Saturday 28 January 2012

Suspension brakes and fuel lines

Now we had all the big important bits in the car it was now a big push to all those little things on order,begged,borrowed,stolen etc,etc.New wishbones had been sourced along with a complete set of poly bushes for the front end.Anti-roll bar painted.Brake calipers rebuilt,flexi hoses fitted,front wheel bearings changed.All new brake lines run in from the master cylinder to the front's and rear's,with the rear lines running through the inside of the car on the passenger side.

With the rear axel fitted I changed the rear wheel bearings,brake pistons and brake shoes with all new springs and clips.Shiny.

Now came the fuel lines.I wanted these run in through the car so to comply with the MSA regs these lines have to be high pressure rated and stainless steel braided.After much messing about I found Earls at Silverstone who were fantastic and sorted me out with all the right bits first time.Brilliant.These lines have special anodised fittings on them and they look the part.A new fuel pump was fitted along with new hoses between the tank,pump and accumulator.

engine and drive train

The build was now getting to the point where the engine,torque tube,gearbox and rear suspension could be removed from the old white race car chassis.In no time atall Erny and I had the engine disconnected from the torque tube and that was lifted out.the tube and gearbox where then dropped out and placed in a position so that we would trip over it for a couple of days.
The rear axel was next out and when we had it on the ground we could compare it against an axel with no adjustments made to it for racing.The race axel setup was altered by some 125mm from stock.A big smile then came across my face as i realised that a very hard job had been done for me already.Nice.

In the original crash the engine had suffered a holed sump,so while the engine was out that was changed.Thanks goes to gary(snaggletooth)from the owners club for the kind donation of the sump and many other parts.
Next job was putting the rear axel and torque tube into the new car.This slotted in without to much rouble in one evening although I found that the rubber mounts for the torsion bar arms were shot so I manufactured some replacements out of solid steel.
The engine was next to go in,again this proved reasonably straight forward with Erny in control.

We now had a car resembling a racing machine on its wheels.Result 



Wednesday 11 January 2012

the wiring nightmare



Once the dash was fitted i could then turn my attention to the wiring and getting some cables and wires to the front and back of the car.This is when i discovered that the chap who done the wiring on the centre consol was not quite right.All of the switches have bolt terminals and the former owner or builder had decided to use push on spade terminals instead.This is fine when a piece of equipment is resonably static and if there are not more than one cable terminated onto the switch.But this muppet had loads of cables running round with multiple piggyback crimps.There were four piggy's on the main switch alone.What a mess,this would not get me to the finish line.

So I ripped out all of the wiring and started again.New M3 nuts,bolts and washers were used on the switches with lovely ring crimps fitted so the buggers wont come off.New tri-rated cables were put into the loom with the earth terminal and fuse box in a more accessable place.Amulti core cable was run  to the back of the car.Here I discovered a piece of wire less than 2 feet long with 4 YES 4 scotch block connectors in it.JOKE.I fitted a new multipin plug so everything is readily accessable and detachable.The multicore handles the rear lights,indicators,brake lights,fuel pump and gauge along with the newly fitted high intensity rain light.

paint and dash fitting

Once all of the welding and removal of everything not needed on the interior it was time for some paint.Brilliant bright white was chosen as that was the colour of the original car with a bright yellow roll cage and inner wings.The hunt was on now for yellow trim and accessories.With Erny doing a fantastic job on the paint inside attention turned to the exterior.Many nights with wet and dry and a bucket of water followed.The sunroof was adapted so that all that was unnesseccary was removed and all that was left was the fibreglass panel.This was fixed in place and then made good with sealant and filler.

The engine bay and nose were cleaned and rubbed down along with the bumpers and front valence.Over several nights Erny painted the exterior and engine bay.All was going well,with a couple of coats going on each evening,until i forgot to put the hardener in one batch of paint.This resulted in the paint not going off and me having to remove this layer,sorry Erny.The finished job is excellent and is a quite striking colour in the sun.lovely.

Once the exterior paint was done then i could get the dash fitted into the car.I had removed this from the old race car wholesale,only having to cut and mark a few cables in the engine bay.With some large screws and a couple of nuts and bolts the dash fitted perfect.I could now fit the front part of the roll cage in place,after all of its modifications,this to fitted well.


Sunday 1 January 2012

More stripping out

When the interior of old red was just about finished my attention then had to turn to the white car as I had to remove equipment and parts from this in a logical order to then install in red.First out was the roll cage.On removing this it was found that the previous owner/builder did not have the same idea of build qualitity as myself.Some of the welds were not up to much so these were cut out and re-welded.

A trial fitting showed that the cage fitted but the door bars were not quite right.in the white car they were welded to the rear wheel arch and not attatched to the rear upright.After talking to scruteneers at Donington the decision was taken to have new door bars made.More of this a little later.when the cage was in a trial fit of the seat also took place just to see if that fitted and that we got it in about the right place.It was found that the front upright of the cage interfered with my foot on the throttle so the cage was taken out and the base plate changed to bring the up right as far out of the way as possible.



The first two pics show the cage in the white car before removal and the next three are the trial fit in old red and Stan the guard dog




stripping out


Once we had got the red car back to the workshop i started removing everything not needed.All of the internal trim was thrown out,I mean recycled,the doors andwings removed.Gary had taken the dash out before collection so did not have to worry about that.Now was the time for the heat gun and scrapper.What a pain it is removing the sound proofing and trim which is glued to the body,but even worse was the 4mm thick bitumen sheet that was on the floor pan,torque tube rear spare wheel well and side paniers,and engine bay.I would think in total I removed 10 kg of the stuff and wrecked one heat gun from BandQ.Still it was February at the time so my hands were warm.Our aim was to make the chassis as light as possible before paint so every metal bracket was removed that was not needed.

top pic is what we started with and the second is with much removed

the removal of the stuff from the interior took about 2 weeks worth of evenings,not a quick job.