New Build thread

[twinturbo]

Not done HomeBrew in 10 years, but with the brother in law moving just 100yards down the road, and having a house to himself... I think we will be starting our own brewing company.

TT

[jps]

slightly off topic.....gonna be enjoying a few drinks in the sunshine over the next few weeks.....just finished a 25 litre wash (alcohol) of 20% ABV at around 40p litre

For sure the various pics of the car look good. But seriously - stick in a link to how you produce 20% ABV @ 40p a litre!!! That could save us all enough to buy a lot of man cave toys!!!

[K4KEV]

sorry guys got me numerals wrong it is 80p a litre the 40p is when I cut it 50/50 with water (sacrilage I know) otherwise I'd be bladdered all the time cut it another 50/50 then its the strength of a 5% lager at 20p pint/500ml...its effin dynamite if left alone......I kmnow evtryeeed yt lo0l:p will do a write next week when I start another:D ....right must get back to the build.

[K4KEV]

been doing a bit on the trans tunnel.....yet another job which is a PIA, wish I had done it before putting on the side panels.
I have now riveted up the rear panel and the nearside trans tunnel, I have the other side marked out and ready to cut.....again I have been using double sided tape and it is working a treat, much better than messy sikaflex and no worries about whether using too much or too little#.....I will need to seal some areas but I think that is the case for everyone.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0618_zps7e5cda8d.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0618_zps7e5cda8d.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0619_zpsd5166727.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0619_zpsd5166727.jpg.html)

[Tatey]

Kev, don't forget to drill a hole for harness mounts for the transmission side panels, I can imagine it being a PITA to do once riveted on.

[twinturbo]

Kev, don't forget to drill a hole for harness mounts for the transmission side panels, I can imagine it being a PITA to do once riveted on.

F.........k

TT

[Tatey]

TT the easiest option for you may be to get a centre punch in for the top of the tunnel and lightly indent it, this should then allow you to see from the outside of the tunnel where you need to drill.

[K4KEV]

Dont worry guys I did not miss it, the picture just shows the panel offered up I drilled all required holes before I riveted it on ( I deemed it a good idea to have some extra inspection type holes to give easier access to gearbox oil fill hole and some mounting point spanner access:) :)

[K4KEV]

Nearly finished the trans tunnel, but waiting for some rivets, so while waiting I decided I wanted to make my short shifter even shorter by around 30mm, I don't want to risk any more than that, but if I do I will make it so ~I can add "some" back on if needed....I think it is one of those thing where you suck it and see
have not threaded it yet just lathed off the thicker part near the thread down to enable a 10mm thread to be cut further down. Does anyone know what the lump off Ally does on a gearstick like this? held on with a circlip.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0621_zps7d977740.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0621_zps7d977740.jpg.html)

[ayjay]

I reckon its a damper:cool:

[twinturbo]

or just a Mass to give the stick some weight.

TT

[K4KEV]

Right hand trans tunnel now on and riveted (all holes present) passenger footwell plate also fitted and shortened short shifter refitted to box

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0625_zps5fb6e862.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0625_zps5fb6e862.jpg.html)


http://i465.photobucket.com/albums/rr12/gfowa/SAM_0622_zps2bd7f575.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0622_zps2bd7f575.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0626_zps01e22c0e.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0626_zps01e22c0e.jpg.html)

[K4KEV]

Decided I needed a change today, so out came a lump of ally and off to a very hot shed and proceeded with a little lathework then various grades of sandpaper then some autosol with it chucked in an electric drill then back down to shed for a touch of anodizing followed by a tint dip then steamed off to seal in the colour
et voila...shiny new gear knob.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0631_zps7b8e2684.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0631_zps7b8e2684.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0632_zps3a3fe9f5.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0632_zps3a3fe9f5.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0635_zpsf8492c2f.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0635_zpsf8492c2f.jpg.html)

[flyerncle]

That's what I call a shiny new knob ! :eek:

[K4KEV]

nothing like playing with a shiny new knob eh Paul:D .....it sits in the hand very comfortably :eek:
got some nice shiny new wheel nuts from our postie just a few minutes ago courtesy of ebay (now theres a surprise), so I will go and try them on a wheel shortly

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0628_zps2f586fc8.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0628_zps2f586fc8.jpg.html)

[K4KEV]

chucked a wheel on with nice new nuts......so I have a nice shiny nob and a new set of nuts.....the IVA examiner will be impressed :eek:
http://i465.photobucket.com/albums/rr12/gfowa/SAM_0642_zpsaa31ad8b.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0642_zpsaa31ad8b.jpg.html)

[voucht]

......so I have a nice shiny nob and a new set of nuts.....

Yes, but I have been told that having them red is not a good thing :D :D :D

[flyerncle]

Red knob and nuts leads to two things,divorce and GUM clinic.:eek:

[K4KEV]

Ha ha ha....
postie just been with some more goodies, some nice red leather gear
and handbrake gaiters which were for a z3 but a little chopping of plastic on sierra handbrake allowed a snug fit, gear lever one just needs shortening ....not bad for £13 delivered from ebay of course, I will make a nice alloy trim to finish them off.....will have to think about dashboard now so its off to b an q for a sheet of MDF.
http://i465.photobucket.com/albums/rr12/gfowa/SAM_0637_zps55d00382.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0637_zps55d00382.jpg.html)

[AshG]

have you thought about how you are going to get in to the transmission tunnel in the future to service the prop or if you need to unbolt the prop from the diff to get the diff out? look like an aful lot of rivets to drill out. i made the passenger side and top of the tt bolt on items and must say they have been off a few times in the last three years.

[Talonmotorsport]

I'm guessing that the counter sunk screws that go in to the rivnuts on the top panels will help with the access.

[K4KEV]

yep... on the button Phil,
Ash....both of the top tt panels are removable and if you look just above that roll of DS tape you will see a small separate riveted panel that I put there just in case, yes I would still have to drill them out but its not that many hoping that I don't have to ever but then I hear what you are saying.....always appreciate anything like that being pointed out especially as I am about to fill do my IVA form.

[K4KEV]

Decided to refit exhaust system which threw up an issue I knew I was going to have to deal with... clearance on the hole in the body work which was around 3-4mm without the sides on.....bad planning on my part, so I found an old 10mm exhaust flange and attacked it with a angry grinder to fabricate a spacer to fetch the exhaust outwards to get back my clearance....still 3-4mm with panels on, so will have to make hole slightly larger and fit a big 3mm ally finisher to act as a bit of a heat sink .....it isn't ideal but all I want to do is get it through iva then improve it over the winter.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0643_zps809ea5d0.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0643_zps809ea5d0.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0644_zps72144f17.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0644_zps72144f17.jpg.html)

[K4KEV]

next big job is looming and I'm not looking forward to it.....the dashboard...since
I am not going to keeping the dash I am putting in now, I am just going to use MDF/lilo/leatherette, route .....I am using the 200sx dash as this will keep my speedo in its correct range, no other fancy items other than the needed but my starter button will be unique in its position

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0645_zpsda3d1ca7.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0645_zpsda3d1ca7.jpg.html)

[K4KEV]

also got my hands on some rear lights that do everything bar reverse they are a bit tatty, but will polish up and do for the iva

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0614_zpsf63c5cde.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0614_zpsf63c5cde.jpg.html)

[K4KEV]

Been busy with the jigsaw and here is the general shape of what it will be, keeping it nice and simples gonna try and get a camp mat today and leatherette I already have an old office chair that will be getting the chop.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0646_zps0bddacb5.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0646_zps0bddacb5.jpg.html)

[Johno]

Hi Kev,
Sometimes the simplest ways are the best, like you say keeping the original dash will be of big help.
Just a question though, are BT setting up a phone exchange behind your dash because that looks like a lot of wires...:eek: :eek:
Looking good as always (the car I mean).:D :D

[K4KEV]

Yup.... I know John its a conglomeration of sierra and 200sx and a lot of it is redundant but I don't want to start ripping it apart until I know what is ok and what is not....will be going into meter mode soon.....and if it means the redundant stuff has to stay then so be it, I won't loose any sleep over a pound or two......dash will be getting a revamp this winter anyway

[K4KEV]

final shape now complete....I decided a couple of leg cut outs mirroring the shape of the instrument cluster would enhance the dash a little. so now ready to get some padding onto it.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0647_zps9f11b2a7.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0647_zps9f11b2a7.jpg.html)

[twinturbo]

Are the rear lamps "F" marked

[K4KEV]

Yup they sure are ....only the fog tho and that is the most important one all the other sections are E marked, just need a reverse and number plate lights.... for those I am going to use the led "bolts" that hold the number plate on.

