15th September 2010 - Exhaust manifold (but not much else!)

Today was a really frustrating day, notable more for the things we couldn't do rather than those we could:
1.  We still couldn't fit the fuel pump or filter as Westfield say we need a rivnut insertion tool (to insert captive nuts) - which we've had to order from Amazon as no-one stocks one locally at a reasonable price
2.  We tried to fit the radiator and fan assembly, but found that the bolts supplied are 5mm rather than 6mm and longer 6mm bolts would put a hole in the radiator (which would not be good!)
3.  We tried to fit the battery tray, but the "pre-fitted rivnuts" in the chassis are notable by their absence.

Not wanting to wade into the engine wiring loom without preparation, we were left with a few minor bits and pieces;  Firstly the horn (wow!) and the VIN plate (yes, we're getting desperate now).  Then we put the exhaust manifold on - mainly because its visible progress, even though it will have to come off again to fit the body.  At least it seems to fit well and clears everything and we'll be able to make a template for where the hole in the body will need to be.

The biggest success of the day ended up being the fitting of a part which should have gone on ages ago - the handbrake warning switch.  We finally worked out how it goes on and managed to find a couple of suitable bolts at the village hardware store (there were none the right size in the dwindling box of bolts).

Other than the jobs we failed to do, we think there's just the engine wiring and ECU to do before we start thinking about fitting the body.... although with all the setbacks and winter approaching, that may not now be until next year.

18th September 2010 - Fuel Tank

After last week's events, this week was slightly lower key.  The first things to do were to re-fit the gear lever after putting some grease on the rather dry-looking selector and to torque up the rear wishbone bolts (some of which will be inaccessible when the fuel tanks on).  The tank itself was fairly straightforward, requiring the fitting of the outlets using PTFE tape on the threads before putting foam tape everywhere it'll touch and fastening it down with aluminium straps.


Fuel tank in place

Next on the list was adding some rubber fuel pipes - one for the breather from the top of the tank to the top of the chassis, the second from the return (copper) fuel pipe to the tank.  Then it was time to prepare the fuel pump and filter, including changing the loom (spade) connections for round ones.  That done, it was time to fit them;  except where the instructions say they should be fitted would require drilling right though the chassis box section, but if we did there would be no suitable bolt.  Another one for Westfield I think - they need chasing about the transducer bracket anyway!  Frustrated at another time-wasting setback, we tried the scuttle in place to see how it looks:

Looks even more like a car with the scuttle on

As a final task we started fitting up the radiator and fan, but didn't put the assembly on the car as the radiator looks so fragile.  One for just before the nose goes on I think.

11th September 2010 - Engine & Lower Steering Column

After a break for summer activities, today was a big day - engine installation.  We started by lowering the car off its trestles so that it stood on the ground for the first time; We attached the engine crane to the rear of the chassis, lifted it to remove the rear trestle, then slowly lowered it whilst making sure the front trestle didn't fall over.  To our surprise it was possible to lower the rear almost to the ground before (manually) lifting the front and pulling out the front trestle.  Wow, you forget just how low to the ground these cars are!  We then decided to turn the car around to fit the engine, which required the second and third momentous occasions of the day - the first time the car rolled, and its first trip outside!



Rolling chassis ventures outside!

  Then came the first engine fitting - "first" because we knew from a preparatory measurement/comparison of mounting hole vs. gearbox mounting and a subsequent conversation with Westfield that we'd need to drill new mounting points once we knew where they go from the first trial fitting.
The installation itself went more smoothly than expected;  we removed the gear lever to make it easier, but then with a slow, repeating "back a bit, down a bit" routine everything lined up perfectly with no squashed pipes or cables in the process.  Getting the propshaft splines lined up with the gearbox took a bit of wiggling, but by then we were on a roll.



Engine in place!

  Still plenty of time left so we moved onto the lower steering column: We'd previously identified that the bracket didn't fit, but Westfield just advised us to "put it in the most suitable place and shorten the mounting plate to fit"!  This turned out to be just behind the engine mount, needing a new hole to be made in the bracket and two in the chassis.  Once done though, the column went together easily and cleared the engine by at least 10mm.  Engine and steering on one day - result!
Still more time available though, so we couldn't resist putting in the driver's seat for that "it really will be a car" feeling.  Although there are pre-drilled holes in the pre-fitted lowered floor pan, they were in the wrong place for our upgrade "Sport Turbo" seats (The name coming from the model they were designed for, not the Halfords boy racer pretensions the name might suggest).  We made the new holes for maximum adjustability, with the result that the seat will go far enough forward for Matthew to reach the pedals.


Matthew trying out the driving position

 A lot done in one day then.  We even had time left to tidy up the garage.