BUILD ~ SEPTEMBER 2002

Opening Note;  This diary is intended for other potential Rush builders, as I found other web diaries very useful (these can be found in links section).  It should also give an indication of difficulty, as I am new to this lark, done basic car servicing before but not much more and my day job is as a Management Accountant.  So here goes, warts and all.

14 & 15/09/2002

Well we collected the van last night, loaded it with ropes, blankets and put its tyre pressures right to hopefully correct the awful steering when collected.  So I was up at 05:30 and with Dad along to share the driving we left shortly after 06:00 for the drive to Essex.  Arriving at Dax about 09:30.  

Darren - helpful - few missing items (having been told all ready) rear springs, quickrack, plus the headlamp shells I knew about.  But we paid in full and started loading.  To the right is a picture before we started.  First was the chassis and body panels, my chassis has already been involved in a three car pile-up (perhaps not the best omen), it was at the bottom of a pile of three chassis.  We carefully wrapped and packed the panels to cause no damage and lashed the chassis at the corner of the van.

We then moved the van round to the yard for the remainder of the parts.  Doing a rough mental check as we loaded.  Found the seats had not been done to my design, see my earlier diagram..  So they were left behind for correction.  Took the opportunity with the seat mistake fresh in mind to exploit a tip from the Dax list and got them to press in the lower wishbone ball joints and the bearings into the dedion tube.  Once it was all packed there was still plenty of room in the van, but it was all closely and securely packed.  

We set off home, with a pub stop on route.  When we got home it was a quick unload piling it all in the garage so we could get the van back by the 5pm deadline.

That evening I went out to have an attempt at checking off the items collected to that expected per the price list build pack breakdown and the list of optional extras I had chosen.  Why ticking all this off we squirreled away many of the items into the garage roof, in such a way as those we need first come to hand first.  It ended up with only a few queries.

I couldn't resist sitting in the chassis and imagining.  It definitely seems small sat on the garage floor.

Sunday we went to Donington Park and the Kit Car Show.  Another chance to have a dig around other people's Rushes and see a little bit of track action.  During the time we watched the breakdown truck had the most track time towing cars out of the gravel traps.  One bloke in a Vindicator sprint went off at the same bend twice in three laps causing it all to be red flagged.  Pictures from the day can be seen here.

That evening we finished the trestles dad has been working on and turned the chassis upside down onto these.

16 to 20/09/2002

As Dax decided to remove chromed SVA bars from the options list (after taking my order) I have had them in bare metal.  Cleaned them up ready to find a local chromer.

I also ordered my differential from Classic Conversions.  I would like a 3.14:1 ratio as this is supposed to be the best for the R V8, was impressed that before they would take the order they wanted to check they could a.) get the crown and pinion, and b.) do this within my requested three week timescale.  Richard phoned me back the following day to confirm and I put a cheque in the post.  Very impressed with the service so far, they are even going to grind the rear mounting lug off for me before they lacquer the diff.

Monday night had to do something, so started rubbing down a few imperfections in the powder coating.  These were mainly on the bottom where the chassis had sat while cooling, but a couple of other patches were a little thin.  Although I must say I was presently surprised by the quality, having heard bad things in other build diaries.

Tip ~ Never deal with Parts R Us - Birmingham, they are lying bu**ers.  Indeed if at all possible deal with breakers that you can meet face to face.

Wednesday evening, had hoped to finish rubbing down the few rough patches of powder coat (on underside) and re-spray with matt chassis black paint.  But found I couldn't resist trimming some panels to size.  This is my first attempt at using tin snips, certainly glad a bought sturdy ones with padded handles.  All went rather well really I soon had the two largest panels trimmed to size and the edges filed.  All this with only one cut to my fingers!  Feels good to have made a start.

Finished preparing the odd bad patch of powder coating touched up others with matt black chassis paint.  Ready to get on with panelling at the weekend.

Tip ~ Trim, mark and drill the inner side panels first.  As it is easier to get the drill square with the tubes before the floor is on.  But I am not fitting these yet.

21 & 22/09/2002

Saturday started with a bit of shopping first today, Dremel ready for trimming fibreglass and to collect the front knuckles which were on order.  Success in first, 50% success in second.  Also spent a while in Jessops helping Dad research digital cameras - ooh this could be useful for the build diary.

Started work late afternoon, trimmed the offside inner side panel and drilled the holes along its bottom edge.  Then set to the floor panels, by end of evening all the holes were drilled in these.  See the following tip for the method I used to get a good job on these.

Tip ~ For best results, trim panel to size then file to achieve good edge.  Using 1" masking tape, tape round the panel (over chassis rails).  This is then easily marked for the rivet holes, drawing straight line and measuring off the intervals.  To ensure no slippage with the drill, first centre punch the marked positions.

Sunday fixed on the floor panels, the picture shows me at work with my "L" plate on.  I chose to securely clamp the panel and pre-drill the chassis, as this gave me the ability to clean out the swarf.  Then sprayed in the "Waxoil", roughed the contact surfaces, applied a generous bead of wurth to the chassis, pushed the panel down, clamped and dropped a rivet in each hole.  Then started with the rivetter, 58 rivets later the first panel was on.  58 is a fitting number, as my father who is a willing assistant was 58 this weekend.  I can see why Duncan calls the Wurth "Black Death" (BD), it is sticky stuff, cleaning the excess off took an age and many bits of rag.

Tip ~ Wear disposable gloves when using the "Wurth".

Well first jobs done, and what's more I haven't sworn once.  Just leaving to let it all set now.

I still need to source the donor parts for the rear end, Gloster Motor Spares is still hopeful, but nothing positive yet.  There is also the chance of some from Derek's (sailing friend) old Sierra, which he has kindly donated for any kit car use.  This is currently residing at John's (another sailing friend) house.  He is going to let me know the spec of the parts sometime next week.

23 to 27/09/2002

Wednesday was the first time this week I had time to visit the garage, and only for ½hour.  Turned the chassis the right way up, and started fitting the rubber bushes for the diff, after doing two was a bit concerned why they are so much longer than the chassis tubes.  Therefore whilst I consider this I fitted the ball joint for the dedion arrangement.

Friday fitted remaining four bushes, having put them in freezer for a few hours to make them a fraction smaller.  Then fitted the A frame and tightened balljoint.

Tip ~ I managed to get Dax to push in the bearings as the Dax List and web diaries always seem to indicate difficulty here.

I spoke with John, who confirmed it was a 7" diff, and reasonable size rear discs, so arranged to go and take it apart tomorrow.

28 & 29/09/2002

Well Saturday was up at dawn for the drive to High Wycombe.  When got there, found the car had drum brakes, so that was 100 miles without benefit.  Anyway spent the rest of the day taking out the V6 engine and gearbox which John may use for his pending low-cost or spares for his other sierra, also stripped out the entire rear end, which he thinks a neighbour will have for a Robin Hood.  Seven hours to strip a Sierra, isn't bad.  But my build has not moved forward.

That evening, all I did on mine was 10 mins putting bushes in the trailing arms.

Sunday brought a small amount of progress on panels.  The cardboard templates for the end panels are done.  The ali interior side panel on the drivers side is ready for fitting.  The interior fibreglass panels have been trimmed a little to improve fit.  To get the plate ready for the right of the pedal box, had to angle grind a little of a large weld away so it would lie better, will paint this up again this week.

30/09/2002

Nothing on Dax tonight as had to change the thermostat in the Rover.

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Last Updated 30/09/2002