[K4KEV]

I had no idea how messy making the dashboard was going to be, I used double sided tape again as it is easy to work with and does'nt go off
Also used a camp mat from argos that was 8mm thick then I had an old new camp mat that was only 3mm but was textured so I used that for the finish as the colour was near to my chassis paint




http://i465.photobucket.com/albums/rr12/gfowa/SAM_0648_zps4a661c86.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0648_zps4a661c86.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0649_zpsf2f5adf4.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0649_zpsf2f5adf4.jpg.html)

[K4KEV]

Time to make a start on spagetti junction and and get the scuttle fitted properly
job for tomorrow that will be finishing the cluster and ouitside edge of the dash with some black cloth piping I have just to add a finishing touch.
with the instrument pod in place and the aftermath of dash making

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0650_zps1fe8aaf4.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0650_zps1fe8aaf4.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0651_zpscf5442dd.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0651_zpscf5442dd.jpg.html)

[K4KEV]

Not much done today due to catching up on garden jobs..... managed to fit the rad fan which took all of 20mins with 4 zip ties and used a strip of DS tape to cushion against the rad itself, grounded the negative to the chassis and routed the relay a positive feed wires but not clipped up yet as there might be more wiring

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0653_zps826da8bc.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0653_zps826da8bc.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0652_zpsfb8dfefc.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0652_zpsfb8dfefc.jpg.html)

[K4KEV]

Its funny how you go through stuff and you realize you have forgotten something important......like a horn....I 'm following this wire and I think what the hell was this wire for.....yep leads eventually back to the horn button, now I spend the next two and a half hours trying to find the part, getting really stressed out and it was in the very last place I could look.....car seat of my donor....could have sworn I had brought it into the house any way fitted now .....so I'm off to hunt down some relays cos I'll need one for the rad fan, wish I had kept everything in one place now:mad:

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0654_zps8a0da4a2.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0654_zps8a0da4a2.jpg.html)

[K4KEV]

After re-appraising my exhaust, I have decided to "make sure" of a pass on iva criteria......mainly the edges so I have used a technique I have used before.
For the muffler ends I took some 6mm brake pipe and bent it to the exact diameter, then I took my b&d powerfile (you could use a flap disc) and began to grind the pipe back to just before the inside of the pipe .....I just used a knife to break through the rest, then it was a case of tweaking it to the same thickness of the muffler ends so it will fit over them and produce a "rolled tip" effect.....gonna solder them up today

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0655_zpsd0d27347.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0655_zpsd0d27347.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0656-Copy_zpseb2e1c9a.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0656-Copy_zpseb2e1c9a.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0657-Copy_zpsb8235c96.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0657-Copy_zpsb8235c96.jpg.html)

[K4KEV]

Got them all soldered up then went at them again with the power file then finally a little bit of autosol so the muffler is ready to go back on but not before I put a little rim on the exhaust pipe just before the muffler.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0658-Copy_zps63a77f47.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0658-Copy_zps63a77f47.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0659_zps5d471b29.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0659_zps5d471b29.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0661_zps04d004e1.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0661_zps04d004e1.jpg.html)

[thailoz]

nice work Kev a great idea you wont be long before you can enjoy the fruits of your labor:D

[twinturbo]

Gettign there, :)

I am just going to wrap my exhaust to hopefully protect from sharp edges.

BTW. Your kill switch will most likly fail the IVA.

TT

[K4KEV]

Hope so Lawrence.. hope so!
tt....it is not going to be fitted for IVA, I am going to blank it off for that then retrofit said item post IVA, I know some peeps have covered the key with some edging and got away with that, but I am not going to chance it.

[K4KEV]

Just finished the exhaust pipe so my exhaust has now got "rolled " edges all round now also have just cut an exhaust outlet finisher just got to polish that up and the exhaust will go on for the last time ( I hope )

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0663_zps3679e2c3.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0663_zps3679e2c3.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0664_zps645af9b3.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0664_zps645af9b3.jpg.html)

[K4KEV]

now polished up and fitted....soon to be followed by the rest of the exhaust
http://i465.photobucket.com/albums/rr12/gfowa/SAM_0668_zpsfad051ba.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0668_zpsfad051ba.jpg.html)

[K4KEV]

Finally exhaust system version II is now back on for good I hope, I think I will make a small decibel killer for the tailpipe just in case....very pleased with the overall look and the exit trim finishes it off (been filed down to 2.5mm radius all around)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0672_zpsc1899fbf.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0672_zpsc1899fbf.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0673_zps7a6d066d.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0673_zps7a6d066d.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0670_zpsb03c7e48.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0670_zpsb03c7e48.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0674_zps5db94942.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0674_zps5db94942.jpg.html)

[SeriesLandy]

Looking very smart as usual kev.

[K4KEV]

Cheers Steve
As most of you know I like to use whatever is at hand, well I like had this very long coil of air hose similar to the stuff used on foot pumps... rubber wrapped in a glued on cloth, well in got me thinking that it would make for a nice finishing edge to the holes at the front suspension, so I very carefully slit the pipe with a very sharp modelling knife an inch at a time.....I tried some on an edge and it worked brilliantly so I did the offside first as it had no suspension items fitted, to hold it I have used loctite superglue....I did purchase some finishing trim but I will use that on the cycle wings and bonnet

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0676_zpsfa2a2cef.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0676_zpsfa2a2cef.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0680_zpsde7a8cb0.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0680_zpsde7a8cb0.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0678_zpsb08dc5f1.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0678_zpsb08dc5f1.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0679_zps62644b6d.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0679_zps62644b6d.jpg.html)

[K4KEV]

Here is a little tip I picked a few years ago and has saved me some work in the past....when you put a tubular conduit in any where, when you thread the wires through attach a piece of string to the end when pulled through leave about 6-8 inches of string either end so if you have something you want to add at a later date (sensors, lights etc) then you can use the string to pull any more wires through(dont forget to attach another piece of string)..... always keep it there in case you need it again
here I have done it for my rad fan feed and switch.


http://i465.photobucket.com/albums/rr12/gfowa/SAM_0681_zps83267624.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0681_zps83267624.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0682_zpsa2c06221.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0682_zpsa2c06221.jpg.html)

[K4KEV]

Already used that string once.....spent a lot of time sorting the headlights and associated relays/fuses but IP have eventually got them to do as they are told.
So the headlamps are permanantley fixed and wired in

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0683_zps4748d9f1.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0683_zps4748d9f1.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0684_zpsdf585c7e.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0684_zpsdf585c7e.jpg.html)

[K4KEV]

Am pleased to report that nearly all of my wiring has been sorted with a mega amount of patience and get this...... up to now only one blown fuse although that could change.....side dipped and full beam were an absolute nightmare all caused by an incorrectly placed earth above the ignition barrel once I got those sorted virtually everything else fell into place ignition light, oil light handbrake and fluid level working as they should indies all working inc hazards all tell tale illuminating when they should.....still looks like spagetti but the tidy up starts tomorrow......really ought to think about getting it off the trestles soon as well

[K4KEV]

Got me a nice Apexi Power Intake air filter all the way from Hong Kong, pleased to say it is the genuine item and what a price ...£17 delivered.....same filter over here is around £40.... rapidly approaching de-trestle time and onto its wheels for the first time...few days I hope ,just need to get underneath fully checked over. and bleed the brakes.

this is not the final resting position of the air filter it will be moved post IVA

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0745_zpsb4720e3a.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0745_zpsb4720e3a.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0746_zpsc84c17db.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0746_zpsc84c17db.jpg.html)

[K4KEV]

Nearly forgot about this little bugger to lock in the mushies .....see the effin tinworm creeping out, you can never stop it entirely:mad:

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0748_zps3ef7616d.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0748_zps3ef7616d.jpg.html)

[Ricky]

Hi kev what if you put the mushrooms on a lathe and cut a groove into it where the grub screw goes into so that its not able to move up just a thought

[Johno]

Builds looking awesome Kev,:cool: :cool:
Really like the exhaust and cover plate, nice touches that make a whole lot of difference.
So what's next on the agenda?

[K4KEV]

Ricky....Could have done that but by my reckoning you will only need to move it once after IVA so I will redrill and tap hole in mushy then.

Johno....yeah, cover plate is functional ...I made it that shape on purpose as it will act as a heat sink/soakaway to protect the f/glass at that closest point of exit....next up will be change water pump as there is a very slight leak so want to get it done before permanently fitting nose cone, then if everything underneath is ok it will be onto its wheels and will be sending IVA form off tomorrow:cool:

[K4KEV]

Well I will need to get my finger out because the IVA forms have just gone to the PO....felt like going for a job interview.

[jason 82]

Well done Kev ! Good luck.

[Oscar]

Thats a very nice little bit of Improv with the pipe-cover-fabric. Looks like it provides a lower profiled radius than edging strip would?

Work like this makes me wonder if I'll ever have the patience to get all thse extra touches done when the time comes! Not that I'd ever have a chance of getting it as tidy as yours ;)

[K4KEV]

It does Oscar....I have always tried to use what I have at hand, but always try to think what can I use instead ?, is it cheaper without looking sh*te, can I "make it" it.......the latter is one I have used throughout the build.
Having just had another scour of the iva manual I have chosen to leave my coolant leak till after the iva as it is more of a weep than a leak, the manual only states leaks from ...steering, brakes, fuel, suspension would be a fail, it says nothing of coolant or oil, so I am going to chance it.

