BUILD ~ APRIL 2003

09 to 11/04/2003

Combination of problems with my main car and going sailing have prevented the build for a while.  However made it into the garage tonight to start working out positions for front components (EWP, Brake Pipes, Coolant Pipes, Oil Cooler, etc.).  Also fixed and bent the first bit of brake pipe.

Bent the other front brake pipe tonight, the picture shows the finished effect.  The little ali brackets are just to ensure support until the side panels are fitted.  Also the brake light switch has been placed horizontal in the hope of preventing an air lock getting trapped in the switch.

After work on Friday, went up to Birmingham and collect my wheels from Image, good job Dad has an estate car.  They look great and could not resist fitting one just to see the effect.

12 & 13/04/2003

Continued work on the scuttle this weekend.  First was the fitting of the vent escutcheons, I want to get these as neat as possible as so visible on the finished article and started by evening up the cuts Dax had made.  Took some very careful filling, but ended up with four straight edges.  Then to decide position found the centre point and measured outwards.  Found that one of the Dax cut outs was 5mm different to the other.  I then painted the white fibreglass in the slits with black paint.  When that was dry drilled the bolt holes and fitted the escutcheon on a thin layer of Wurth, as I only have one set of clamps large enough, the others will have to wait until tomorrow.

Then while that sets, I started on the holes for the wiper spindles.  Again very careful over positioning and angle of drill hole, then opened out with a small file until a snug fit was achieved.  Does not sound much but took a fair time.

Sunday I fitted the other escutcheon and a angled the ends of the spacer tubes that fit on the wiper spindles.  This is to keep the spindles square to the mouldings on the scuttle.  Also decided were the wires would enter the SVA bars, drilled holes.  These are now ready to be chromed.

14 to 16/04/2003

Removed the clamps and cleaned up the small amount of excess wurth from the second escutcheon.  Then started working out relative positions for wiper system, demister duct and the 12v heaters.  As luck had it, flicking through manual for a clue as to which way round the duct fitted (v.tight tolerance to wiper wheel boxes), came across the note that the rear mirror should be fitted before duct.  So a small hunt was on to find the rear view mirror.  Decided to fit this with captive fittings so it can be installed at the end rather than break it during the build.  As the picture shows two M4 rivnuts are on a small strip of galvanised metal and I will wurth this in position.

So not a very productive evening, but I think a few decisions may have been made.

Wednesday was just a short session, started to fit the 12v heaters from Car Builder Solutions into the demister ducting.  All fits snugly, only to then realise it might foul the tacho etc.  So will need moving to the right, bugger!  So ended with fitting the wiper boxes as the picture shows, the small spacer tubes previously being painted to ensure they don't rust.

22/04/2003

The engine mounts I ordered from the Runcorn SD1 Centre, never arrived despite regular chasing and many promises.  So cancelled the order and asked for a refund a few weeks ago, they are as slow with the refund as they were with the mounts.  Anyway, I ordered a set from Rimmers just to get this moving, costly but at least I have the piece of mind of brand new rubbers.  The brackets are second hand and spent a while this evening cleaning them up ready for painting.  Dad will hopefully do the painting tomorrow as the temperature is a bit low tonight.

26 & 27/04/2003

A weekend at home, so determined to make some progress.  First on the list was fixing demister ducting and heaters.  However, first needed to move the drivers side further outboard as it might foul the instruments.  Opened the hole, then wurthed a plate where the gap had been made, at the same time fixed the captive nuts for the rear view mirror.  Whilst this was setting I rubbed down the engine mounts ready for a few more coats of paint.

I then cut a hole for second heater (got this one in the right place, I hope).  These were then duly fitted with wurth and an ali strap, the demister ducting then being wurthed into the scuttle and left with various weights holding it down whilst it sets.  Hope Mum does not decide to do any baking.

Again a waiting game for the adhesive to set, so started making a cardboard pattern and then cutting the drivers footwell end panel.  Although I won't drill holes or anything just yet.

Also fitted the brake master cylinders, having spoken with Peter @ Dax, I have put the ¾ for the front circuit, and positioned this outermost as I think this should prevent the pipes having to cross over.

On Sunday the ducting was now stuck enough to remove the weights, so I moved onto the wiper motor bracket.  Positioning this is not easy as it needs a straight run but also has to clear my heaters and the demister duct.  The position this then yields is far from flat.  So I trimmed and bent the plate to try and follow the contours of the scuttle.  Anyway the picture shows were it ended up.

I then turned to the battery shelf and pedal box cover.  The battery shelf required a few nips and tucks, plus some holes to clear the rivnuts for the scuttle mounting.  All this was fairly straight forward, the pedal box cover is a bit more complex.  Instead of the Dax supplied angle plus an extra sheet for the pedals to go through, I have decided to make all of this out of one piece.  This will hopefully look more professional as there will be less joins.

So at the end of the day, I was left with three prepared panels, except for the rivet holes, which I will do another day.  They will also need polishing slightly to remove a few minor scratches.

I then painted the inside of the scuttle, as 'Detail Dean' recommends painting the inside of the panels to improve the lustre of the gel coat, certainly in a few places the fibreglass appears thinner than in others.

28 to 30/04/2003

First job was fitting the wiper motor onto its plate and securing the last part of the wiper boxes, could not resist a quick test, the spindles turn, yes, job done.  Except it only seems to be a 90º wheel, argh.

I then positioned the scuttle onto the car to work out the position for the dish which provides clearance for the backs of the master cylinders, plenty of masking tape and marked it out.  Will try and cut this tomorrow.  I then made a bracket for the fuel filter / regulator.  This is just bent out of some sheet steel.  Not 100% certain that it is going to be rigid enough.

Following yesterdays measuring, I cut out the place for the recessed dish in the scuttle, which ended up looking like this.  It was then a simple job of wurth'ing it in the right place and leaving it to set.  

Today is a great day, V8 Developments report my engine is finished, run in and dyno tested.  I am one happy bunny!  This is it on the dyno, an mpeg should follow in a few days.  All that remains is to send them the final payment and arrange delivery.

Now that the dish is stuck, I have been working out where to cut to make the dish clear the pedal box and steering column supports.  Want to take out the minimum amount of material to ensure a good watertight fit.  Ended with painting the inside of the scuttle where the latest bit has been glued.

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Last Updated 30/04/2003