BUILD ~ SEPTEMBER 2003
01 to
05/09/2003
Monday evening, although I only managed a very short stint tonight, I benefited from Dad doing some more cutting on our trial dashboard blank. With a bit of trial and error we have found a shape we both find acceptable and started thinking about layout. This was done with lots of paper circles and blue tack. The current thoughts are shown in the picture.
This evening I have
not got any work done, but could not resist of another picture of the trial
dashboard which now boasts a complete set of instruments, along with holes for
key and warning lights.
15 to 19/09/2003
Tuesday, and a day off work in an attempt to make some progress on the Dax. First up was some more prep on the side panels, the ali strips that go along the top edge and the bonnet rest against were first cut to length and then suitable holes drilled, then the side panel and chassis were done.
Then jumped to the
cooling system, and fitted the header tank. Having first very carefully
washed out all the swarf, that would not do the engine much good. To the
tank we then connected the main feed and p-clipped this hose in place.
Also added a overflow pipe.
Next came some work
on the nearside exhaust. We supported the aft end on a box and bolted the
manifolds to the engine. These all went well except for one bolt, the
threads in the head look damaged. Not sure how much of a disaster
this is going to be. I have not tried forcing it yet as don't want to make
matters worse. With the front fixed we then spent a while working on the
rear bracket and spreader plate. Once happy with all the positioning holes
were drilled and the spreader plate bonded in. As this now needs
time to let the wurth set. We did some measuring of the pipes exiting the
side panels ready to transfer the data, then took the exhaust off. Before
it goes back on I will paint the rear bracket.
We then moved back onto the side panels. Working out holes for the lower fixings and adding rivnuts to the front infill panels (I will use self tappers at the aft end). We have decided how to make the top edge of the carpet (where it meets the side panel and kick strip) look neat. More on that later in the week.
Thursday, and
another day off work. Started with fitting the final piece of fuel pipe,
from the regulator to the carb. This predictably is in overbraided hose
and blue finishers. Found the trick to cutting this hose well is to
regularly change to a new blade.
Also fitted the now
painted exhaust bracket.
We then returned to
the side panels, most notably the exhaust holes. Using the measurements
from Tuesday, Dad had cut these into a piece of plywood to test the theory, he
and his woodwork project can be seen in the photo.
Happy the exhaust went through these holes, we carefully translated the measurements onto the inside of the side panel, then drilled a small pilot hole through to the primary face. This was then used as the centres to draw shapes around, a 75mm circle was drawn. Then we used a hole cutter set at its max of about 60mm, followed by drawing vertical lines on the edges of these circles, until they meet the 75mm circle. We can then file out to this line to get an elipse, that the headers should just fit through.
Whilst Dad continued
to work with the file, I started thinking about fitting the initial bits of
carpet.
By the end of the
evening we had the first side panel fitted. This is a large relief as it
has been going on for months.
20 &
21/09/2003
First job this morning was to fit the nearside (port) exhaust. The lower thread on no.5 cylinder is damaged, so I borrowed tap (cheers Rodney) and tidied the threads up slightly. We then manoeuvred the exhaust in through the side panels and loosely connected to the mount by the cockpit. With a couple of bolts in to hold in place, it was then a case of slowly putting in all eight bolts, with the gaskets and copper grease on the threads. A few were very easy, others were pigs! Although these Dax exhausts seem to fit well (so far), one of the pipes is 3mm out. To force this over we made sure the pipe on the other side of it was firmly bolted, then coerced the pipes apart using a bolt, nut and long socket, basically by undoing the nut, the whole assembly gets longer and hey presto the pipe moved, exhaust bolt slipped in a treat. Just then a case of tightening them all and the rear bracket. Shoved a wheel on and stood back to admire the effect.
