427 roadster

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  • 1

    ASSEMBLY AND

    SERVICE MANUAL FOR THE

    Era Replica Automobiles 427 ROADSTER

    Chassis 758 on

    Revision 10m 06/2012

    Copyright 2012, Era Replica Automobiles

  • 2

    Updates/Addenda

    We try to keep the manual current with the state of the kit, but there may be kit changes not already noted. If the error is significant, please drop me a note. Thanks for your patience. Significant updates, corrections and supplements to the manual will be sent to you if required. Lesser partial updates and helpful hints will be posted to our web site at

    www.erareplicas.com/427man/

    The latest entire manual in PDF format is posted on the web. Use the e-mail below for the location.

    Thanks,

    Bob Putnam -ERA- e-mail: eracars@sbcglobal.net

    Please direct your parts inquiries to: eraparts@sbcglobal.net

    The Manual The text and layout of this manual was done with MSWord XP. Some of the illustrations were hand drawn and scanned, and some were done in DesignCad 2D and 3D. Images were translated to GIF and JPEG format, and linked to this file.

    The Legal Stuff

    Information in this manual is correct to the fullest extent of our abilities. Era Replica Automobiles assumes no liability for any direct, indirect, incidental or consequential damage resulting from the information within..

  • 3

    Contents

    This manual is arranged by assembly sequence, not topic. For information on a specific topic - assembly or service, see the index.

    READ ME FIRST ...................................5

    SECTION A PARTS NEEDED ..................................... 6

    PICKING UP YOUR KIT .........................7 SPECIAL NOTES ..................................8 ENGINE..............................................9 CLUTCH ...........................................11 BELLHOUSING..................................11 ALTERNATOR...................................11 IGNITION NOTES...............................11 TRANSMISSION.................................12 SPEEDOMETER DRIVE GEARS ............15 SHIFT LINKAGE ................................16 REAR DRIVE/SUSPENSION ASSEMBLY........................................................17 STEERING GEAR...............................17 FRONT ROTORS AND CALIPERS.........18 DRIVE SHAFT...................................18 OIL COOLER SYSTEM .......................18 STEERING COLUMN (UPPER) ............18 STEERING WHEEL ............................18 SEAT BELTS .....................................18 WIPER MOTOR AND COMPONENTS ...19 FRONT SHOCK ABSORBERS ..............19 FRONT COIL SPRINGS:......................19 EXHAUST SYSTEM............................19 WHEELS, BOLT-ON ...........................20 WHEELS, PIN-DRIVE .........................20 TIRES...............................................21 RADIATOR HOSES ............................21 EXPANSION TANK ............................21 JACK, ETC. .......................................21 PART NUMBERS AND SOURCES ..........22 SOURCE MASTER LIST.......................28 TOOLS NEEDED ................................29 SHIPPING COMPANIES (PARTIAL LIST)29

    SECTION B: PARTS PREPARATION ..................... 31

    ENGINE/COMPONENTS ......................32 ALTERNATOR MOUNTING: ...............33 REAR SUSPENSION, JAGUAR: ............40 REAR SUSPENSION, E.R.A. DESIGN ...44 SHIFT LEVER (FORD)........................48 DRIVE SHAFT...................................50 STEERING GEAR ...............................50 STEERING COLUMN (UPPER) ............50 WIPERS............................................51 DAMPERS AND SPRINGS: ..................54 REAR HUBS, BOLT-ON WHEELS: ......54

    SECTION C: CHASSIS PREPARATION ......................55

    BODY REMOVAL ..............................57 CHASSIS PAINT ................................59

    SECTION D: BODY/CHASSIS ASSEMBLY......................................................60

    FASTENER NOTES.............................61 BODY MOUNTED PRE-MOUNTED ON CHASSIS OPTION ...............................61 BRAKE AND FUEL LINES....................62 HORNS.............................................62 FLOORS............................................62 FOOT BOXES.....................................62 BODY MOUNTING ............................67

    SECTION E BODY PREPARATION ......................70

    FITTING THE ROLL BAR.....................71 BODY PREPARATION AND PAINT......71 HOOD ..............................................74 DETAIL UNDERCOATING ..................77 WINDSHIELD WIPERS.......................77 TRUNK LID ......................................78 HOOD GASKET .................................79 FRESH AIR HOSES .............................79 TONNEAU SNAPS ..............................79 WIRING AND ELECTRICAL ................80 WIRING AND ELECTRICAL ................80 REAR HARNESS ................................82 INTERIOR PANELS ............................83 ENGINE AND TRANSMISSION INSTALLATION..................................83 DRIVE SHAFT...................................84 DOORS.............................................85 ACCELERATOR PEDAL AND LINKAGE87 EXHAUST HEAT SHIELDS...................88 ROLL BAR........................................89 RADIATOR AND FANS.......................89 GRILLE AIR FOIL..............................91 OIL COOLER (OPTIONAL)..................91 FUEL TANK......................................93 FUEL FILLER CAP.............................94