[Davidbolam]

Have you decided which. Test station you are going to use?

David

[K4KEV]

I opted for Newcastle, even though they are supposed to be pretty harsh, I did have a think about Beverley but it is a wee bit too far away and Newcastle is only 40 mins.....Carlisle was my second choice, you are welcome to come along to see what its all about David.

[Davidbolam]

I opted for Newcastle, even though they are supposed to be pretty harsh, I did have a think about Beverley but it is a wee bit too far away and Newcastle is only 40 mins.....Carlisle was my second choice, you are welcome to come along to see what its all about David.

I'm only 2 mins from the test centre so if you need any urgent mods you can lend my tools!

[K4KEV]

Thats brill Dave ....I will let you know when my test date is when I get it.
Been having a play with some buttons today and so far so good I now have an engine start button in the dash..except you cannot see it as I am working it so you have to press the "word" START to turn the engine over and at the same time I have put a remote start button in the engine bay as well so I don't have to run backwards and forwards to start the engine. will get some photo's up tonight.

[K4KEV]

Here are those photos I promised off last time showing my "invisible" start button, and my remote start in the engine bay.....and speaking of which I have now finished the wiring in the engine bay yet it still looks like spaggetti junction but at least it is all secured, need to move on to internal wiring which is done but needs taping and cable ties
http://i465.photobucket.com/albums/rr12/gfowa/SAM_0755_zps9819c86f.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0755_zps9819c86f.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0756_zpsca28a8b7.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0756_zpsca28a8b7.jpg.html)
http://i465.photobucket.com/albums/rr12/gfowa/SAM_0757_zpsd43e1e2d.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0757_zpsd43e1e2d.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0760_zps6a6cf897.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0760_zps6a6cf897.jpg.html)

[K4KEV]

Now I have to do the inside.....ain't looking forward to that
itsa Dolmio day!!!!!

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0762_zpsdd934c76.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0762_zpsdd934c76.jpg.html)

and here is that remote starter button ...its the black one ...it is simply wired into the same starter circuit that I made rather than the one off the ignition key

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0761_zps6c124130.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0761_zps6c124130.jpg.html)

[ayjay]

Hi Kev
Just noticed your post re water leak a little while ago.
Mine developed a leak at the test centre:mad: It wasn't a fail in itself but the testers were concerned about either possible burst or having hot water dripping on them whilst checking the car. They asked me to do something about it. I fixed it while they were inspecting:cool:
The car is running for a long time during the test

[K4KEV]

Funny you should mention that AJ, as I could'nt live with the said leak so I sent away for a new water pump yesterday and it has just come a few minutes ago. so it is a job for today.....tw*t of a job as the crank pulley has to come off
I did get my clutch and brake system filled and bled ...pleased to say no leaks and brake pedal has hardened up very nicely.

[K4KEV]

water pump off now ...thankfully the crank pulley came off with out a a hitch, tied off the timing belt so as to not loose the timing, when I took off the bottom cover I could see where the water was coming from and it was the water pump as I suspected.....these water pumps have a tell tale hole to warn you the bearing seal or bearing is on its way out before it lets go completely which is a brilliant idea, any way when I got the pump off sure enough that was where the water was coming from that little hole.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0763_zpse1e8ea35.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0763_zpse1e8ea35.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0764_zps37a36e20.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0764_zps37a36e20.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0765_zpsed839787.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0765_zpsed839787.jpg.html)

[vmax1974]

Its made a bit of a mess of your shiney bits

Good you spotted it now rather than after it took your cam belt off

[K4KEV]

There is one thing I have learned Dave.....at this stage of the build the cosseting of parts goes out of the window, a little chip here a scratch there and it is impossible to avoid even my beloved wishbones suffered....everything I do now is geared towards IVA ....more titivating can come after that.:)

[K4KEV]

Pleased to say the last part I needed working is now functioning as it should .....the speedo, so as it stands now everything is working A OK...water leak was solved with the new pump. I can now concentrate on finishing the dash wiring...oh and my super bodge hydraulic clutch system working good too.
Will be starting a brew tonight so see other thread for that.

[K4KEV]

Now to start sorting out the little odds and ends....like where to mount the header tank...decided on here
http://i465.photobucket.com/albums/rr12/gfowa/SAM_0782_zps94dcb265.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0782_zps94dcb265.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0783_zps85cf52aa.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0783_zps85cf52aa.jpg.html)

[K4KEV]

BIG job done yesterday .....although it still looks messy, it now looks something like a wiring loom ECU bolted in place, just have to make sure nothing is liable to chaff and the scuttlle will be permanently fixed followed by the dash....by the end of today it will feel like the end of the build will be well within sight

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0789_zps480f5096.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0789_zps480f5096.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0790_zpsd0438ca8.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0790_zpsd0438ca8.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0791_zps6db25e23.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0791_zps6db25e23.jpg.html)

[K4KEV]

Thought I would use today to weed out any projections in the drivers footwell and get them covered with trim or split pipe before I fix the scuttle and I think I have got them all covered bar a few nut covers which I am waiting for

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0792_zps29816236.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0792_zps29816236.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0793_zps5bcefa6c.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0793_zps5bcefa6c.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0794_zpsb91b6028.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0794_zpsb91b6028.jpg.html)

[K4KEV]

few things done today....managed to permanantly fit the scuttle, I have used double sided tape but left the upper paper on so as to become foam seating, I am retaining the possibility that I might need to remove it when it comes to a dash upgrade also have bolted up the firewall bulkhead to scuttle, thought I might as well fit the aeroscreen and edge it off,so that is done as well, all in all a productive day.....piccies

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0799_zps8ce71495.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0799_zps8ce71495.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0800_zps01d492a2.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0800_zps01d492a2.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0803_zps768b3084.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0803_zps768b3084.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0802_zpsd2d87ecf.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0802_zpsd2d87ecf.jpg.html)

[twinturbo]

That's a lot of fixings :D probably pay dividend in the end although I wonder if the counter sunk ones may rip through the GRP.

I still have not fitted my AeroScree, I am convinced I will ripp it off by accident, mind you eveything is trial fitting to be taken off again anyway so I could just fit it up and take it off.

TT

[K4KEV]

re the csk bolts.....it did cross my mind TT and I think you are right BUT if there was enough force applied to do that the scuttle and bulkhead then would be knackered anyway.
Dashboard in today and fastened up.

[K4KEV]

Decided to use the sierra repeaters up high on the scuttle. Dashboard now in and fixed....with a few bolts here and there

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0807_zpsb0a19a27.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0807_zpsb0a19a27.jpg.html)


http://i465.photobucket.com/albums/rr12/gfowa/SAM_0809_zps4f94be50.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0809_zps4f94be50.jpg.html)

[alga]

Looks like that dashboard is not coming off anytime soon! But seriously, what will you do if you need to change something in the wiring beneath the scutte? My scuttle is fixed on just 4 bolts, and I take it off quite often.

[K4KEV]

I don't like to think about it Albert if I do have to then I will have a good cry first:( ....I will not be repeating the exercise on the mk2 dash when I come to lose the one thats on now.

[flyerncle]

Its taking shape Kev,is that the injector resistor on the bulkhead,it may get rather warm when running and possibly burn the glass behind it.

[K4KEV]

Yep it is the ballast resistor, I gave the engine a run up today and checked for it getting warm but it just stayed stone cold, but if there is an issue with it then I will add an aluminium heat sink to keep the temp down....another suck it and see scenario:rolleyes:

[flyerncle]

Was not sure but remember them on Bosch systems usually bolted to the most non sensible place on the engine block where you could not get at it or test it.

[K4KEV]

Have been making up the permanent fixings for the nosecone bottom fixing is a simple piece of angle ally pop riveted on to the bottom of the front frame and then the nosecone fitted over it and three boltholes drilled.
Also been working on the front indicators.....not as straight forward as I thought what with the angles and limits so I found I have had to make a couple of extensions to come within IVA specs still have not decided where to mount them...have also made a couple of teardrop shapes echoing the exhaust one to spread the pressure on the outer gel coat and reduce the risk of stress fractures and will be making the same for the mirror mounts

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0824_zps8fb6da54.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0824_zps8fb6da54.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0825_zps561f60c1.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0825_zps561f60c1.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0827_zps5052f2cd.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0827_zps5052f2cd.jpg.html)

[K4KEV]

Well after considering the usual places for to mount the indicators I decided to be a little different and mount them fairly high and further back... the height was to allow them to be visible on the 45 degree rule but it also had the bonus of keeping the stubs short and they marry very well with the headlamps, another added bonus is you can see them blinking in the reflection on the headlamps should you ever forget to cancel a left on signal.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0833_zps4e607dae.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0833_zps4e607dae.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0834_zps205f2061.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0834_zps205f2061.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0835_zpsd06a88d0.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0835_zpsd06a88d0.jpg.html)

[rpjg1975]

Extra bonus is you get to look at more shiny bits

Russ

[K4KEV]

Never thought of it that way Russ, but hey you are right been having a bit of a tidy today as the garage was becoming a death trap so not much done ...in fact only one paltry looking thing.....my start button:D

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0836_zpsc4704874.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0836_zpsc4704874.jpg.html)

[rpjg1975]

More productive day than me then!!!! :D

[twinturbo]

I finished a rack unit to go at the bottom of the garage over the spare engines. should make storage easier and tidy up the space.

TT

[K4KEV]

Got me mirrors fitted today and then spent a good hour just tidying the inside of the cockpit to prepare for some seat mounting reinforcement

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0838_zps414557cb.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0838_zps414557cb.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0837_zpsb27db43c.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0837_zpsb27db43c.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0839_zps7599750b.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0839_zps7599750b.jpg.html)

[alga]

Just a small note about mirror mounting. I think I am a proficient user of mirrors, I find it easier to park a car into a tight spot in reverse, controlling the clearances with the mirrors. Not so with the roadster. The mirrors are closer to the centreline than the outer edges of the rear arches, so you do not get a view of the car's outer dimensions in them. This way they are almost useless for maneuvering in reverse, you're better off turning your head and controlling the corners directly. Now, for normal highway use the height of the mirrors is more important, as the rear arches obscure the lower part of the view. Based on this consideration, window-frame-mounted mirrors should be more convenient, once we get around to fitting a windscreen.

I've also used cheap scooter mirrors with M10x1.25 threads and mounted them like so:
https://picasaweb.google.com/lh/photo/zESOSACuYn2_2ddOob9e8dMTjNZETYmyPJy0liipFm0?feat=d irectlink
Looks like the position of the mirror ended up very similar to yours.

[K4KEV]

Albert....the main reason for mounting them there was the fact that I would have two thicknesses of fibreglas for support hence a much stronger place to mount them.
yesterday I got around to reinforcing my seat mounting points.....my initial thoughts were the flat bar that I used would be strong enough, but after having a read of the IVA manual I was not so sure, so I opted for beefing up the floor with some 3mm ally, top and bottom so now the bolts go through 9mm of ally and 6mm of steel:eek: .....I am fairly sure that will be enough

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0840_zps1a2651e7.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0840_zps1a2651e7.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0843_zpsf2cc7d99.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0843_zpsf2cc7d99.jpg.html)

[TheArf]

Don't think they will be going anywhere with that lot in place

Arfon

[dubzter]

Hi there, first time poster, long time lurker :D

Having finally managed to make my way through this entire thread it has prompted me to make my first post and to say that it is an inspiration to me as a dreamer (hopefully soon to be a builder). I've just recently picked up "the book" after having a weekend in a Caterham CSR 200 and trying to figure out how I could replicate "some" of the fun I had.

Keep up the good work.

Alan

[K4KEV]

Cheers for that Alan ...yep it is a looong thread that is now over three years old and I happy to say the car is nearing completion for IVA but then after that there will be endless tweaks to get it just the way I want it and maybe a screen at some point.....if you are hoping to replicate any of the Caterhams I would opt for a good strong engine that will accept some tuning mods, this was exactly the reason I chose the CA18DET and I know what it is capable of.
get yourself some steel Alan and get going:D

[dubzter]

Cheers for that Alan ...yep it is a looong thread that is now over three years old and I happy to say the car is nearing completion for IVA but then after that there will be endless tweaks to get it just the way I want it and maybe a screen at some point.....if you are hoping to replicate any of the Caterhams I would opt for a good strong engine that will accept some tuning mods, this was exactly the reason I chose the CA18DET and I know what it is capable of.
get yourself some steel Alan and get going:D

I'm in the process of building a parts list and hunting for a donor, thinking of going the zetec route, don't really expect to get to the same levels as the caterham but 150hp would be nice. My current toy is sitting in the garage on stands at the moment as the brakes are away to get refurbed. It's a mk4 vw R32 with VF stage 1 supercharger :D, once that is done and the garage is clear again think I'll get some steel and build my table to make a start. Seeing build threads like yours certainly makes me want to get cracking.

Cheers

Alan

[SeriesLandy]

Only 3 years kev, I looked at a bill from rally design and realised it was dated July 2009! Although I started building in November 2008.
Slowly getting there but much further behind than you.

[K4KEV]

Well get your bluddy finger out Steve......I must admit mind getting a lot of stuff prefabbed before hand has made the last 6 months seem like a breeze ....#I think because I set myself a target to get it on the road this year helped, you know PMA and all that stuff:rolleyes: .....hoping to fit the seats soon on with harnesses at the mo

[flyerncle]

PMT ?, sorry mis-read should have been PMA. :p

[K4KEV]

Yeah I know Paul... how mentsrual tension and mental attitude can easily get mixed up lol ....especially in a feminist scenario

[K4KEV]

Have had a couple of days off from the build and now back all fired up to get cracking again......have now fitted all my harness's, but really need some black shoulder pads and need to make edges safe on roll bar mounts also managed to get all my rear lights fitted and wired up permanantly, steadily working my way over every inch of the car to eliminate any issues that I have missed along the way.....car is still on trestles as I still feel that it is better to work on up at chest level until I am sure nothing else underneath needs doing.


http://i465.photobucket.com/albums/rr12/gfowa/SAM_0846_zps4d3f46fc.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0846_zps4d3f46fc.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0847_zps1902bb8f.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0847_zps1902bb8f.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0856_zps25f8cb32.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0856_zps25f8cb32.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0850_zps8ed42e33.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0850_zps8ed42e33.jpg.html)

[locost-turbo]

is it just a wieght to make the gear change feel smoother and lighter?:confused:

[K4KEV]

lol ...you are a bit late with that one Nick :rolleyes:

[twinturbo]

Do the lights fall within ther required distances?

TT

[K4KEV]

You don't wanna know how many times I have measured to make sure they fall into all the correct dims but yes TT they do... although the fog lights in the clusters do not have any bulbs in and are not wired up. I used the Westfield diagram but also checked the IVA table in the manual and all ok need to sort the bonnet now.

[K4KEV]

nearly forgot the grill so have just been doing that minus the roadster logo until after iva ....nose cone fully mounted now and solid
http://i465.photobucket.com/albums/rr12/gfowa/SAM_0868_zpsf149963e.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0868_zpsf149963e.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/6cb52da3-0259-4df6-9128-ed9ca494beae_zpsb7cd92b9.jpg (http://s465.photobucket.com/user/gfowa/media/6cb52da3-0259-4df6-9128-ed9ca494beae_zpsb7cd92b9.jpg.html)

[K4KEV]

tidied up the rear light wiring behind the tub yesterday....bit of a bugger as there ain't a lot of space to work with

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0854_zpsf22d9123.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0854_zpsf22d9123.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0855_zps2d0c66e0.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0855_zps2d0c66e0.jpg.html)

[K4KEV]

Good progress yesterday ....managed to trim and fit bonnet so it sits right now ..did have a problem with the inlet plenum touching so I HAD to make a cut out its not nice having to make a hole in a nice clean space but hey choice of engine dictated that and I think that out weighed the cutting of the hole, but then I remembered a fibreglass scoop I had sitting around so a bit of edge trim and soon a lick of paint.... problem sorted
http://i465.photobucket.com/albums/rr12/gfowa/SAM_0874_zps4f1a4d31.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0874_zps4f1a4d31.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0875_zps6b6b0e17.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0875_zps6b6b0e17.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0878_zps443970e1.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0878_zps443970e1.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0881_zps31b840ae.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0881_zps31b840ae.jpg.html)

[K4KEV]

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0880_zps28013ab2.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0880_zps28013ab2.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0879_zps2d8c4214.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0879_zps2d8c4214.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0883_zps1c277f0c.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0883_zps1c277f0c.jpg.html)

[flyerncle]

Pitot on a homebuild (nearly put kit car) :confused:

[K4KEV]

Well it is gonna fly Paul.....gave my "pitot" tube a lick of paint, hope to fix it on proper today, also did some work on the aerocatches.....jeez they are awkward buggers to get right

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0885_zpsb369b6b9.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0885_zpsb369b6b9.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0884_zpsc49a6d56.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0884_zpsc49a6d56.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0888_zpsaf1b3f97.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0888_zpsaf1b3f97.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0887_zps287aca18.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0887_zps287aca18.jpg.html)

[flyerncle]

Worth the effort though,looks a million dollars.:cool:

[SeriesLandy]

Tell me about the aero catches, I've just fitted my front 2 and made a deliberate mistake. All the large parts are to the rear of the bonnet except 1 I cut the wrong way round.
It's nice to see what other people have done when they made their brackets.

