AK Sportscars AK 427 Manual

AK SPORTSCARS

AK SPORTSCARS
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DEAR FELLOW ENTHUSIAST
CONGRATULATION`S ON YOUR CHOICE OF AN AK 427 COBRA KIT.
THE AK 427 WAS INTRODUCED IN 1990 AND IS THE RESULT ENTHUSIASTS
LIKE YOURSELF WANTING TO SEE A QUALITY PRODUCT THAT WAS
STRONG WITH A FLEXIBILTY OF BUILD ENABLING THE USE OF
DIFFERENT ENGINE GEARBOX COMBINATIONS COMBINED WITH THE
STRENGTH AND RELIABILITY OF JAGUAR RUNNING GEAR.
WE HOPE YOU HAVE MANY HOURS OF ENJOYMENT WITH YOUR BUILD,
THE BUILD MANUAL IS FOR YOUR REFERENCE BUT REMEMBER WE ARE
ONLY A PHONE CALL OR E-MAIL AWAY SHOULD YOU NEED ANY HELP
OR ADVICE. WE CONTINUALLY STRIVE TO IMPROVE AND UPDATE
THE KIT AND MANY IMPROVEMENTS ARE DUE TO OUR HANDS ON
APPROACH AND AK OWNERS FEEDBACK.
THE AK 427 IS DESIGNED WITH FLEXIBILITY IN MIND,YOU BUILD
FROM THE BASIC CHASSIS BODY PACKAGE OR FROM A ROLLING
CHASSIS,WE EVEN DO TURNKEY OPTIONS,THIS FLEXIBILITY
ENABLES YOU TO SPREAD THE COST TO SUIT YOUR CIRCUMSTANCES.
AS WELL AS THE BASIC KIT,WE ALSO SUPPLY SOME OF THE SPECIALIST
PARTS REQUIRED IN THE BUILD WITH OPTIONS FROM STAINLESS STEEL
ENGINE BAY CLADDING TO HEADER TANK`S AND WASHER BOTTLES.
WHATEVER YOUR REQUIRMENTS, AK WILL ENDEAVOR TO MEET YOUR
NEEDS
WE WISH YOU GREAT SUCCESS WITH YOUR PROJECT.
KEN , JON and DAN FREEMAN.

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INTRODUCTION
WE WOULD ADVISE THAT YOU READ THIS BUILD MANUAL IN ITS
ENTIRETY SO AS TO FULLY FAMILIARISE YOURSELF WITH THE
CONTENTS HEREIN.
ALTHOUGH EVERY EFFORT HAS BEEN MADE TO APPROACH THE
BUILD COMPREHENSIVELY, THIS IS NOT A DIFINITIVE WORK AND
IS INTENDED AS A GUIDE WITH WHICH TO ASSIST AND ADVISE YOU
DURING THE BUILD PROCESS.
DUE TO THE VERY NATURE AND CONCEPT OF BUILDING A REPLICA
CAR IN COMPONENT FORM AND THE DIFFERENCES WITH WHICH
EACH CUSTOMER WILL APPROACH THEIR PROJECT, THERE IS GOING
TO BE AREAS NOT ADDRESSED, WITH THIS IN MIND THE CUSTOMER
SHOULD APPROACH THE BUILD AWARE THAT THERE PARTICULAR
CHOICES WILL AFFECT THE FINAL OUTCOME.
WITH THIS IN MIND WE ARE ALWAYS HERE TO HELP AND ADVISE
SHOULD ANY PROBLEMS AND/OR QUERIES ARISE?
WE HAVE SOLVED MANY PROBLEMS FOR PREVIOUS CUSTOMERS
DO NOT HESITATE TO ASK, YOU WONT BE THE FIRST.
GOOD LUCK.
KEN, JON and DAN

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CONTENTS
CHAPTER ONE…………. Your AK 427
Specification
Engine and Gearbox options
AK 427 Kit contents
Optional Parts Manufactured by AK
Donor list
Parts suppliers list and approximate costs
CHAPTER TWO…………. Preparation
Safety
Tools
Workarea
CHAPTER THREE……… Chassis/Body
Chassis support and preparation
Body storage
CHAPTER FOUR………… Running gear/Suspension
General information
Selection of suspension/Running gear
Front suspension stripping/preparation
Rear suspension stripping/preparation
Ready to rebuild
CHAPTER FIVE………….. Chassis build
Front suspension fitting
Rear suspension and differential fitting
Brake lines/pipes
Fuel tank
Fuel pump and fuel lines/pipes
CHAPTER SIX……………. Engine/ Gearbox/ Exhaust
General information
Fitting
CHAPTER SEVEN……….. Cooling System
Radiator/fitting
Header tank
Plumbing/hoses
Electric fans/thermostatic control

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CHAPTER EIGHT……….. Body/Fitting
Preparation/fitting body
Roll bar & seatbelt brackets
Windscreen
Door locks
Screen washers
Boot Hinges/locks/bonnet stays
Lights/Head /Indicators/Brake/Number plate
Petrol filler/Pipework
Nudgebars/Overriders
Seatbelts
CHAPTER NINE…………. Cockpit/components Mechanical
Pedal box assembly
Steering column
Handbrake
Heating system
Wiper motor/wipers
Instrument panel/instruments/Switchgear
CHAPTER TEN…………… Electrical
Wiring loom/Fitting
Cockpit
Engine bay
Dashboard
Front lights
Rear lights
CHAPTER ELEVEN……… Cockpit/Components Upholstery
Carpets
Door panels
Seats
CHAPTER TWELVE…….. Finishing
Wheels/Tyres
Hood.