Rather than immediately
start on the other side, I am having a change of jobs by starting work on the
fittings for the rear tub. First up I drew vertical and horizontal lines
on the tub, these were established by measuring in from the edges rather than a
spirit level (garage floor not level). Then to establish the
distance down for the fuel filler, I resorted to a mix of measurements from the
demonstrator, advice from the Dax list and a bit of guess work. In order
to make sure the fuel filler is not covered by any weather gear, its top edge is
75mm down from the top of the tub. The distance in from the edge was
worked with reference to the reversing light, I want all the centres to line up
and reasonable spacing. In the end we were 72mm in from the left, and the
reversing light will be 70mm. After much checking we used the filler as a
template and marked the six wholes. Using these as a reference the centre
was found and a 3mm pilot hole drilled (at the same time a horizontal line from
this was drawn across the tub). We then used a hole cutter to cut a
circle out, followed by a file to make a notch at the base. See picture.
We then trial fitted
and had to slightly adjust some of the bolt holes to ensure the bolts sit
square, this ensures the best possible look when complete. The pipes were
difficult to fit, in the end we cut ¾" off the tanks vent pipe, improving
the pipes run and preventing the
pipe collapsing on the bend. Once fitted the cap and pipes looked like
this.
Using the horizontal
line drawn earlier from the centre of the fuel filler, I established the
position for high level brake light and marked out the hole to cut. This
was done mainly with the Dremel and then a file. Once the hole was done I called it
quits as we are going out to dinner.
Sunday, Dad's birthday, but he is still going to be dragged into the garage occasionally during the day. Continued work on the rear tub, first up was the high level brake light, followed by number plate light and number plate surround. These were slow jobs with hopefully accurate measuring to ensure all the centres line up. I also drilled pilot holes to mark the centre point for the reversing and fog lights. I will leave it at this for now, as I am not sure of how I will deal with the vertical fog light issue (pre and post SVA!). That said with all the masking tape removed from the rear tub, it looks great.
Next we moved on to the screen wash system. Positioned and fitted the bracket for the screen wash bottle, just behind the expansion tank. It is being fixed to the scuttle, this has the advantage that if the scuttle is ever removed the associated plumbing and wiring is all contained on the scuttle. Also drilled the hole for the screen wash nozzle. Will fit all this next week.
27 &
28/09/2003
Saturday was a slow start with some work done on the scuttle, such as cutting a hole for and fitting the fuse box, a small amount of work on the electrics (now I have got more terminals). The rest of the day was lost to being out test driving 'normal' cars.
Sunday, and determined to make some progress, we drilled the holes for fitting the offside side panel in the same way as the nearside. Second time around this did not take to long.
It then came to a test fit of the exhaust, so as to fix the rear bracket and determine the positioning for the four holes in the side panel. Fairly soon after it was bolted home a problem came to light.............. the exhaust pipe from no.8 cylinder touches the steering column! Whilst I think of a solution we moved to working on the rear bracket and spreader plate. Which was soon ready for painting.
While measuring for the holes in the side panel, we spotted that the distance down was more than on the nearside. Conclusion the engine sits on a slant. Some measuring confirmed this, so after a debate the weight of the engine was carefully taken on the trolley jack (large piece of oak spreading load). The steering column extension was removed to gain access, then the engine mount disconnected from the chassis. Then two large stainless penny washers where inserted between the two halves of the mount. With it all bolted up tight further measuring showed the engine to be almost perfectly level.
Also this had opened 2mm of clearance to the column. Not enough I hear you all shout! My adjustable rake steering column now comes into its own, although it is more comfortable higher, a small adjustment down, increases the exhaust clearance.
We then transfer the
measurements for the exhaust holes onto the side panel and employ the hole
cutter again. Dad has been asked to file these out to shape over the next
few days.
Last job for the day was to re-install the steering column extension, ensuring the steering wheel and rack are in the straight ahead position. This also has necessitated a small semi-circle being filed into the engine mount.
Second problem for the day, is that the spread plate stops my seats fitting as low as they previously did. Hence the fixing holes do not line up. It looks like I will have to raise the seat by about 4mm. However, this can wait for another week.
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Last Updated 28/09/2003