Introduction and progress so far

[Eddy]

Whilst building, I'm going to keep it black - The garage is pretty small and it is constantly getting knocked/moved around. Its nice to not have to worry too much about damaging it, like I would with new fibreglass (or if I painted or wrapped it now).

When its finished I will look at options for paint or vinyl wrap. I'm quite liking colours similar to Porche's riviera blue at the moment, like this:

http://2.bp.blogspot.com/-aB6duV_lng...0/_DSC1647.jpg

But I do change my mind a lot!

[alga]

In my experience the abuse the bodywork got during the build is nothing compared to what it gets during normal driving!

[Eddy]

Hello all,

I haven’t updated for a little while, but have been steadily making progress in the background.

Since my last post I have:

Made the side panels
Made the rear panel
P-Clipped the front brake lines
Put the engine back together after having the head skimmed with new gaskets and a shortened sump
Finished off a few bits of welding – Added dowels to the column extension, a couple of bits on the peddle box, and made the inlet manifold
Mounted the radiator/fan and most of the plumbing

When I got to this point, I couldn’t resist the urge to bodge a few wires on, chuck in some fuel and see what happened when I turned the key.
Aside from being a bit of a child and wanting to hear my toy make some noise, it was quite important for me to give this a go – The engine hadn’t been started for 3 years and 5 months and it had been apart for 3 of those. It was also now using bike carbs with a bike fuel pump and running EDIS/Megajolt for the spark, both of which were untested. I really just want to know if it was all OK before going any further with the CVH lump.

So....

I wired up the crank sensor, coil pack and EDIS (I am waiting on a TPS connector and usb to serial adapter for use with the MJ, so limp mode only for now). Took a lead out and used it with a spare plug to see if it was sparking – Nothing. Scratched head before realising I’d missed an earth off! With this attached there was spark.
Wired up the fuel pump. Gallon of fuel in the tank. Ignition on, fuel pump was initially loud, then quiet when it had primed the new lines. Turned the key only to have it turn over and backfire loudly. After this happened a few times, and following some more head scratching, I swapped the two wires to the coil pack over and turned the key. IT STARTED!!!

Obligatory video:

https://www.youtube.com/watch?v=EEb1-lLYD0I

Since the video I have fitted the side panels, made an under scuttle panel to mount the loom to, fitted the nosecone, and fitted the proper exhaust.
The next steps for me are going to fit the rest of the bodywork and roll bar, tidy/permanently fix the wiring, and get back to the position where it starts again. Then I’ll be on the hunt for some shocks, a prop and some rear lights!

As it sits now:




Cheers
Eddy

[Eddy]

Afternoon all,

Another long gap since my last update. I’ve continued to make progress:

Fitted the front wing stays
Drilled and tapped the front hubs/mushrooms for a second fixing point
Fitted the rear arches with p trim
Fitted a prop
P clipped rear brake lines
Heat wrapped the exhaust manifold
Installed the rear lights
Roughly cut out the dash and boot panels
Made the rear bulkhead panel
Made a panel for the front of the scuttle
Probably a few other things I've forgotten!

A couple of reasons for this update though…..

I picked up some black Team Dynamics alloys (used to belong to Ben on here, who sold them to Bob on locostbuilders, who I got them from) and had them fitted with some Toyo T1Rs. I was hoping they would be a bit lighter than the Escort alloys they were replacing…. Escort alloy with worn ‘Camac’ tyre 14.7kgs, Team Dynamics Monza with new T1R 16.1kgs. I was a little disappointed that they weigh a little more, but I guess they are 6.5J wide as opposed to 6J and a little bit of weight in the trye. I do think they suit the car a lot better though.

I wrapped the side panels and rear panel in gloss black vinyl. The rear panel didn’t go too well – It was the first thing I’d ever tried to wrap. I pulled all the backing off in one go before placing it, which made it a bit of a nightmare - I have ended up with a crease under the fog light and another that will be hidden by the rear arch, but I think it is good enough for now. I am very happy with the side panels though – They came out really well and were surprisingly easy to do. I stuck a bit of the vinyl on towards the back of the car and left the backing on the rest, and once I adjusted the angle so I was happy that it was lined up all the way to the front of the car, I pulled the backing back on itself and the vinyl stuck to the aluminium as I went. After that it was just a case of smoothing out any bubbles with a felt edged bit of plastic before cutting and folding over the edges. It may have been easier with better quality vinyl and if my heat gun didn’t decide to set fire to itself at the start of the day, but for a total cost of £40, I’m chuffed with the results.

These are the pics I took as I was going, and one with the car reassembled, I’ll get some better ones when I can roll it out of the garage:










Next up, I’ll be making the transmission tunnel panels, finishing the roll bar, securing the tank and properly wiring everything up ready to start AND move under its own power.

[SteveH1]

Japers that looks good fair play
I also like the wheels.

[Eddy]

Getting some time to work on the car at the moment.
I have changed the main jets in the ZX6R carbs to 160s, checked the needle height and the circlip is sitting in the middle slot of 5, and adjusted the air/fuel screws to 2.5 turns out. Megajolt is connected up running a map I found online for a 1.8 cvh and bike carbs and the TPS has been calibrated.
It seems to start pretty well, especially when using the choke, but it boggs down a bit if you open the throttle quickly. It does get there if you open it slowly though. From reading some bike forums, this could be dirty idle jets - Anyone got any other ideas?

I did fill the cooling system, but had a load of leaks. I have bought a few new gaskets and blanked off a couple of take offs I no longer need, so hopefully I can have that sorted and get it running up to temperature to see if it is any better then.

In the mean time, a video:

https://youtu.be/J8b4KOHnzss

[Eddy]

Another few months since my last update.

I have made some more progress:

Brake system filled with fluid (and inevitable leaks fixed!)
Short shift fitted
Bracket made for acewell speed sensor (magnet still needs to be fixed to prop)
Made a bracket for the bottom of the radiator and underside of nosecone
Fitted some 25mm hubcentric spacers/extended studs to the rear
Fitted some shocks purchased from Matt (rapidtornado)

Some pics as it stands now: