April 2004 Update

I've not been updating the website but I have been busy trying to finish off all the little bits and pieces which are preventing me from painting the chassis and/or getting the engine started. The main problem with starting the engine is with the exhaust silencers as it is too noisy to start it without silencers. I had been debating whether to build or buy but opted in the end to buy a pair of Jetex Turbex silencers from Demon Tweeks. These are 625mm long and 125mm diameter with a 3" pipe bore. The pipe is bigger than I wanted (3" instead of 2") but I'll just step the pipe up from 2" to 3" where it enters the silencer. Hopefully this will help by slowing the exhaust gas down and allowing the silencers to do a more effective job. No I'm not convinced either...

Click images below for high-res and description

A few other things to report:

I've ordered my bodywork kit from GTS Tuning. This will be a seven piece kit comprising the Bonnet, nosecone, scuttle, rear arches and front arches. Unfortunately I will need to cut the first three bits in half and widen them by 4 inches each to fit my chassis which is a shame as the quality of GTS fibreglass bits are said to be second to none! I must also give a mention to Darren George and Mark Bean from GTS who seem to be highly committed, very friendly and happy to give up their evenings to advise on and sell car bits. I called Darren at about 9:30pm the other night to order my GRP bits and caught him in Marks and Spencers getting his dinner! Despite my offer to call back another time he was happy to talk and emailed me later that night with the information I was needing. Top blokes!!

I've also ordered my aluminium sheeting, from Aalco in Cambuslang, which will be used to panel the sides and rear of the car as well as the seatback and tunnel sides and top.

I also received a bunch of bits from MAC#1 Motorsports including a set of 4 point seat harnesses (Sabelt Clubman) in blue with bolted mounts and pushbutton release. These are great value at £80 inc vat for a pair. A fellow builder Paul Gooderman has made me up a set of mountings which should fit through the crosstube in my rollbar and which are threaded with 7/16UNF threads to match the harness bolts. Thanks again Paul!

Other things I got from MAC#1 are a roll of brake pipe £6.99 for 25ft and various pipe clips and spiralwrap etc. I would highly recommend them as they seem very happy to give advice and you don't get the impression that they are trying to get you off the phone as quick as possible as you often do with some other retailers. Their prices are also good and delivery was prompt.

That's all for now, I'll post some more pics once my bodywork parts arrive and once the chassis painting is completed.

 

Review Of ToDo List

Made a list of things still to do with the chassis:

  1. Fuel tank support straps
  2. Spare wheel support strap
  3. Roll bar rear corner plates
  4. Suspension turret end plates
  5. Braces from tubes 'M' to tubes 'K' to brace the trailing arms mounts better
  6. Extra two front diff mountings
  7. Seat mounting tubes on floor
  8. Seat back extra triangulation in centre above diff
  9. Handbrake mountings
  10. Tunnel spars - One behind gearlever and one near handbrake
  11. Footwell end plates
  12. Tunnel side plates
  13. Tunnel top plate
  14. Triangulation tubes at front near engine mounts and top rear wishbones mounts
  15. Close tops of trailing arm mountings (May leave open or removable for access)
  16. Front wishbone - lower rear mountings to be strengthened
  17. Plate to be added at front of chassis between tubes LD and E
  18. Close ends of all tubes (6x1" and 2x3/4")
  19. Tunnel floor - small triangulation tubes needed where front and middle tunnel sections join
  20. Steering rack mountings
  21. Radiator mountings
  22. Steering column mountings
  23. Pedal mountings
  24. Brake master cylinder mountings
  25. Clutch master cylinder mountings
  26. Scuttle assembly (Removable but brackets need welded to chassis)
  27. Various other little brackets and fixings for bodywork, brake systems etc
  28. Seat belt anchorage plates and welded nuts

As you can see there is much to do. It is worth making a list like this from time to time otherwise you tend to start messing about aimlessly rather than working systematically through a list of "chores" like this.

From the list I have completed 1,2,4,5 and 6 today. Here are some pictures to prove it:

 

​Extra tube welded to brace tube M against tube K3/4. This was done to remove the reliance on the weld strength between tube M and tube K1/2.

​Extra diff brackets welded in place (please excuse the very spattery welds - I didn't clean the weld sites properly beforehand as I couldn't use the grinder so late at night...shhhh!) It's also CO2 that I'm using so it's a bit spattery anyway.

End cover on the suspension turret. This is 3mm plate for extra strength. I felt that it was important to retain tubes W1 and W2 at the top here as otherwise in the event of a rear corner shunt, the tube might break away and go straight through the back of my head!!

Fuel tank supports and spare wheel support. I'm not sure if I'll carry a spare wheel or not but it makes sense to add the support anyway just in case.

That's it for this weekend, hopefully I will continue with my list during the coming week.