[K4KEV]

couple of brackets marked out to bend for my aerocatches.
'Have also made some tongue style catches for the front of the bonnet so that there is no physical catches at the front, they just "clip" under the ledge of the nose cone.
fitted some P strip to be ready for the rear wheel arch permanent fitting, decided to cut some darts out to make it bend easier.
Also made some ally bezels for the gear lever and handbrake

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0886_zps68f7d0a2.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0886_zps68f7d0a2.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0888_zps1a97df96.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0888_zps1a97df96.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0889_zps5901ced7.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0889_zps5901ced7.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0890_zpsb54babe8.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0890_zpsb54babe8.jpg.html)

[K4KEV]

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0892_zps226b6289.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0892_zps226b6289.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0891_zps533be5fa.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0891_zps533be5fa.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0900_zps07e18d06.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0900_zps07e18d06.jpg.html)


http://i465.photobucket.com/albums/rr12/gfowa/SAM_0901_zps23cec964.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0901_zps23cec964.jpg.html)

[TheArf]

Fair do's mate the bezels around the gear stick and hand brake are well tidy lot of time and patience went into them.

Arfon

[flyerncle]

He's Good ! :p

[TheArf]

Setting the bench mark there

Arfon

[K4KEV]

Thank you guys....its great when you see it all coming together and you can stand back and say "I did that"
Another wee job polished off yesterday....fitting the seats, a bit fiddly but all holes lined up kindly for me, but tell you what....I'm a bluddy tight fit in them, but it was nice to find all the pedals felt good and the clutch although felt heavy by hand, was actually light as a feather and my little stubs built into the chassis to aid getting out were spot on.
also checked rear wheel fitment with rear arch on and its ok but there aint a lot of room.
http://i465.photobucket.com/albums/rr12/gfowa/SAM_0904_zps2b14572e.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0904_zps2b14572e.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0903_zps5413e756.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0903_zps5413e756.jpg.html)

[SeriesLandy]

Looking great kev, it feels really nice when everything starts going together (for possibly the last time)

[TheArf]

Don't know about tight, I wouldn't get my arse in to start never mind being tight, its looking good there Kev.

Arfon

[K4KEV]

Huge huge milestone .....its down on all fours.....after 3yrs of working with it at chest height, seeing it on the floor gave me quite a shock as it barely sits higher than my knees. It was surprisingly easy to lift with my engine crane with a long strap fixed to the roll bar and front frame diagonals even balanced first time just above the aeroscreen..... I am on a bit of a high at the mo.
I know I have said this before ....it was a doddle to work on when it was on the trestles and even though I was not able to "test" it out, the ease of construction made it worth it and I would not hesitate to recommend this method of mid phase construction

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0919_zpsd59aa266.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0919_zpsd59aa266.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0922_zpsb180fc57.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0922_zpsb180fc57.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0920_zpsf362218d.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0920_zpsf362218d.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0923_zps3dc4033d.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0923_zps3dc4033d.jpg.html)

[CTWV50]

Well done that man, looks great. Been thinking about trestles today. Hmmmmm.

[Davidbolam]

That's looking good. Must be a good feeling for you to have it on 4 wheels.

Remember to post a video if you go for a spin tomorrow!!

David

[alga]

Kev, congrats on the milestone, the car looks great!

Trestles, Chris? I've built a pair of wooden ones according to this classic plan:
http://www.owdman.co.uk/howto/howto2.htm
It was a fun woodworking project, they held the rolling chassis fine when I was fitting side panels, and they are generally useful in the garage now.
https://picasaweb.google.com/100881048868628458396/HaynesRoadsterLocostBuild?noredirect=1#58484760528 79010562

[Johno]

Yeah its a lot easier working on it at that height.:)
Can't wait to get mine on the floor to but that's some way off...
Cars looking stunning Kev:cool: :cool:
Keep the pics coming you're a inspiration to us all...:)

[TheArf]

Cracking achievement bet you have a grin thats about 2 ft wide

Arfon

[CTWV50]

Steve.....it was just regular double sided tape that was about 5mm thick and about 10mm wide and made of a kind of neoprene.....basically I used it only because it was there, but then again I did not want the fg panels to be a nightmare to remove if damaged which would be the case if I had used Sikaflex, so it was a no brainer for me.
As for the cut out on the rear tub, I have chosen to go all the way back to the chassis .....I figure muck will get everywhere regardless and yes I was planning on trying to tie in as many fasteners as possible to be dual purpose.
I might use the DS tape for mounting my wheel arches as well as is does compress very well and gives an excellent seal while allowing a little be of "give" that might mean the difference between a crack, split or nothing with a gentle impact.

Cheers TT..the arches I am just going to put where everybody else has which is tip to tip to the edges of the chassis/tub.

Great idea I think I'll use DS tape too when fitting mine, just like on Blue Peter. :D

[voucht]

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0923_zps3dc4033d.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0923_zps3dc4033d.jpg.html)

It is such a long time I've been longing to see how the whole car will look. Now we can see it entirely. Thanks for these pics.

As expected, I'm not disappointed at all, this Roadster look really awesome. Very good job Kev' :cool:

Now I can't wait to see it on the read :)

[AshG]

come on kev dont keep us hanging where is the vid of it moving under its own steam for the first time?

[K4KEV]

Ta for some very kind comments......don't you worry yourself Ash I won't keep you in suspenders for much longer.......since there are 2 policemen live on our cul de sac.....I thought it rather pertinent to crack on with one of these (see photo) so I can take it some where unobtrusive ....kills two budgies with one stone.....I get to try the car and the trailer out.....should be finished the trailer tomoz with a possible try out on Wed.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0927_zps528b8b9d.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0927_zps528b8b9d.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0928_zps04c6bbb6.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0928_zps04c6bbb6.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0929_zps0aa7a402.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0929_zps0aa7a402.jpg.html)

[jason 82]

Well done Kevo ! Who's caravan have you shredded for that babey ?:D just need a kick ass v8 to pull that thing now !

[TheArf]

I found a caravan advertised on ebay last week, bare shell £150 just needed the body ripping off to convert to a trailer, as all modern caravans are galvanized chassis they make the ideal starting point for a car trailer just wish I had room to put it right now.

Crack on mate dying to see that thing running

Arfon

[K4KEV]

Well done Kevo ! Who's caravan have you shredded for that babey ?:D just need a kick ass v8 to pull that thing now !

van chassis and steel were a ebay jobbies, local as well alas no v8 to haul just a lowly little C3 diesel with 80 BHP but it will do the job.

Arf....I would have expected a crap fully built car hauler for £150:eek: :D
paid £80 for mine and the steel was £5.50 a length (40x40x3mm).
with a bit luck I will double my money on the trailer when I come to sell it.

[flyerncle]

I know the guy that owns Eshott if you fancy a zip up "01" nice tarmac runway. ;)

[twinturbo]

I thought the ALCO chassis were alloy not galvo?

TT

[TheArf]

Mine ain't

Arfon

[jason 82]

Well done Kevo !

[Davidbolam]

Ta for some very kind comments......don't you worry yourself Ash I won't keep you in suspenders for much longer.......since there are 2 policemen live on our cul de sac.....I thought it rather pertinent to crack on with one of these (see photo) so I can take it some where unobtrusive ....kills two budgies with one stone.....I get to try the car and the trailer out.....should be finished the trailer tomoz with a possible try out on Wed.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0927_zps528b8b9d.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0927_zps528b8b9d.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0928_zps04c6bbb6.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0928_zps04c6bbb6.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0929_zps0aa7a402.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0929_zps0aa7a402.jpg.html)

I like your idea of making a trailer but have you not got massive holes in you deck now? My wife would go off it lol!

David

[Davidbolam]

I know the guy that owns Eshott if you fancy a zip up "01" nice tarmac runway. ;)

I was going to take mine to raf topcliffe to do my testing. If you know storm at eshott I wouldn't mind going there! Plenty of workshop space.

David

[K4KEV]

I know the guy that owns Eshott if you fancy a zip up "01" nice tarmac runway. ;)

That is very tempting Paul if it wasn't so bluddy far....might mull that one over

Alco trailers on the whole are Ally but most of the others including mine are galvanized which is better because after grinding away the zinc you can just weld stuff together.
luckily Dave I had some bits of decking left over from years ago so it came in handy
Gonna do the ramps today.

[flyerncle]

Kev,David, I know Storm well and I would think he would have no objection and if you want to sort something I can have a word with him,they definately will l not let us on "25/07" at EGNT :rolleyes:

[Davidbolam]

Kev,David, I know Storm well and I would think he would have no objection and if you want to sort something I can have a word with him,they definately will l not let us on "25/07" at EGNT :rolleyes:

Do you know stan purdy with the jondel. (I think) I know instruct on the same sqn his son and he used to take his exige there.

Would love to take it for a blast once its done Just need a trailer !!

Ps sorry for hijacking your thread kev

[K4KEV]

Don't worry about it Dave, and I think you mean Jodel for the aircraft...it used to be manufactured but I think the majority now are home builds.
As for testing the car ...I have found a disused factory very close by which has an extensive area around it which will be ideal for me to test the roadster, (but thanks for the offer Paul). Got one more ramp to make and the the lighting board to fit, then I will be in full shakedown mode getting all the "little stuff" done.