    SECTION F: SUSPENSION ASSEMBLY ..............................95

    FRONT SUSPENSION .........................97 LOWER STEERING COLUMN..............97 REAR SUSPENSION, JAGUAR-BASED 100 REAR SUSPENSION, E.R.A. DESIGN .103 BRAKE AND CLUTCH PEDAL........... 104

    SECTION G: BODY/INTERIOR.................107

    WINDSHIELD WASHER ................... 108 WINDWINGS AND SUNVISORS ......... 108 WINDSHIELD.................................. 109 HEATER/DEFROSTER...................... 110 DASHBOARD .................................. 110

    SPEEDOMETER CABLE.................... 111 BATTERY AND CABLES .................. 114 STEERING COLUMN AND WHEEL .... 115 SHIFT LEVER ................................. 115 TUNNEL......................................... 116 CARPETS........................................ 118 HAND BRAKE LEVER COVER ......... 125 SHIFT BOOT ................................... 126 SEAT BELT/SHOULDER HARNESS..... 126 SEAT MOUNTING ............................ 127 DOOR INSTALLATION..................... 128 SEAT BELT/SHOULDER HARNESS..... 129 BUMPERS, JACK-PADS.................... 129 FRESH AIR INLET DUCTS................ 130 FUEL FILLER CAP............................ 130 LIGHTS .......................................... 131 REAR REFLECTOR (BOTTOM) .......... 132 LICENSE PLATE LIGHT ................... 132 BACK-UP LIGHT (OPTIONAL) ......... 133 MIRRORS ....................................... 133 TOP SNAPS .................................... 134 EMBLEMS ...................................... 135 LICENSE PLATE(S).......................... 135 SIDE PIPES ..................................... 136 CONVERTIBLE TOP ......................... 139 SIDE CURTAINS .............................. 141 FITTING THE TONNEAU COVER........ 141

    SECTION H FINAL OPERATIONS.......................142

    CLUTCH HYDRAULICS .................... 143 BRAKE HYDRAULICS ..................... 144 BOLT-ON WHEEL NOTES ................. 144 PIN DRIVE WHEEL NOTES ................ 144 INSTALL WIPER ARMS..................... 145 SUSPENSION ADJUSTMENTS ........... 145 BRAKE BALANCE ADJUSTMENT....... 148 ADD FLUIDS .................................. 149 COOLING SYSTEM........................... 150 HEADLIGHT ADJUSTMENT .............. 151 YOUR FIRST DRIVE........................ 151 DRIVING/CONTROLS ...................... 152 FUSES............................................ 152 RECOMMENDED PERIODIC SERVICE 153 STARTING A CARBURETOR CAR....... 153 MAINTENANCE/PARTS ................... 154 INSPECTION AND REGISTRATION .... 158 INSURANCE.................................... 160

  • SECTION A - PARTS NEEDED

    4

  • SECTION A - PARTS NEEDED

    5

    READ ME FIRST

    Congratulations on your selection of the E.R.A. 427SC! We at E.R.A. hope that assembling your kit will be a pleasant experience. We share your goal of creating a great automobile.

    Our objective, when we started on the design and production of this kit was to create a Cobra replica better than all the rest. To keep quality consistently high, we have designed-in almost everything, making this kit one of the easiest to build.

    Even though the E.R.A. 427SC kit is extremely complete, we realized that it is your labor that puts the final quality into the product that bears our name.

    If you have problems, E.R.A. will help you as much as possible to complete your kit. After all, you are really an extension of our production line. And please, feel free to offer suggestions that might improve the end product or the process of construction.

    Remember, the E.R.A. 427SC Cobra replica is usually a very good investment! Of course you are free to make "improvements" to the design but be aware. Changes from the original Cobra concept may not increase the value of your car, and may even decrease it. E.R.A. has spent many years perfecting the details of the 427SC.

    We would love to hear from you, but.... Please, if you have a problem, use the index first! We have tried to include all the information necessary for you to complete this project in a timely fashion.

    Information on the parts required starts on page 8, parts preparation on page 32, and the actual process of assembling the kit begins on page 55.

    Please insert any addenda before you start.

    Some of our electrical equipment may vary, dep