THE BUILD

The Dax Demonstrator My Car
Rush_01.jpg (60067 bytes) DRB_0287_Ready_for_MOT.jpg (76298 bytes)

The following chapters deal with the build.

Also you may be interested in the section on preparation, which covers activities up to collection of chassis.

Month Main Jobs Tackled

September

2002

Chassis collected.
First ali panels fitted.

October

2002

Diff fitted
Collecting and reconditioning donor parts for rear end.
More ali panels.

November

2002

Rear bulkhead side panels (aka "ears").
Rear bulkhead
Fuel pump and tank.

December

2002

Mountings for the high back seats.
Started reconditioning front donor components.

January

2003

I will do some work honest.
Finished reconditioning donor parts, fitted steering rack.

February

2003

Replaced diff flanges.
Fitted additional ali side panels.
Work on transmission tunnel.

March

2003

Fitted transmission tunnel.
Rear Brakes and handbrake.

April

2003

Front brake pipes.
Scuttle including; vent escutcheons, demister ducting, 12v fans, wiper system.

May

2003

Wiper system
Engine arrives and is trial fitted.
Most ancillary components, located and brackets designed/made.
Starting to resemble a car.
June

2003

Cockpit panels.
Steering column
Battery shelf, pedal box cover and pedals.
Fuel regulator, fuel lines and brake pipes. 
ENGINE IN
Propshaft connected, starter motor.
Rear wiring started
Transmission Tunnel fitted and started work on the rear tub.

July

2003

Lots of wiring.
Steering column correction.
Special lower coolant pipe.
Oil cooler/filter pipework.
Alternator.
Radiator & fan.
Engine turned over on starter to pump oil.

August

2003

More wiring and air horns. 
Choke cable and bracket.
Fixing transmission tunnel.
Initial work on side panels and bonnet position.

September

2003

Dash layout.
Expansion tank.
Progress on side panels and exhausts.
Rear tub fittings, fuel cap, brake light, no.plate, etc.

October

2003

Exhausts finished.
Coolant system finished.
Wiring.
ENGINE START.
Oil pressure problems.
Leaky fuel tank replaced.

November

2003

Wiring.
Headlights.
Carpets.
Nose cone fitment.

December

2003

Nose cone pivot mounting and brackets.
Wiring finally gets finished.
Bonnet trimming.
Wiper Gear to 130° sweep.
Carpets.
Front Suspension.
Headlights.
Radiator Grill.

January

2003

Radiator Grill.
Windscreen.
Carpets.
Kick strips.
Front wings.
Alarm
February

2004

Scuttle fitted.
Hydraulics plumbed in and bled.
Bonnet catches fitted.
SVA APPLICATION.
LIFT DOWN.
Stalks.
Dashboard.
Rear wings.
Rear lights.
Suspension set-up.
Pond liner.
Wing mirrors.
Harnesses.

March

2004

Dash infill panels.
Carpeting pond liner.
Bleed brakes.
Ride height adjustments.
MOT.
SVA.
Registration.
Number plates.
Mudflaps.
Sump gasket replaced.
Sticking throttle resolved.

Please note;  If you have any technical queries, you should clarify those with Peter or Gary at DJ Sportscars.  They are the guys who know, not me.

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Last Updated 28/03/2004