[flyerncle]

Don't know many from up there David just the ones who frequent NFS or people I have met up there repairing planes etc.

If you are stuck for a tow car Kev just shout and I will give you a hand no probs.

As I posted previously I don't think he would mind and it would be fun to try my Quattro against some ones Haynes.

[AshG]

just remember where ever you do it make sure its somewhere the public cannot freely access. i.e park your car in front of the entrance to stop anyone getting in.

[AshG]

i live opposite a copper he only knows what he is told :D

[K4KEV]

Again cheers Paul but I think the C3 will be up to the job.....then again will let you know

just remember where ever you do it make sure its somewhere the public cannot freely access. i.e park your car in front of the entrance to stop anyone getting in.

entrance too big Ash....would need an artic....it is very quiet so should be ok
Got the trailer finished today just the lighting board to fit, I may trundle the roadster onto it tomorrow after the rains gone.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0930_zpscd91514e.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0930_zpscd91514e.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0931_zps65d446ec.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0931_zps65d446ec.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0932_zpsd76cab8d.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0932_zpsd76cab8d.jpg.html)

[jason 82]

Well done Kev, bet it's going to be a cracking test. One thing is for sure, nobody is going to miss the tango machine, you will be seen from miles around ! Enjoy fella. :D

[Talonmotorsport]

Are those rims on the hubs back to front? Also you might want to weld some wheel chocks to the front of that in case you hit the brakes and the Roadster carries on in to the boot of the tow car, just a thought.

[K4KEV]

Well done Kev, bet it's going to be a cracking test. One thing is for sure, nobody is going to miss the tango machine, you will be seen from miles around ! Enjoy fella. :D

Will be getting a hammerite job soon.

Well spotted Phil....yes they are .....I dressed a small grindstone to have a 60 degree cone and then ground the back of the mounting holes to give them the necessary seating angle, it was one way to get the width of trailer without having to search for some wheels with a silly negative offset

[TheArf]

Looking good that may I can almost hear that roaring sound of a roadster

Arfon

[vmax1974]

Looking good kev look forward to seeing photos with the roadster all loaded up

[twinturbo]

you need some rear drop legs too ;)

TT

[flyerncle]

Shoot oot loud if ya stuck ;)

[K4KEV]

FINISHED WU HOO
FINISHED WAAH HOOOOOO
FINISHED YEEEEEEEEEEEEEEHAAAAAAAAA

well just about am now into the official shakedown phase and going for a kind of pre mot at my local garage to check headlight aim, brakes etc. trailer worked a treat all the angles I had calculated were bang on like having 10mm clearance at the apex of the ramps at mid load, so feeling real good at the mo
anyway a few piccies and the first true light of day she has seen.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0936_zpsa496d9de.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0936_zpsa496d9de.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0938_zps6910e38b.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0938_zps6910e38b.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0939_zpsd79b0c52.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0939_zpsd79b0c52.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0940_zps05ea395f.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0940_zps05ea395f.jpg.html)

[K4KEV]

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0942_zps0318ca21.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0942_zps0318ca21.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0943_zps0506663a.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0943_zps0506663a.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0944_zps3c7ee430.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0944_zps3c7ee430.jpg.html)

[ayjay]

Looks awesome-well done;)

[The V8 Files]

Congrats there Kev, looking good :D

[jason 82]

Well done Kev. Now for build number 2 ! Lol:D

[jps]

looks very nice!

[TheArf]

Very nice indeed sir, very nice

Arfon

[Stot]

Its amazing up til now we have only really seen snapshots of areas of the car and then *BING* its done. It does look good as a whole car. :cool:

Wheres your numberplate light? :p

Cheers
Stot

[thailoz]

She looks an absolute treat Kev you should be well proud.
:)

[AshG]

vid vid vid!!! :D

[flyerncle]

The bogs dollocks mate well done :cool:

Don't let them log it on as test,but you probably already know that.

Get the brake force readings from them,it will give you an idea front to rear balance,if it's atl you should get a weight reading too.

[SeriesLandy]

Well done kev, looking great

[Davidbolam]

Well done kev. Have fun testing it out!

[K4KEV]

Hi guys and thanks.....may have an issue to solve, my local garage checked the car over and the only 2 things they could see that might be a problem was tracking and emissions .....now the tracking I am going to sort out tomorrow, but does anyone know how to get the emissions down ....my CO is around 4.5 and needs to be under 3.5 ....I have heard retarding the timing a little helps.
no cat or lambda, never was any.
Trailer works brilliant by the way

[Johno]

One nice car you got there Kev:cool: :cool:

[K4KEV]

Well guys, had my Iva today and failed on a few things:(
1. Speedo was under-reading 7% at worst 3% at best..... I believe on my dash it is a potentiometer to twiddle so relatively easy fix there.

2.headlamps are "kicking up" the wrong way ie lhd.......might just be a turn of the bulb to rectify or new headlamps.

3.rear fog was operating with sidelights........re-wire

4.Axle weight at rear was over stated axle weight .......As manufacturer I can write a letter to the examiner and advise him of a re-distribution of axle weights

5.Parking brake cable had wire joiner which is not allowed.........new correct length handbrake cable.

6.Locking device required on screw seats of shock absorbers.........simple drill,tap and fit grub screw

I have no complaints what soever with the examiner, he was a nice guy who chatted throughout the test and described everything that he was doing and offered advice regarding possible solutions/fixes, so I am hoping to get sorted within a few weeks and get back over there to pass.
Ironically the one thing I was worried about was the emissions were fine at 1.7% CO (limit 3.5) HC was 260 ( limit 1200).
So all in all I would say it was not a bad fail as all of the fault are easily rectified.

[Stot]

Not too bad Kev. Interesting about the handbrake, I thought most people used cable clamps here? These are the type I used.

http://www.tecni-cable.co.uk/DIN-741-Wire-Rope-Clip_2.gif

I have 3 or 4 of them on there.

Cheers
Stot

[SeriesLandy]

Unlucky kev but not a bad fail.
With the fog light, if you are using the sierra stalks.
Take a feed from pin 56 (brown/black wire) on either connector and use it as the relay earth and the fog will only operate with dipped/ main beam.

http://locostbuilders.co.uk/upload/2stalk.jpg

[ayjay]

Well done, nothing serious as expected. :) At least you have a list if things to fix . Its just a pain having to go back for another test:rolleyes:

[voucht]

So sorry to hear the news Kev, really :(

Well, it is small things you will easily fix, and you look to be positive, so it is comforting.

Your call will be soon on the road. Hopefully winter will come a bit later in the UK that it does here in Sweden (I fitted the winter wheels on my every day car today :eek: )

Good luck!

[ayjay]

http://www.antarctica.ac.uk/images/p2260601.jpg
Sylvain says he's got his winter tyres on.
This is a pic of his local Aldi car park:D

[TheArf]

No its not that was coedpoeth last easter

Arfon

[K4KEV]

cheers for that tip Steve it worked a treat.... slowly worked my way through the failure sheet and glad to say everything is done and I have my retest tomorrow. I will elaborate on how I fixed them later on today.

[flyerncle]

This time ;)

[voucht]

In French, we say "merde" to wish good luck (no need to translate I guess ;)).

So, "merde" for tomorrow Kev! This time is going to be the good one :)

[Davidbolam]

In French, we say "merde" to wish good luck (no need to translate I guess ;)).

So, "merde" for tomorrow Kev! This time is going to be the good one :)

Good luck kev.

David

[K4KEV]

In French, we say "merde" to wish good luck (no need to translate I guess ;)).

So, "merde" for tomorrow Kev! This time is going to be the good one :)

It will be effin merder:p :p if he fails it this time lol
Anyways please excuse the lack of activity on here ....have had a few surviving day to day issues, but I am back on song now so the fail list

Well the handbrake was straight forward enough, buy a new cable and get it swaged to the right length and retro fit it.....took nearly a day as the tank had to come out ....beware if you are thinking about using Newcastle don't use any kind of "cable joiner" it wont do.

The under-reading speedo was fun as I had put that dash in so it was not going anywhere jeeez it was a big pita but sure enough my research did prove worth it when I drilled a hole roughly where I thought the potentiometer would be and it was.....after making a record of speeds to rpm it was just the slightest tweak clockwise to bring the reading to a passable level, but even if it is still out I can get to it at the re-test .

kick up on the headlamps turned out to be a relatively easy fix.....after grinding a small glass locating "bobble" down I was able to move the lens and reflector around 10 degrees to get the kick up the right way.

Easiest of them all....axle weights, just simply typed up a letter on pc saying I was the manufacturer and I was informing the examiner of a design axle weight change.

Rear fog light was resolved using Sirieslandy's diagram further up this page.

