Rear arch trim

This evening I started putting the tadpole trim on the other rear arch as there were small gaps on the one id attached earlier - and it was supposed to be on there!!

I ran a very thin bead of sealant around the inside of the arch.

Then cut the tadpole trim to size and added small cuts so it would bend around the curve of the arch.

As i'd just got the trim out of the shed, it was cold and not very flexible so popped it on the radiator for 5 mins which made it nice and flexible. 

Then attached it to the trim and left it to dry. Will trim the excess tomorrow and then attach it to the car. I will the do the same to the other arch. 

Rear Arches

The last job of the weekend (as it was the only parts I had left) was to fit the rear arches. I jacked the car up and removed the right hand wheel. Then placed the arch over the wheel and drew its outline on  the side of the car. After checking there were no obstructions I drilled out the 7 holes for the mounting bolts and attached the arch. 

Before fitting

After...

It looks really really low and wide now. I loved the drive back to the garage - Well the wife pushing me!!!

I then ran out of time and day light so only ended up with one side finished.

Seats Fitted

After sitting the seats in position, I was unable to get to the seat runners so I could mark where I needed to drill. I decided to lay some masking tape on the floor and then press the seat into it so it left a mark. I then drilled these out to 9mm and put the seats in the holes. Worked perfectly.

Drivers seat in place.

Both seats in and looking good. Not much room in the cockpit though. 

Gearbox mount

After a small amount of cutting, I added the gearbox mount. Now the car is on the ground it was particularly hard!

Rear lights

A quick job to start the day, I fitted the rear lights onto the rear panel.

Need to check the fitting for the reverse light as the connectors inside the light are visible from outside.

Rolling chassis

Today I spent 4 hours on the car and got it to the rolling chassis stage. I did lots of little jobs but its all looking good now and could (with a little muscle) sit on its own wheels for the first time.

I started by pulling though the cables for the rear lights. Nice and easy but very tight. They are now ready to accept the light units.

Then I attached the wheels and sat a front cycle wing on just to see how it looked.

Finally attached the Steering boss, column surround and steering wheel. All looking good and the self correcting indicators work too.

Wheels

After a 5 hour round trip to GBS, I now have the wheels, tyres and a few other parts.

Looks great now one is fitted. Hopefully a rolling chassis this time next week.

Shroud plastic removal

One thing I really don't enjoy is peeling the plastic coating off the body panels. However, today I had to do some more so I can look to finish the shroud off. Started as normal and then finished off by rubbing the excess with a cloth and some white spirit. It all cleaned up nicely and now looks really nice.

I finished the edges off with some rubber IVA trim. I will attach it with sealant and rivets next weekend - if the weather is nice.

Fuel pipe

As the fuel tank is now set and in place permanently, I attached the large fuel pipe. Was straight forwards which I was glad about because it looked and felt like it was going to be a pain. Anyway, two jubilee clips later and it's all sorted.

Indicator extentions

Just a quick job for today, I added the extentions to the front indicators so it passes the IVA. I will probably take them off when its through as they look too long for my liking.

Was an easy job, I cut off the nipples of the indicators, threaded the cable through the extention and the nut and then tightened everything up.

Rear panel, fuel tank, boot infil panels

So the hard job of the day was installing the fuel tank, boot infil panels and then the rear panel itself. After much checking I attached the fuel tank.

I then attached the infil panels and the rear panel. All was straight forwards but took a lot of checking. 

It really looks good now and only needs a bit of tidying up before moving on.

The rear shroud needs some more work before attaching permanently.

Stalks

Another nice easy job to start the day. I added the stalks which was straight forwards. Simply added two bolts to each and then sat the newly formed dash on top.

Handbrake finalised

An easy job to start with, I clipped the last part of the handbrake cable in place on the rear hubs ready for the rear panel.

Disaster!

While moving the car from my garage to my drive (25m or so) the trolley partially collapsed and one wheel fell off. I managed to wrestle it off the road and into my drive where I attempted a repair.

I think it's just too heavy now and in need of its wheels to get it off the trolley. My repair should hold but don't know how long for.....

Engine arrived

After being told no more engines were availiable, I found one online and it arrived this week. Very lucky!

Not at a stage to use it yet, but at least I've got it.

Dash prepped for the clocks

So after my build order changed massively due to a possible shortage of engines I have put an order in for the engine which now means I can't afford the clocks when I wanted them so have had to do other jobs. I decided (due to the weather), to finalise the dash so it's ready for the clocks when I do get them.

A very straightforward process, but very time consuming. 

Firstly was to attach the GRP dash to the scuttle. I lined everything up and then marked the first two holes. These were then drilled out while a rivnut was inserted into the scuttle. I drilled to 7.5mm even though the bolts are 6mm to give a little room for error.

After the first two holes were perfect, I moved into the next two. Repeated the above and moved on etc etc. 

Finally it was all drilled out and bolted to the scuttle which made it feel much more solid than before.

Next up I set about drilling the holes to mount the clocks. I've opted for the stainless steel surround as I like the mirror like finish it gives. I lined it up with the cutout for the steering shaft and ensured it was level using a spirit level and the kitchen counter. Once lined up, I marked the holes and was impressed with how close my pure guesswork was a few months ago.

As I didn't have a hole cutter, I drilled loads of small holes using a blunt 3.2 mm bit I had from drilling rivet holes in the chassis.

I then used some small snips to cut the holes through to each other.

Once the holes were loose, they pushed out and I sanded using a flap sander attached to my dremel. This made short work of the GRP but had to control myself so I didn't sand too much excess away - this will be done when I have the clocks to ensure a snug fit. 

I then added the surround so I could see how things are going to look and peeled back a small but if the protective film to see the mirrored finish.

It looks great and can't wait to get it fitted.

Just a word of caution, if working with GRP use a dust mask and eye protection at all times. It's horrible stuff and will cause you issues if you don't.

Car seats

As standard GBS don't sent fitting kits with ANYTHING arghhhh, so could only sit the seat in the car before removing it once I'd finished for the day.

I had the obligatory sit in it and smile - much tighter than I remember. 

Trial fitted a headlight.

I couldn't help but trial fit a headlight today as I thought it would set the car off nicely - it did. 

I also sat the cycle wing ontop just to see how it would look. 

What a day!!

I had a fantastically productive day today, I spent 7 hours outside, endured a few showers but loved it.

Firstly I added the front left wishbones, shocks, hubs, brakes, calipers and discs. Before repeating on the other side.

I started with the lower wishbone using a double ended hook I've made from a cheap ratchet strap. I then added the shock absorber before adding the upper wishbone utilising the same strap I used on the bottom.

I didn't take many photos during the build but it's all straight forwards and obvious.

Discs and calipers were then added which went on easily and I'm nearly in a position where I can bleed the brakes.

I also found some small plastic caps on eBay and used them to fill the holes on the cycle wing carriers to try and prevent rust in the future.

I repeated on the other side and it's looks amazing.