June 15th 2013 - Finished?

Expecting a date from Swansea anytime now, so it was time to try to finish off the remaining jobs.  First of these was to re-route the front brake pipes so the flexible pipes mount securely to the chassis.  Not sure why I didn't do this before filling the braking system and still not sure that its the right thing to do, but it was relatively easy (other than having to bleed the brakes again) and seems much safer.

Next job was to re-bend the battery clamp to fit the new, smaller, battery.  Not being used to cars that aren't used every day, I hadn't thought to charge up the old one regularly, so after 3 years it was flat and wouldn't recharge.  Another one the same is over £70, but GBS came up with this one for just over £40.  Its slightly lower powered, but they think it'll be OK.

Next was the side indicator repeaters.... again.  The one's I'd sourced from ebay turned out to be far too flimsy and the cable on one of them broke where it joins the light.  Searches for better self-adhesive units proved fruitless and the Westfield ones are too ugly, so I picked up a couple from GBS of a type that is sold by other suppliers and is said to be IVA compliant.  They did require holes in the wing though, so I guess they won't be able to "mysteriously" move to the far better (but not IVA compliant) location on the side of the car.

Time then to repeat another already-done job by adding edge trim to the cycle wings for IVA compliance.  The stuff supplied with the kit kept falling off, so eBay to the rescue again with a metal-reinforced version.  Harder to fit, but at least it should stay on:

Having attached the remaining earth strap I connected the battery to see what happened:

What worked was:

• Headlights and rear lights
• Fog light
• Wipers
• blower
• handbrake warning light
• gauge illumination
• indicators
• fuel pump (I think)

What didn't work was:

• Horn
• Hazard lights
• main headlight beam
• Windscreen washer
• starter motor (it whirred but didn't engage)
• Reversing light and brake lights (forgot to test them)

I suspect the first three may be down to the wiring of the switches, since I connected them based on verbal instructions from Westfield.  The washer may be simply the absence of fluid. The starter motor is slightly more worrying, but will have to wait for another day (or professional help).

Newark kit car show tomorrow, but I hope to fill the cooling system, possibly put some fuel in, fit the press studs for the door retaining straps and fit some edging around the reversing and fog lights (Matthew wants to do that).  That should be everything.... I think.

June 2nd 2013 - Bravery Pills! (AKA Alternator Connections and Oil pressure sender)

Having worked out where most of the remaining wires go yesterday made it easier to work out that the others are for the alternator.  Not sure why I hadn't realised it wasn't connected nut there you go.  The connections to it, even in daylight were really hard to get to and even harder to see, so I decided to temporarily remove the alternator, which was a bit of a fiddle and needed some flexible socket bars, but actually came away easier than expected.  Once off, connecting the wires was simplicity itself and well worth the effort.

With the alternator off I could see the star-drive plug on the side of the engine block which needs removing to allow the oil pressure sender to be fitted and feeling brave after having removed the alternator I thought I'd have a go at removing it.  Other reports say this is quite difficult, but it came out with no fuss at all.  I then wrapped the thread in PTFE tape and screwed it in easily.  I'd have done this earlier in the build if I'd known it was going to be this easy!

Oil pressure sender in place

With the alternator back on and the sun still shining, I had a go at the IVA covers (having previously scrawled down some instructions over the phone from Westfield.  I checked all the front suspension and steering bolts were torqued up correctly first then added covers to any bolt heads or nuts that would be visible with the nosecone on, although there's no photo because the cammera battery went flat. 

Talking of which, with nearly all the wiring connected I thought I'd connect the battery to see what happened when I turned the key..... which turned out to be.... nothing!  I'm pretty sure the battery's flat after 3 years without use, even though I did try charging it to no avail.  It looks like I'll need a new one.

June 1st 2013 - Almost finished

For the first time this year it was warm enough to wheel the car outside to work in the sunshine... and this seemed to make a huge difference on some of the small but significant jobs I've been struggling with.

First though, was the other side repeater.  Unfortunately, after running the wiring and changing the connectors, the wire broke just at the point it enters the light unit.  This doesn't look fixable, so another unit is the only option. At least they were less than a tenner the pair - I guess you get what you pay for!

Whilst working on the near side, I started thinking that the angle between the l-shaped cooling pipe and the lower t-piece didn't seem as impossible as it has done for two years, so I had a go at fitting a hose to connect them.... and it seems fine!  I now can't believe I've been worrying about this for so long.

Spurred on by this success, I had another look at the starter motor wiring: The manual says there should be two connectors with two wires on each, but this didn't fit with what's available on the loom with the right connector, so I went with what did fit.  This only leaves a couple of wires plus the oil pressure sensor, so I'll stand a better chance of completing all the wiring now by checking the wiring diagram.  I also managed to route the starter motor wires well away from the exhaust!  Its amazing what a bit of daylight can do!

I've also charged up and fitted the battery, so tidied up the wiring at the front and refitted the nose cone.  Time for another photo: