SS/Comp Style Cobalt build
 

I have always loved the Super Modified Cavalier and Cobalt cars, so when I saw this sitting behind my local bank in the repo lot I knew I had to have it. Blown head gasket, dirty, bald tires, broken front bumper......the perfect racecar platform.

http://i178.photobucket.com/albums/w...spflrey4p.jpeg

I made a call to the bank and they said it was sold. So I started searching Craigslist and such but the car just sat there everytime I went by. I kept calling but the answer was still the same. Finally after a few weeks they tell me they are taking bids. I offer $750 and they promptly accept. I tow the car the 10 or so blocks home, the front end is shot, brakes suck, shocks are toast and I couldn't be happier......it's all going in the trash.

Re: SS/Comp Style Cobalt build
 

Since I haven't built a car in a few years, I decided to tool up. I ordered a new tubing bender, upgraded to a real notcher, and got a TIG welder.
http://i178.photobucket.com/albums/w...s383c2zyp.jpeg
http://i178.photobucket.com/albums/w...spaglufi8.jpeg

Re: SS/Comp Style Cobalt build
 

I wasted no time disassembling the car, I mean GM puts them together in like 12 hours, how long could it take to rip apart?
http://i178.photobucket.com/albums/w...srznmambf.jpeg
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Re: SS/Comp Style Cobalt build
 

With the engine and front subframe gone I could trial fit the new front end from FJ Smith.
http://i178.photobucket.com/albums/w...smwtizfou.jpeg
http://i178.photobucket.com/albums/w...svywyw6cz.jpeg
I ran into an issue with the upper strut mount. The strut cups were the same design as the cavalier/sunfire but GM changed the hole pattern on the Cobalt for some reason....go figure. Also the locknut would not fit into the bearing housing, I suppose a jet nut would have fixed this but I decided to fab new upper mounts instead of drilling the strut towers to for the mounts. http://i178.photobucket.com/albums/w...sdhc3rbpg.jpeg
So with a little CAD work and a 3D printed prototype I was able to have the mounting plates waterjetted and used the spherical upper strut mount from Chris Alston to fab the new mounts.
http://i178.photobucket.com/albums/w...sgokkatvs.jpeg
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http://i178.photobucket.com/albums/w...snbmdyauu.jpeg
Here is the front susupension after the final mock-up.
http://i178.photobucket.com/albums/w...skefxciqp.jpeg
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http://i178.photobucket.com/albums/w...sdmkzenrj.jpeg
http://i178.photobucket.com/albums/w...simxupczy.jpeg

Re: SS/Comp Style Cobalt build
 

I was under the gun to make the car mobile again as I had an appointment for a storm shelter install that I really didn't wanna miss but I made it and rolled the car out of the garage for the 1st time in 3 months.
http://i178.photobucket.com/albums/w...psfb9myrny.jpg
After this the car went back in and got squared up on a frame, I pulled the rear axle and the gas tank and began making room for the backhalf.

http://i178.photobucket.com/albums/w...sm2rngzco.jpeghttp://i178.photobucket.com/albums/w...slextdm3b.jpeg
http://i178.photobucket.com/albums/w...sgav6pud7.jpeg
Time to test fit the slicks and get an idea of what kind of room there will be in the rear.
http://i178.photobucket.com/albums/w...sfeel1pyv.jpeg

Re: SS/Comp Style Cobalt build
 

So I came across some old pictures while uploading these. The white Camaro is my old Super Street car, the black one is my brother's car.
http://i178.photobucket.com/albums/w...pstw10uupf.jpg
http://i178.photobucket.com/albums/w...skki4fm3b.jpeg
This was my Gebhardt dragster, it was a bare chassis and I finished the car then sold it.
http://i178.photobucket.com/albums/w...svh5lvbch.jpeg
This is the car today, the new owner runs Top Dragster with a blown KPE engine. The car runs 4.10's.
http://i178.photobucket.com/albums/w...ssfenqvyn.jpeg

Re: SS/Comp Style Cobalt build
 

Looks great keep the pics coming!

Re: SS/Comp Style Cobalt build
 

Wow! Great show! Keep'm coming and good luck!

Re: SS/Comp Style Cobalt build
 

Colby, off to a good start. Please keep us up to date. I like what you are doing.

What engine combination and what class is planned?

Re: SS/Comp Style Cobalt build
 

Colby your work looks very nice. Keep us updated on your progress and best of luck to you.

Re: SS/Comp Style Cobalt build
 

Colby… Cool Project. MB.

Re: SS/Comp Style Cobalt build
 

Colby,, my hat is off to you for taking on a project of this nature. Like Larry and his Super S-10 truck, you guys obviously have the talent, know-how and access to equipment to pull off these kind of builds.
I'm hoping, if you don't mind, to keep a running tab on this build,(I'm sure you are) and would be willing to let us know when you're done, what the costs are to a modern do-it-yourselfer who would consider doing a project like this, as opposed to cutting a check to one of the big name car builders across the country.
I love these Cobalts myself, and wish you well on the rest of your journey to get this car down the track,, you've gotten off to an awesome start. Take care.
Danny Durham

Re: SS/Comp Style Cobalt build
 

The engine will be a 416" LS style motor. 6.0 iron block with modified LSA castings, super victor intake, dominator carb. Planning to make 750 Hp. I picked up an ATI Superglide and plan to run a 4.56 gear with 32x14x15 tires.
Below are some of the goodies I have already picked up.
Crank trigger and timing pointer. A lot of time went into finding these parts as they are not part of the late model EFI platform.
http://i178.photobucket.com/albums/w...shmdrxw78.jpeg
The plan to run a JESEL belt drive, which will also facilitate the front distributor eliminates the factory oil pump location.
That along with the low stance will make this a dry sump engine. There will be no clearance issues with this pan.
http://i178.photobucket.com/albums/w...stxfwaffh.jpeg
Peterson oil tank
http://i178.photobucket.com/albums/w...seswvekvb.jpeg
This picture represents a lot of searching for solutions to the cooling system. LS engines water passages are much different than the traditional SBC/BBC combo. Aftermarket pumps are pricey and bulky and with the front distributor they wont really work. The solution comes with a Meziere remote pump that mounts on the radiator and has 2 outlets to go to each side of the motor. The 2 return lines will then connect to the black moroso thermostat housing. The piece on top was sourced from a NASCAR team who builds the LS2 spec engines. It allows a single connection for the upper hose, a filler neck, and an isolated section to connect the 4 steam ports from the cylinder heads.
http://i178.photobucket.com/albums/w...sntsmfy8y.jpeg
Manley valves
http://i178.photobucket.com/albums/w...shsypd58c.jpeg
A little bling for the valley cover
http://i178.photobucket.com/albums/w...s0ijw0qeq.jpeg
ATI trans
http://i178.photobucket.com/albums/w...psl7saadxt.jpg

Re: SS/Comp Style Cobalt build
 

I always wanted a Racepak setup and came across a smoking deal on the whole kit so I pulled the trigger.
http://i178.photobucket.com/albums/w...s7pccomi5.jpeg
Both of my other cars had a full range of Auto-meter gauges, but since I already bought the Racepak I had to get the dash too. It's cheaper, lighter, cleaner, and easier to wire than the gauges.
http://i178.photobucket.com/albums/w...srfzgpn0c.jpeg
Also picked up the MSD Grid setup on a great deal
http://i178.photobucket.com/albums/w...sykuuzc2g.jpeg
Pro Bandit shifter with the Air cylinder and mount
http://i178.photobucket.com/albums/w...siwt51a2z.jpeg
No pictures but I bought a Kirkey Pro Street seat and cover so I can figure out where to sit and layout the cage design.
Also had to grab the steering wheel setup so I can layout where the column will be
http://i178.photobucket.com/albums/w...siofgmutx.jpeg

Re: SS/Comp Style Cobalt build
 

What class are you planning to run?
The reason why I ask is in Super Stock Modified and Comp Super Modified, dry sump oiling systems are prohibited.

Re: SS/Comp Style Cobalt build
 

Rear suspension
The rear will of course be 4-link.
I ordered the brackets from Chris Alston because I like the extra adjustability of the shock mounts.
http://i178.photobucket.com/albums/w...ssxihziiq.jpeg
I had the doublers installed, needless to say my welder is an artist.
http://i178.photobucket.com/albums/w...psik6rrstl.jpg
I ordered the rod ends and Strange DA shocks from RJ and saved 10% thanks to a Christmas sale. Some may criticize my shock choice, but I figure if Strange struts are good enough for 90% of the chassis cars, the shocks will work for me.......we'll see I guess.
http://i178.photobucket.com/albums/w...shzfwtnte.jpeg
I picked a 4130 housing and wishbone from Bickel.
The housing is amazing compared to others I have seen.
http://i178.photobucket.com/albums/w...stbxscqde.jpeg
I plan to mount the wishbone on the top side of the housing for easier thirdmember access so I bought the fabricated housing mount and billet mounts for the front. They are trick.
http://i178.photobucket.com/albums/w...pswsfl5zwm.jpg