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YOUR AK 427
SPECIFICATION
CHASSIS………………… Ladder frame construction of 75 x 50 x 3.2 section steel
for the main rails and 25 x 25 for the backbone section,
floors are paneled in 12 gauge steel for extra stiffness.
The chassis is jig assembled for accuracy of and comp-
nent fit ensuring correct suspension geometry
SUSPENSION……………. Front
XJ6/POST 1974.Front Upper and lower wishbones,swivel
hub assembly,stub axles,AK supplied mounting plate for
coil over shocks,AK supplied coil over shock absorbers
Rear
XJ6/POST 1974.Driveshafts and lower wishbones shortened
supplied by AK on an exchange basis,rear axle tie bars
supplied by AK,rear diff mounting bracket supplied by AK
rear hub assemblies.
STEERING……………….. Rack and pinion modified and supplied by AK and Rover
SD1 steering column
BRAKING SYSTEM…….. Pedal box, servo, master cylinder (Dual circuit) sourced from
Morris Marina,Pedals modified by AK,or AK manufactured
pedal box using rover 214/216 master cylinder incorporated
with front and Rear calipers and Discs (vented front) from
Jaguar XJ6.
FINAL DRIVE……………. Differential from Jaguar XJ6/12/s
RATIOS 3:54:1 for Rover 3500
3:31:1 Larger capacity(350 ci)
3:07:1 With 4 speed box
2:88:1 Automatic box
Utilising Jaguar Or Rover Propshaft shortened to fit.
BODY………………………. GRP body gel coated to customer choice constructed in mold
With only three main components (multi layered chopped
Glass mat layed for strength in key areas,Cockpit and Boot
Jig bonded to shell for accuracy and rigid monocoque,double
Skinned Bonnet,Boot and Doors,complete with interior side
Panels and Dashboard.
WHEELS/TYRES.………… Halibrand replicas with spinners 16inch or 17inch,check with
AK for correct OFFSET.
ENGINE & GEARBOX APPLICATIONS
GENERAL INFO………….. The AK 427 is designed to accept various Engine and Gear
box combination`s, listed below are some that have been
applied previously to the AK chassis,and have proved to be
reliable,easily fitted and giving excellent performance in
keeping with the concept of the original.

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YOUR AK 427
ENGINES………………….. ROVER V8, 3500cc/3900cc/4200cc/4500cc/5000cc/6300cc
Although expensive to tune in its standard forms ie 3.5ltr
3.9ltr and 4.2ltr this is a very capable engine of light weight
compared to alternatives and extremely reliable with an
output of 165bhp to240bhp,the tuned versions of all the
above whilst an expensive process can yield power outputs of
over 350bhp the power to weight ratio of this engine and its
CHEVROLET (small block) 265ci/283ci/302ci/327ci/350ci
4 bolt mains, cast iron or aluminium cylinder heads,solid or
hydraulic or solid lifters, power outputs of 170 bhp to 380bhp
achievable,these engines are easily obtainable and comparat
ively inexpensive to tune compared to the rover, although it
is heavier due to being a cast iron block.
FORD V8, 221ci/260ci/289ci/302ci/351ci the 289 being the
original choice of these engines as fitted by Mr Shelby himself
like all the above Chevrolet engines the Ford power units
lend themselves to tuning with high outputs attainable
BIG BLOCK CHEVROLET AND FORD,whilst these engines
Appeal is obvious,a tight fit and cooling can cause there own
headaches.
GEARBOXES……………… ROVER 5 speed for Rover engines
CHEVEROLET,T5 or T10,Trimac or Getrag
FORD, T10 or 4 speed top loader or or any of the above as
fitted to chevy with suitable adaptors.

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YOUR AK 427
LEADING DIMENSIONS
& DESIGN WEIGHTS
AK 427 DESIGN WEIGHTS.
AXLE 1 638 kg
AXLE 2 780 kg
GROSS 1400 kg

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YOUR AK 427
AK 427 KIT CONTENTS
CHASSIS…………………………Ladder type with partial backbone and full steel lowered
Floors
BODY…………………………….Finished in white gel coat,(colours optional)
• scuttle hoop bonded into full inner tub
• body temporarily bolted to chassis
• doors and bonnet pre-hung
• top and bottom radiator frame
• steering rack
• track rod ends
• steering arms
• steering rack to column extention
• front shock absorber mounting plates
• engine and gearbox mounting plates
• wiper motor bracket (attached to scuttle hoop)
• steering column bracket (attached to scuttle hoop)
• handbrake mounting bracket
• handbrake cable
• rear axle tie bars
• shortened rear wishbones (exchange)
• shortened driveshafts (exchange)
• roll bar mountings
• front and rear nudge bar mounting brackets
• dashboard (blank)
• interior trim panels
• glove box moulding
• modified pedal box (exchange)
• all body holes marked or pre-cut
• holes drilled and tapped for door locks
• rear differential mounting bracket

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YOUR AK 427
OPTIONAL PARTS SUPPLIED BY AK
(all prices plus VAT)
COIL OVER SHOCKS (6 of)
PETROLTANK STAINLESS STEEL (14 gall)
HEADER TANK (stainless steel polished)
WASHER BOTTLE (stainless steel polished)
REAR WHEEL ARCH STONEGUARDS
(stainless steel)
SIDE VENT`S (stainless steel)
BONNET AND BOOT GAS RAMS plus fitting kit
STAINLESS STEEL ENGINE BAY CLADDING
(cut and folded)
STAINLESS STEEL ENGINE BAY CLADDING
(fitted prior to delivery)
SEAT SHELL`S
SEATS --- LEATHER
SEATS --- VINYL
UNDERFLOOR EXHAUST SYSTEM and MANIFOLDS
STAINLESS STEEL SIDEPIPES and MANIFOLDS
AK MANUFACTURED PEDAL BOX –
uses ROVER 214/216 servo/master cylinder