Coil spring "locks".....I was not sure how I was going to sort this one out, I was not keen on the examiners suggestion of small grub screw through the threaded ring seat as it would defo create a weakness at that spot so I decided to fabricate a aluminium jubilee type clip to clamp on the shock body but also have a small tab that locates into a notch on the threaded spring seat .....this provided two "locking actions" and no need to take the spring off.....I have had to sacrifice a little adjustment, but I can live with that for the mo

only have pics of last item on list....see next page

[K4KEV]

see previous page for a little write up on fixing the faults


http://i465.photobucket.com/albums/rr12/gfowa/SAM_0964_zps34a63b5e.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0964_zps34a63b5e.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0965_zpsd2de4add.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0965_zpsd2de4add.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0966_zps0671850e.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0966_zps0671850e.jpg.html)
http://i465.photobucket.com/albums/rr12/gfowa/SAM_0967_zps958aa988.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0967_zps958aa988.jpg.html)

[rpjg1975]

Dont forget nut covers on there kev incase the buggers fail you on that!

Good luck for tomorrow mate

Russ

[K4KEV]

they cannot Russ.... as that is in a zonal area that is not checked but cheers anyway

[rpjg1975]

Thats a bit of a bonus then, one less thing to worry about!

[jason 82]

Good luck Kev !:D

[twinturbo]

Bestest of Lukiness...

TT

[SeriesLandy]

Good luck for tomorrow and I'm glad I could have been helpful.
I've pinched a few of your designs for my build.

[vmax1974]

Good luck for today kev will be good to see all your hard work come to fruition would anytime you want to bring your roadster to mine and have a cuppa your more than welcome

[flyerncle]

Good luck mate,dont stand in the Merde ,it wont come off your shoes !;)

Je parlez petite francias,merde non bon mon ami.

[flyerncle]

Might be a good idea when its shocker time to get a spare set of locking rings;)

[K4KEV]

YIPYYIYOOOOOOODA....WAHHHHHOOOMABA:eek: ..........
Tetaumata*whakatangihanga*koaua*o*tamatea*urehaeat uripuka*pihimaunga*horo*nuku*pokaiwhenuaa*kitana*r ahu:eek: , (place in New Zealand ) just felt like saying it and yes I can actually
Guess what guys .....yip number 31.....the bugger wound me up a bit tho ....all in good fun.....just gonna ev a few beers now and will be back on here later with a lickle vid
jeeeez life feels gud when you pass an iva...fuuuwowweeematulanu:eek:

[ayjay]

Brilliant---well done Kev:) :) :)

[jason 82]

Brilliant ! Well done Kev. :D

[vmax1974]

great stuff that man well done you deserve a few beers now and maybe some of your home brew

[Davidbolam]

Well done kev. If you new shock absorber clips "fall off" can I borrow them?

Looking forward to seeing the video and maybe a hoon together around the twistys next year!

David

[rpjg1975]

Well done kev. See you down here soon then :)

Russ

[twinturbo]

woooop....

That's gr8 news..

TT

[flyerncle]

Nice one,worth the hassle in the end.:cool:

[K4KEV]

Sure you can Dave (clips)
Ok so arrived at Newcastle VOSA station 15 mins early which was just right for getting it off the trailer (which has performed great by the way) just as I pull off Alistair opens up the roller doors and I drive in and leave it running while he asked me to go off and "settle up" the £90....by the time I got back he had already gone through some of the previous failure items fog and headlamps although the headlamp pattern was not the best he had seen (sounds familiar that). So then on to speedo test this was way out as I had tweaked it the wrong way so out with 2 screwdrivers and a tweak the other way had it bang on with hardly any error. Up onto the 4 poster to check hand brake and he is happy with that in fact he said the effiency had gone up substantially since I changed the cable. No weighing to do as I had given him the letter stating the changed axle weights, and that was it... done and dusted. He said if he was a long time start to worry ....he was back out before I had strapped the car up ....then he said " do you want the good news or the bad news" I always opt for the bad when some one says that so he said " you will have to come back and see me (pause) for a social visit" good news is its passed and he gave that treasured piece of paper and wished me luck and that it was a very tidy build......couldn't stop smiling or singing all the way back, What a day as well wall to wall sun.
Anyway here is the car outside the station.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0969_zps52e2ed45.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0969_zps52e2ed45.jpg.html)

and here are a few short clips outside a disused factory unit.

http://i465.photobucket.com/albums/rr12/gfowa/th_SAM_0970_zpsb8222b65.jpg (http://i465.photobucket.com/albums/rr12/gfowa/SAM_0970_zpsb8222b65.mp4)

http://i465.photobucket.com/albums/rr12/gfowa/th_SAM_0971_zps122a605d.jpg (http://i465.photobucket.com/albums/rr12/gfowa/SAM_0971_zps122a605d.mp4)

http://i465.photobucket.com/albums/rr12/gfowa/th_SAM_0972_zpsb9ea6cb0.jpg (http://i465.photobucket.com/albums/rr12/gfowa/SAM_0972_zpsb9ea6cb0.mp4)

[voucht]

Congratulations Kev, I'm so happy for you, you really deserved it. That is just great!

Now, enjoy the roads, but pay a visit now and then here on the forum, we still need your advices!

Great job mate, congrats again!

I wish I could see your car with my own eyes... one day perhaps...

[alga]

Congrats, Kev! What can I say, it looks and sounds great, well done!

[thailoz]

Well done great looking car

[Dualist]

Congrats Kev, looks and sounds great too :)

[SeriesLandy]

Well done mate, looks great.

[rpjg1975]

Kev,

Are my eyes deceiving me or have you only got side repeaters on the scuttle?

Russ

[K4KEV]

Errr yep Russ ....why should there be more?.....not that it matters mind you

[Stot]

Well done Kev. Glad your side repeaters were high enough in the end!

Cheers
Stot

[rpjg1975]

Just with the discussions all the time about passing or not passing in the scuttle and whether or not you need them on the rear wings like some builders have done...

[ayjay]

They are fine on the scuttle as long as they are visible from the angles specified
in IVA manual
Mine were slightly obscured but my IVA man said he could still see them so they were ok by him;)

[K4KEV]

Well done Kev. Glad your side repeaters were high enough in the end!

Cheers
Stot

by the way Stot.....forgot to get back to you on the cable joiners ....the guy at Newcastle would have none of it, it had to be a full length cable unjoined, funnily enough its performance improved by about 30% I have no idea as to elsewhere being different, so I guess its down to you if you wish to risk it on an IVA

[jason 82]

Lol. Kev, you must have the most recognisable Haynes Roadster in the uk, with those back lights stood up on end. Well done fella, enjoy the fruits of your labour, top man. ;)

[Davidbolam]

by the way Stot.....forgot to get back to you on the cable joiners ....the guy at Newcastle would have none of it, it had to be a full length cable unjoined, funnily enough its performance improved by about 30% I have no idea as to elsewhere being different, so I guess its down to you if you wish to risk it on an IVA

Kev, Did you find a local company to make a new cable up for you. I was going to go to the newcastle VOSA as its just around the corner from me... but... I have had to shorten the front section of the mx5 cable to fit in with the Saturn plans. It looks like the ends etc are not standard. The only thing I can think about doing is buying another front section and having it swaged at the end to make it "look original". If there is a company who can make a new one this would be great.

Here is a picture of the cable

http://www.mx5parts.co.uk/handbrake-cable-front-mk1225-p-384.html

David

[flyerncle]

I cut mine to length and drilled a section of bolt and crimped in a press and dab of mig on the end .

Yatch suppliers can crimp stainless cable to make you one if needs be, storrer marine in gateshead possibly ,south shore road.

[davidimurray]

Congratulations Kev.

[flyerncle]

IVA manual seems to be made up of MOT/Constrution and Use rules,only one cable adjuster is allowed for MOT so it makes sense that they fail more than one.

Section 3.5 RFR n would explain it.

[K4KEV]

Cheers for all the great comments guys ....they are defo appreciated,
Well now its time to tweak the the roadster into the post IVA car that I want and for a start that orrible sierra steering wheel has got to go......so off it came and the bandsaw fell on it loads of times until what I had left was the bare bones of the central boss.....this was duly hoyed into the lathe and turned down, then I grabbed a lump of ally that I also turned to fit the "new" boss then I needed some plastic spacers turning up so I could still use the central horn push on my new smaller snazzy steering wheel.



http://i465.photobucket.com/albums/rr12/gfowa/1384543523387_zpsaafd5a41.jpg (http://s465.photobucket.com/user/gfowa/media/1384543523387_zpsaafd5a41.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/1384790313496_zps2e4279bc.jpg (http://s465.photobucket.com/user/gfowa/media/1384790313496_zps2e4279bc.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/1384619210981_zps5c8899ee.jpg (http://s465.photobucket.com/user/gfowa/media/1384619210981_zps5c8899ee.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/1384718565107_zps29ad2096.jpg (http://s465.photobucket.com/user/gfowa/media/1384718565107_zps29ad2096.jpg.html)

[K4KEV]

http://i465.photobucket.com/albums/rr12/gfowa/IMG_20131119_194637_zps319f3231.jpg (http://s465.photobucket.com/user/gfowa/media/IMG_20131119_194637_zps319f3231.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/IMG_20131119_194707_zpsef0bf51c.jpg (http://s465.photobucket.com/user/gfowa/media/IMG_20131119_194707_zpsef0bf51c.jpg.html)

[ayjay]

Thats great .
I bought an 11" wheel on ebay but cant find a boss with a hex fitting. I was toying with the idea of adapting the extg wheel. The angry grinder will be dusted off next week. Cheers:) :)

[flyerncle]

When I saw the first pic I thought you were making some sort of "tiller" for the steering :eek: . I remember seeing that wheel you had,thought you were loosing it Kev ;)

[rpjg1975]

I thought the original was getting top and bottom sliced out like the one on the knightrider car :D

Must be the excitement of passing iva, kev has gone all bling!