Re: SS/Comp Style Cobalt build
 

I usually do a good job of visualizing things in my head and knew how I wanted to lay out the cage, but I just couldn't seem to visual it with the car. My work as a design engineer gives me the opportunity to use some cool tools (if you didn't pick up on the 3D printed prototype part earlier) so I decided to model the basic car and lay out the cage.
http://i178.photobucket.com/albums/w...smjpxcmrg.jpeg
After adding some bracing to the front end, I cut of the rear of the frame stub to tie the main rails of the chassis in.
http://i178.photobucket.com/albums/w...suekomvnj.jpeg
Then a lot of cutting the remove the factory k-member mounts and structure. Here are the main rails slipped into the front stub.
http://i178.photobucket.com/albums/w...sta0moxds.jpeg
The #1 bar is bent and in place
http://i178.photobucket.com/albums/w...s5acjkcxv.jpeg
And finally the last picture brings everything up to date as I clearanced for the rocker bars and notched them to fit the #1 bar. The big floor beam in the center will be removed once the floor structure is welded in.
http://i178.photobucket.com/albums/w...sjsznexqf.jpeg

Re: SS/Comp Style Cobalt build
 

I plan to bracket race and run one of the super classes for now. If I did venture into S/S I would need a whole different engine setup. It would still require at least an external pump as the Jesel belt drive eliminates any internal pump.

Re: SS/Comp Style Cobalt build
 

Coly, great job. Hang with the updates

I know from experience with posting the Super 10 project the more details and the more photos the better. Us gear heads like the tech items and "how I did this" items.

Re: SS/Comp Style Cobalt build
 

I kinda got a late start with the documentation of the build.

Re: SS/Comp Style Cobalt build
 

Nice job. What class are you going to run?

Re: SS/Comp Style Cobalt build
 

Really Cool Project, keep the pics coming.

Re: SS/Comp Style Cobalt build
 

I apologize for the lack of updates, I lost several weeks due to my welding partner backing out. But I am glad to say that I have found someone else and couldn't be happier that actual progress is taking place. I also did a little two steps back one step forward as I have decided to run Super Stock Modified, not just build a legal car to bracket race with. That means the dry sump equipment was sold and replaced with a trick custom Moroso pan. http://i178.photobucket.com/albums/w...scyvzzvmj.jpeg
http://i178.photobucket.com/albums/w...se5kppvuh.jpeg.
I also found that the GM heads I planned to use were not in the classification guide so.....that had to be corrected too.
Back to the progress on the chassis......
The 4 rocker panel reinforcement plates have been welded
http://i178.photobucket.com/albums/w...sovorsmkl.jpeg.
Moving onto the floor structure.
The main frame rails are spliced into the SPS front frame and connect to the 4 link crossmember. With everything squared, leveled, measured, and checked half a dozen times the rocker bars and forward bars are added. The crossmember in the center will locate the center X bars and a tans case was set in place to ensure the crossmember is not offset too far from the front bars. In the picture below the driver side is done with the exception of seat mounts and pedals. The pass side should be done this week and then it all gets welded up!
http://i178.photobucket.com/albums/w...sa2soham6.jpeg

Re: SS/Comp Style Cobalt build
 

awesome job...its also one of my favorite cars also in SS/Comp trim

Re: SS/Comp Style Cobalt build
 

Ford guy myself but love those when done for SS/Mod! Need pics!

Re: SS/Comp Style Cobalt build
 

Was able to get the majority of the floor structure completed this weekend. Trying to fit everything in this little car take a lot of planning. With the way the OEM floor is built, the tubing must go inside the car which eliminates being able to build the floor structure under the car then remove it to weld it up. With a lot of planning and little luck my inner frame rails tie into the FJ Smith front sub frame which allowed me to rotate them for welding since they are reinforced with a sleeve. They were then rotated down and welded to the reinforcement plates after all of the measurements were re-verified. The end goal is the be able to complete the chassis without cutting the roof off. I think with enough planning and forethought it should be possible.

http://i178.photobucket.com/albums/w...svqjr1zes.jpeg

Re: SS/Comp Style Cobalt build
 

Latest update:
The chassis has gone 3D!
With the floor complete minus trans crossmember the uprights and dash bar have been installed and tied into the strut towers. Next the front sheetmetal will be cleaned up and clearance to prepare for the motor install.
http://i178.photobucket.com/albums/w...sjhyl0e8o.jpeg
http://i178.photobucket.com/albums/w...sj3jvdxjb.jpeg
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