02 &
03/11/2002BUILD ~ NOVEMBER 2002
02 &
03/11/2002
First job was to get
the ears ready to fit. Whilst doing this we also put the rear bulkhead in
position to check fit. With all holes drilled and waxoil'd I quit for the
day. I did decide to rivet to the diagonal round tube, the layout is shown
in the diagram on the right.
Sunday saw both ears fitted, they have pulled up nicely and are very rigid. Although quite a large amount of Wurth was required to ensure they are totally watertight. I will rivet them to the stainless roll bar tube, at the same time as the back panel.
04 to 08/11/2002
Another manic week at work has prevented any progress on the Dax. The most I managed to do was order a fuel pump and the front brake upgrade from Dax. The headlight buckets also arrived back, all they have done is cut off the front where the moulding was bad and painted the inside black to cover up where the blue gelcoat was thin. But, where they cut the front off the line is nowhere near straight. Thus when offered up to headlight gaps abound, so they are still really crap.
First job on Saturday was to remove the excess powder coating from the roll bar (where it will disappear into the bodywork), this was accomplished with paint stripper and then the dremel to polish the stainless.
I then worked on the fibreglass back panel and gearbox tunnel to try and make them fit better, this took along time due to offering up regularly and working carefully. The tunnel is the biggest problem as it will not sit down on the floor as it is fractionally too long and the inside of the tunnel sits down on the diagonal tunnel brace tubes. However, the glass fibre is relatively thick here, so it can be improved slightly if you are careful not to to rub down too much.
Tip ~ Buy a Dremel!
That evening Dad and
I started drilling the holes to rivet on the rear bulkhead. A lot of
careful measuring will hopefully leave it looking neat as well as meaning we
drill into a rail rather than space.
On
Sunday we made and painted a bracket for the fuel pump. This will be
situated behind the drivers back, but in front of the offside drive shaft. It is
a simple steel plate which rivets to two horizontal chassis rails (4 x
rivets) and the diagonal brace tube (1 x rivet). The Carter
supplied bracket (which Dax gloriously calls a fitting kit) is then
bolted to this plate (red holes on diagram). As that is probably
clear as mud, there is another doodle.
Also got the rest of the holes drilled in rear bulkhead. All but two of these will be rivets, these other two are M6 rivnuts. So when the tunnel is fitted, it will be possible to put a domed bolt through both and hopefully pull up neatly. Ended the day by 'Wurth'ing on some wing piping to the bulkhead, as another vain attempt at neatness. Guess what, I will be going to work with black fingers again tomorrow.
11 to 15/11/2002
Work left me either no time or to knackered to work on the car much. However, we did stick wing piping round the top curves of the bulkhead, so it will fit neatly round the rollbar. These were simply stuck on with Wurth, and whilst this was open we fitted the fuel pump bracket made at the weekend. Dad had painted this for me earlier in the week.
16 &
17/11/2002
I have not managed many hours this week or indeed this weekend but at least what I did achieve went rather well. First job was to fit the fuel pump to the bracket which we fitted in the week. The rear bulkhead panel was then fitted, I am quite please with neatness, but this will all be hidden under the carpet anyway.
A relatively quick win was to fit the fuel tank, this really couldn't be easier stick foam in appropriate places, four holes, four bolts. That's not going anywhere. As the photo shows the back of the car is starting look a bit crowded. Still got wiring, fuel pipe and handbrake cable to route through there.
Tip ~ Some extra self adhesive foam on the inside of the ends of the tank support rectangle and coming slightly up the sides of the flat under rails, means the tank is totally cushioned.
18 to
22/11/2002
Absolutely nothing done on the Dax, work manic. The picture to the right illustrates current state of play.
Had a phone call from Classic Conversions informing me of new information from Quaife on the output shafts of my LSD. Apparently they now need a new sort which includes a "special" circlip. It is refreshing that CC have contacted me and will dispatch replacement parts and instructions as soon as possible (that diff is not coming out again). Only trouble is it is likely to be January, so have to hold off with the rear tub!
23 & 24/11/2002
Had to work Saturday, so that put pay to making any major progress this weekend. Sunday I set about reconditioning the rear callipers. Pistons appear in good order, so the only parts required look like being new seals. However, I would like to check the handbrake mechanism as I believe one of the seals round the actuator arm has perished, to do this I need a special Ford tool and a longer thinner pair of circlip pliers. So stop for the day and wash the other car. Sorry no pictures as no progress.
Rest of November
As you would of by now gathered the Dax has been pretty much on hold at the moment. This is due to the new computer system at work and needing to source more bits including major items such as engine and gearbox.
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Last Updated 30/11/2002
