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  • 5th December 2011 – Engine Bay

    Once we had got the body back on it was really late into the evening, but these are some pictures taken the next morning in proper daylight. We are delighted to finally have the body back on the chassis ready for further work over the winter months. We think the complete set of heat shields now fitted and polished up just look amazing! Thank you again to Dale and Phil and Slipstream design for the CAD work and production.

  • 3rd December 2011 – Body Bolt locations

    Since writing our post on 3rd December about getting the body back on, we have had a few people email us asking where the 20 bolts for securing the body to the chassis are located. So this is a little extra post with some pics showing the locations. 20 bolts in total. 2 each side at the rear of the boot, there is 1 each side of the rear wheel arch in the boot, 1 each side next to the sill in the cabin, 4 each side in the foot welld holding the dash frame and door hinges and finally 2 each side at the front. In the picture below, the front bolts are not in yet as we haven’t got around to drilling the holes through the heatshield panels. These 2 are alan key bolts going through to the front wheel arches.

  • 3rd December 2011 – Body goes back on!

    After the final bits of painting and polishing, finally it was time to get the body back on the chassis. By this point we had been working on the body all day and was getting quite dark so had to work quickly. We thought the best way to do it was to wheel the rolling chassis out onto the street and get the body on where it was flat and where we had more room.
    We acquired some help from a couple of the neighbours to lift it, one person on each corner, and very quickly on it went. It wasn’t quiet that straight forward getting it in the correct position though, as we quickly realised we had to cut away some of the floor to allow the prop shaft and safety loop to fit through the hole in the floor. We did this very quickly and we will go back and tidy the holes up at a later stage.
    Once back in the garage we fix the body down with the 20 bolts we took out back in July 2010 when we detached the body. Seems a while and much work ago now. 4 bolts at the front in the engine bay, 10 in the cabin and 6 in the boot. They fitted very easily giving us confidence we had got the body on correctly. It actually looks like a car now, which is another real milestone. Still lots to do though.
    We will probably be looking at doing the wiring and electrics next and getting the master cylinder fitted and connected up. Check out further posts coming soon.

  • 3rd December 2011 – Fitting Inner wing heatshields

    We fitted the remaining side panels heatshield next, which would also neatly fit over the top of the new well section panels. As we had with the other panels we used a metal folder to create a really neat edge on the bend where the panel would wrap around the corner of the wheel arches. We then fitted by drilling the holes through the fibre glass and riveting into place. As they were pre-made these panels fitted very quickly and easily.
    Once all the panels were fitted we gave them a really good polish up to really bring out the shine. We are really happy with the results and completely glad we spent the extra time getting the CAD design done.

  • 3rd December 2011 – Engine bay – extra metal panels

    We decided after a little discussion to make some extra aluminium panels for the well sections connecting the inner wings inside the engine bay to the pedal box and footwells. Originally we had planned to leave these as a fibre glass finish. We had some extra aluminium sheet left over from the manufacture of the other heatshields so we thought this would really finish the engine bay off nicely. So as went about making simple templates from a couple old cornflakes box to get the shape and size of the 2 well sections. The offside proved a little trickier than the nearside as we had to negotiate the gap for the pedal box.

    Marks cleverly had the idea to give ourselves enough overlap of metal to be able to fold the aluminium right over on its self on the edges which would give us a great finish. So this is exactly what we did.

    We then used tin snips to cut the template out of the 1mm aluminium before using the metal folder to get the shape and the vice to fold the edges over getting a really neat finish. Then we finally fitting and riveting into place on the car.

    I have to confess this was more Mark’s handy metal work than mine (in fact my first attempt was rubbish and we threw this away as a tester piece) but when Marks stepped in, his metal work skills got them both fitting beautifully. With a little polish, we both agreed that this little addition really added that little extra quality to the overall appearance of the engine bay and well worth our efforts. I hope you agree from the pictures.

  • 3rd December 2011 – Fitting side vents

    We managed to get another day set aside to do some kit car. Today we were determined to finally get the body back onto the chassis and in the garage before winter and the bad weather really kicks in.
    First job to get out of the way was to getting the side vents fitted. We had cut the holes out some time ago (link to post). The standard way to do this is to make some aluminium brackets and to fibreglass them in place. Mark had spent a few hours the previous week making 4 brackets, 2 for each vent top and bottom. He drilled out holes in the brackets to allow the P40 fibreglass to grip the bracket better against the body. We lined the vent up to the hole then used masking tape to secure into position, then mixed up the P40 fibeglass and layered in over the bracket. As it was a cold day it took a little while to go off and harden but we did 2 layers of fibreglass in the end which seems to have set ready solidly. This is a really messy and fiddly job.
    After doing the first one we realised we had put the vent in the wrong way around. Doh! so quickly unbolted it from the bracket then turned it round 180 degrees, we realised at this point we’d have to modify the bracket slightly by drilling 2 new holes for the bolts holding the vent in place.
    Once both fitted, the final thing we did was to carefully mask up the inner wings areas and spray paint the area black to cover the newly fibreglassed area and also give a nice neat edge between the outer wing and the footwells painted white.