Brakes
It is starting to get very interesting.

 This section will cover the brake system installation.    We will install the pedal box, master cylinder, proportioning valve and brake lines.  Rather than use the line provided in the kit we purchased new lines that came with fitting already installed.  They are available in lengths of 8, 12, 20, 30, 40, 51, and 60 inches long.  It was a bit of trial and error to see what lengths we needed.

These pictures aren't really for the brakes, but they show the progress of the project.  Along with part of the brake system, we have also installed the steering wheel and shaft as well as most of the cockpit aluminum.

Whole Car01.jpg (48320 bytes)

Whole Car02.jpg (50867 bytes)
Our master cylinder and front brakes came from a Lincoln Continental.  The master cylinder has a larger diameter (1.125") piston that should be well matched to the larger front brakes.  Rather than using the stock proportioning valve we are running an aftermarket adjustable valve.  This will allow us to adjust the rear brakes so that they will be balance with the front  

   Brake Lines01.jpg (48333 bytes)

Brake Lines06.jpg (36187 bytes)
We had not been looking forward to running the brake lines.  But, we used lines that had fittings already installed which eliminated the need to flare the lines.  We made a hanger wire model of the complex bends and then bent the brake line to match.

Brake Lines02.jpg (41708 bytes)

The Mustang pedal box attached fairly easily to the frame.  There are two pivot points in the pedal box for the brake pedal.  The upper for power brakes and the lower for manual brakes.  We plan to relocate the pedal to the lower hole and then shorten the pedal so that it won't sit too low.  Pedal Box01.jpg (55480 bytes)
The pedal needed a stop to keep it from swinging rearward under acceleration.  We used an adjuster for a table leg.  The pedal stop can be adjusted by adding or removing washers.

Brake Stopper01.jpg (15081 bytes)
We have not been able to get the brakes to work really well.  The car stops, but it takes a lot of pedal pressure  BrakeBooster03a.jpg (35822 bytes) BrakeBooster04a.jpg (38315 bytes)
We plan to switch the manual master cylinder for a master cylinder and power booster out of a 1985 Buick Grand National.  This car was turbo charged and a standard power booster driven by engine vacuum would not work. BrakeBooster08a.jpg (43032 bytes) BrakeBooster14a.jpg (60152 bytes)
The bower booster has an electric fluid pump to provide extra brake pressure when you hit the brake pedal.  With some minor modifications it will fit in the Cobra. BrakeBooster10a.jpg (37275 bytes)

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