats hot.

 

[Dalamar]

Very nicely done so far!

Can I go for a ride when your done?

 

[wldtang]

Very nicely done so far!

Can I go for a ride when your done?

sure. I even let you take the wheel.

BTW, any further progress on the 67?
I hope to start this year on my 66 coupe and 66 fastback.

 

[bigjohnson4.6gt]

this is an awesome build HH HH HH HH HH HH HH HH, subscribing

 

[Dalamar]

Woot!
Steggy Eatons sound awsome. my buddy Todd has an 03 with a stage 4 ported, and it feels and sounds really good!
I see you've got long tubes, what pipe and muff's are you going with?
and what is your suspension setup?


on the 67, no porgress just yet. just more research.
Next few items on my list are to change the bushings out on the IRS with MM stuff.
Mount the IRS which will take some fabrication.
find some cheap stocker wheels/tires to make it a rolling chassis.
and start on the body.

there's some pics of the Nemesis 67in the thread. I'll be getting body parts from them.

Check it out, i'd like your feedback.

 

[wldtang]

Woot!
Steggy Eatons sound awsome. my buddy Todd has an 03 with a stage 4 ported, and it feels and sounds really good!
I see you've got long tubes, what pipe and muff's are you going with?
and what is your suspension setup?

Yea. I have the new stage 5+. More power and lots more torque. Like these motors need more torque.

Looking at a X pipe with mac flowpaths. The mac's are loud but I like the sound of them on the mod motors.

K member up front with 03 control arms. Saleen lowering springs with billisten front struts. No suspension work in the rear yet other than springs. Need to look at some control arms for the back.

 

[wldtang]

Update 3-16-08

Finished patching the pass side fender apron (from the power pipe when I had the S trim on the 302). Rolled the car outside and scrubbed the engine bay with Simple Green. Wow does that stuff work. Changed out the wiper motor and linkage assy.
The 94 wiper motor uses a different connector than the 01+ motor. I just change the whole assy since I had it.

I also adjusted the hood hinges so the 96-98 cobra hood lines up.

Next up, engine bay painting.

 

[Javi]

:ttiwwp:

 

[wldtang]

:ttiwwp:

what's wrong? Not enough pics above for you?