BUILD ~ JULY 2003

12 & 13/07/2003

This weekend I have been dabbling a little, whilst enjoying the fantastic sunshine.  First job was to disconnect the steering, yes I thought I had finished this job!  Realised that I had set it up with the indicator cancelling cam, 180° out.  It should be at nine o'clock when the wheel is straight ahead, this was quick to change and everything was tightened and the indicators tested.  Then moved onto wiring, started the wiring of the two front looms (engine and lights).  Also fed the wires into the SVA bars and fitted the indicators, very fiddly, basically ran twine through to use as a mouse.

Also trial fitted my special coolant lower pipe, this has been made to my drawing back in May.  It consists of a machined flange for bolting to the EWP, a take off at the very top for the pipe to the expansion tank.  The rest consists of two 90° bends to route the water under the rack, up and then over the column extension into the pipe.  Upon fitting found as expected it placed two much weight on the pump, so an extra bracket was added to the remote filter support, giving an adjustable support for the pipe work.  

17/07/2003

Had the final parts from V8Developments arrive this week, as well as the oil pipes and some more wiring bits.

On Thursday made it into the garage to trial fit the oil pipes with the great looking Aeroquip fittings.  It soon transpired that I had underestimated the size of the fittings and thus the amount of flexibility the pipe would give.  Retired hurt, to think of a solution.

19 & 20/07/2003

Saturday was a slow start but began with adapting the bracketry for the remote oil filter, to take into account one of the oil pipes.  Then went through a few permutations for the fitting the other pipes.  I have come to the decision that only one will need to be re-made, longer and with a different fitting.  

Also fitted the water hose between the EWP and the engine, sadly breaking one of the small plastic brackets.  This meant making a replacement from angle iron.  Can't finish this assembly until the paint dries.  Therefore moved onto fitting the alternator and bracket, which appears to be spot on.  This is a great relief as many of the Dax list seem to have had problems.  Although I will need to design a belt tensioner, but this can wait for a while.

My custom stainless water pipe, has one flaw.  The take off for the expansion tank, has too larger lip for the 5/8" hose to fit over, although the pipe is the perfect size.  So a long and arduous job with the file was required to bring this down to size.

Carried on the work to the rear tub, by fitting a strip of ali' to the leading edge (underneath).  This hopefully will stop the air frapping the fibreglass around.

Sunday seemed to yield more progress, firstly the new bracket was used to fit the electric water pump.  To this we then fitted my custom stainless water pipe, remembering the O ring.  I had also pre-fitted the lower flexible water hose ready for attachment to the radiator.  

Using the brackets we adapted yesterday for the remote oil filter, the filter and cooler were bolted in.  We then filled the cooler with the recommended Motul 300v 15W50 oil, so as when the engine turns over for the first time it won't be simply trying to fill the cooler.  I will do the filter at a later time.  Oil pipes where then added between the engine and the cooler and the cooler to the filter.  Looks great, there certainly is not a lot of spare space, but it does all fit.

The 5/8" pipe to the header tank was then fitted and fixed for the first part of its route.  I cannot finish this at the moment as the final position of the header tank is still to be decided.

With the connections to the cooler tightened it seemed logical to attach the radiator.  As this had already been trial fitted and brackets made it was the quickest and simplest job of the day.  Even the lower hose went straight on.  That said it will probably leak when we add the water.  So the coolant/oil systems requires two hoses to complete.  As soon as that is done I will turn the engine over with the plugs out and coil disconnected, as the engine has been standing idle now for two months.  So would be good to coat the internals with oil.

With the front feeling much more complete (and crowded) we moved onto the rear tub.  One last test fit, identified where to fit rivnuts into the forward fuel tank rail.  Then it was off again, fit rivnuts and get ready for final fit (coffee break).  I want it be possible to remove without major surgery or leaving parts of rivets rattling inside the chassis rails, so other than the ears all is being done with bolts.  Also sealant is being used instead of wurth.  It was lifted/rotated into place and the bolts all went in easily, this left it in position and firm.  So we moved onto the curved forward edges that are beside your shoulders.  These need to be riveted to the corner bulkhead panels (aka ears).  I found drilling these holes particularly nerve racking, as if I went too deep, I would come out on the external part of the car.  That would be a rather visible error!  Anyway, ten large head rivets later and both it and I were feeling good.  To add perspective for the picture I brought one of the wheels out of Mum's spare room, but finding the wheel bolts to attach it with required a long search.

Carried on with the front wiring loom, the extra wires ordered last week were added.  It was then necessary to route into the scuttle area.  This was done via the passenger foot well end panel, using grommet and convoluted tubing.  The first part of its route was then laid out using cable ties.   The only connection made was the oil temperature sender which is the central part of my sump plug.

Ended the evening by fitting the Kenlowe fan.  This is done with what can be described as a cable tie through the radiator matrix.  Despite the simplicity seems to have fixed it firmly.  And more my chance than by judgement they came through either side of the oil cooler with just enough room for the backing pads.  A jury rigged wiring system, allowed us to check operation, this provided our own mini-gale.

Retired quite satisfied from a weekend of progress.  Although it will slow down now as I am away for the next three/four weekends sailing again.

21 to 25/07/2003

Tuesday evening we made it into the garage for a short stint on the front wiring harness, and fitting the adjustable thermostat for the Kenlowe fan.  Dad also has been making a extension bracket for the alternator adjustor, which has now been painted.

Wednesday and the alternator adjuster is now on as the picture shows.  The rest of the time was spent continuing with the front loom, I occasionally wonder why I decided to make the wiring from scratch.

28 to 31/07/2003

Monday night fitted the remaining oil pipe, which had been re-made by Think automotive.  Thankfully it fitted fine.  So we moved on with an attempt to pressurise the oil system, by changing the plastic blanking plug in the bottom of the front cover for a brass one (not forgetting the O ring).  Then all eight plugs were removed, the alternator belt removed (charging circuit not complete), temporary oil pressure light connected.  So moment of truth, the hope being that the starter motor would have sufficient power to pressurise the oil system enough to put out the light.  Just as about to put the wire across the terminals remembered the car was in gear.  That rectified, we turned it over, after four ten second bursts, it has not managed to put the light out.  So quit and I will talk to the engine builder tomorrow.  Still big grin from seeing it turn.

I phoned Dax again this week, I am still about 20th on the list for an exhaust.  What's more one of the exhaust men is leaving.  Absolute best is three to four weeks more to wait.  But hopefully the trim I ordered nine weeks ago, might be with me next week.

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Last Updated 31/07/2003