[rpjg1975]

Thats great .
I bought an 11" wheel on ebay but cant find a boss with a hex fitting. I was toying with the idea of adapting the extg wheel. The angry grinder will be dusted off next week. Cheers:) :)

If you are using a sierra donor I managed to get hold of an rs item that fitted the column :D Also doesn't move the wheel much closer. Don't know if that would work for your wheel?

[K4KEV]

If you are using a sierra donor I managed to get hold of an rs item that fitted the column :D Also doesn't move the wheel much closer. Don't know if that would work for your wheel?

I think it depends on the boss Russ.....I got an RS one of the bay and although it did fit the column its actual diameter was a little smaller and it would not fit over the horn contacts.....I was well miffed when I found out and that was why I went with the mod job

[rpjg1975]

Yeah, could well do kev. I managed to re drill and countersink the holes in the wheel to fit the boss but I could have just been very lucky.....

[K4KEV]

Well, I have another wee addition to my roadster or should I say I will have when I have re-engineered this lil old spartan solid alloy surround and windscreen......no prizes for where I got it from, gud ole ebay ....£50 and a 200 mile round trip
I have checked the curves at the pillars and at the front it is nigh on perfect but I may have to fill in a bit at the back. The whole thing bolts together so it will be a case of taking a few chunks out of it and bolt it back together although I will have to tackle cutting the glass and I am not good at that, I also have not ruled out cutting chunks out of the middle and tigging it back together. I wasn't really planning for this yet but at that price and quality it was a no brainer.
As for wipers, the electrics are still there.....not sure yet as this could easily be made removable anyway

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0985_zpsb152ada1.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0985_zpsb152ada1.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0984_zps0937f68e.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0984_zps0937f68e.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0986_zps3f116a6d.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0986_zps3f116a6d.jpg.html)

[jason 82]

Well done Kevo ! That middle picture reminds me a little bit of a cyclone. I take it a classic mini wiper motor is on the agenda then ?:D it may be easier & safer to flare the bodywork to match the screen than cut it. Lol.

[flyerncle]

When are you fitting a heater ? :p

[twinturbo]

If it's toughend glass you will be very very very very lucky to cut it.

If it's not toughend and not laminated then you will want to deplace it as the fisrt stone hit could send a shard heading in your direction.

Will be a custom order job.

TT

[K4KEV]

Jase.....could be bud then again a sierra bodge could be on the cards
Paul.....as above matey as above:p
tt....me is thinking wet cut diamond tile cutter as I think it is all square underneath.....anyways I have a few tanks to sort oot first and the missus's "list" to get through yet:(

[twinturbo]

If it's toughened then it will almost certainly 99.99% explode into a million bits. Even with a diamond cutter.

Laminated should be ok if you do a cut accutarly on both sides andthen carefuly break and cut the membrane layer.

Plate. Simple enough to cut but I would not want it in any car I was driving.

TT

[rpjg1975]

Chatting to my mate last night and he said that autowindscreens will cut any shape windscreen providing you can give them a template.....unsure of price but could work out cheaper than hassle and hospital appointments :D

Russ

[ayjay]

If you want toughened glass and its a flat panel then make a template and take it to a glazier.I had one made for my boat for next to nothing. Toughened glass will always have a kite mark or manufacturers mark and is heat treated(tempered) after cutting and edge grinding. Dont even consider trying to cut it.

[flyerncle]

Company called Spartan do plant glazing in the NE Kev (No everybody not flowers)!

Worth a look.

[K4KEV]

Gonna start getting ready for this summer now and first thing I am going to look at is a home brew version of a 3" straight through cherry bomb using stainless wool instead of the traditional glasspack.
there is only 1/4" between the inner core and outer body this is due to the heat shield I have being only just under 4" dia so everything has to be quite compact, you will see what I mean over the next few days

the raw materials:D

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0989_zpsab5d8f7d.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0989_zpsab5d8f7d.jpg.html)

[skov]

Looks interesting!

Just to warn you, I packed my exhuast with wire wool to get through IVA and it disintegrated into dust after a few hours of driving!

[K4KEV]

It better bluddy hadn't John:mad: as it is the proper stainless stuff from an exhaust company.

[skov]

Ah, you're should be alright then. Mine definitely wasn't proper exhaust stuff!

[K4KEV]

So I have started with the outer case and some heat and gentle persuasion with a nammer and it all curls round enough to make a nice tight fit for the 3" perforated inner of the bomb

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0990_zps910a0046.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0990_zps910a0046.jpg.html)

next was to tig on a 90 degree bend that would eventually be sliced to allow it to go inside the cast exhaust outlet of which I will be refurbing and possibly getting a proper rechrome

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0993_zpsaea4322f.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0993_zpsaea4322f.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0991_zps5d6e333f.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0991_zps5d6e333f.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0992_zps1f4363a3.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0992_zps1f4363a3.jpg.html)

[K4KEV]

Made the slice in the 90 degree bend and offered up the outer casing and fits up good so now to wrap the inner core with the stainless wool, managed to get two full wraps and this left it a nice snug fit when I fitted the outer casing should be tigging it up tonight.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0995_zps8b8bdbd9.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0995_zps8b8bdbd9.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0997_zps8a756088.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0997_zps8a756088.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0998_zps1ea81cb9.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0998_zps1ea81cb9.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_0999_zpsc59d7ba6.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_0999_zpsc59d7ba6.jpg.html)

[K4KEV]

Not far to go now, have tigged up the open end

http://i465.photobucket.com/albums/rr12/gfowa/SAM_1000_zpsdb18ce72.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_1000_zpsdb18ce72.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_1002_zpsb2390603.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_1002_zpsb2390603.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_1004_zps2b610f06.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_1004_zps2b610f06.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_1003_zps6ea0e156.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_1003_zps6ea0e156.jpg.html)

[K4KEV]

All fully welded up bar the v band collars which I will be doing today.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_1006_zpsd82b62ed.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_1006_zpsd82b62ed.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_1007_zps4f9960fa.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_1007_zps4f9960fa.jpg.html)

[flyerncle]

Nice one as usual ,did you get that pm I sent you?

[K4KEV]

Ooops sorry Paul ...I meant to acknowledge it but forgot... anytime matey its not going anywhere

[flyerncle]

Brilliant,no worrys I will be down to collect as arranged.

Thanks again.

[K4KEV]

Right ....have been having a little think and have come up with a much cheaper solution to the re-chroming that I was going to go for (although it is still a possibility) these pics are a quick mock up using chrome vinyl wrap......now I know it may be questionable next to a hot muffler but for the sake of a fiver it is worth a bash as the muffler does not touch the heat shield until the very rear and I am leaving the front open to allow cooling air to flow between heat shield and muffler .....will be running the engine up tomoz to find out if it is a non starter if it works then I will be ordering some more to do a better job of it.

http://i465.photobucket.com/albums/rr12/gfowa/SAM_1008_zps4754446f.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_1008_zps4754446f.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_1015_zps7eb7ece1.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_1015_zps7eb7ece1.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_1011_zpsce0c2a91.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_1011_zpsce0c2a91.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_1009_zpsb94188e4.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_1009_zpsb94188e4.jpg.html)

[TheArf]

Can't you get a cream for that

Arfon

[flyerncle]

Beat me to it,damn :p

[TheArf]

first up best dressed

[K4KEV]

Now if I start putting Canesten on it the chrome effect will suffer:p :p

[flyerncle]

Nothing better to do !:rolleyes:

[K4KEV]

Well the number of radiators on my car has risen to 3 what with fitting a new oil cooler and my charge cooler radiator in front of my cooling fan, things are starting to get a little tight in front of the engine bay

http://i465.photobucket.com/albums/rr12/gfowa/SAM_1021-Copy_zps5e375486.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_1021-Copy_zps5e375486.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_1022_zpse45d8f6e.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_1022_zpse45d8f6e.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_1023_zps482fa08c.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_1023_zps482fa08c.jpg.html)

http://i465.photobucket.com/albums/rr12/gfowa/SAM_1024-Copy_zps609ce586.jpg (http://s465.photobucket.com/user/gfowa/media/SAM_1024-Copy_zps609ce586.jpg.html)