8th May 2010 - Front Suspension

Matthew & I fitted the front suspension today - fairly straightforward apart from the top balljoint which, according to the manual "may need some pressure to be directly applied to stop it turning". TOO RIGHT IT DOES! The nuts still aren't tight so we'll have to find a better way of applying that pressure!. We also couldn't find the spacer for the headlight bracket, not helped by the fact that the manual doesn't say what size it is. Another job to come back to.

We also fitted the steering rack (same unresolved turning problem with the track rod ends) and to make it start to look like a car rather than a climbing frame temporarily fitted the front wheels. Looks good:

As we were on a roll, we started on the rear suspension and came across another place where the two manuals disagree: After failing to fit the washers as described in the older diagram-based book we looked at the newer book, which said that long studs should be used instead of bolts. We then came across two studs of the size described which we had previously thought were for the differential. A quick check revealed that they're too short for that application so they were used for the upright and went on much easier than the bolts. In the same bag as the studs were some spacers which look about right for the previously-missing headlight brackets! I wonder where the studs for the diff are?

2nd May 2010 - Stoneleigh Show

Away this weekend, so no build progress (boo!). We did go to the Stoneleigh show though, so here's a video of Matthew doing the Westfield Drift Experience at the show.

24th April 2010 - Brake Pipes

Fitted the brake pipes today with no real problems. Slightly nervous about the task having read tales of kinked expensive-to-replace pipes, but they bent to shape quite easily with just thumb pressure. The most difficult was the short pipe from the master cylinder to the brake pressure switch t-piece, the most time-consuming the long pipe under the car. Still managing with the chassis the right way up and now can't see it being necessary to turn it over..... although we may yet come unstuck!

Also fitted the loom attachment points (rivetted on hooks to tie cable ties to), except for the ones at the back for which the pictures in the manual are rubbish and taken with the chassis upside down. I'll have another look at it next time as there aren't many places to run the cables.

Couldn't resist jumping ahead slightly and trial fitting the front wishbones to make sure they fit (see picture). Proper fitting of these will be done by Matthew in the next session even though the following (in theory, preceeding) tasks are still to be done:

Fit rear chassis loom mountings, fit loom (unpacked it to see what it looks like and quickly put it away again!), bend and fit rigid fuel pipes, fit aluminium panels to the sides of the car.

April 9th & 10th 2010 - Panels & Pedals

Starting to make really good progress now. All the panels are on except the sides (left off to allow easier turning over of the chassis if necessary) and tunnel top (to allow access to fit the propshaft). As suspected, we did have to cut a tab each side of the rear panel to accomodate the "new" chassis tube and then bend the panel in an S-shape to get it in. The build manual said that the chassis should be flipped to fit the floorpan, but we managed ok doing this from underneath. We may even attempt the brake and fuel lines (the next job) with the car the right way up thanks to the access afforded by our adjustable trestles.

Matthew also fitted the remaining pedals, along with the clutch cable (we worked out it is a cable clutch!) and throttle cable. He also fitted the three brake union "T" pieces and the brake pressure switch with no problems, although we had to guess the tightness for the latter as our torque wrench doesn't have a setting low enough.

2nd April 2010 - More Panels

MUCH better progress today. The new tools, and particularly the harder drill bits (5% cobalt from Amazon) and right-angle drill attachment made a huge difference. Both inner tunnel panels were fitted, along with the drivers footrest panel (once I'd realised the footrest protrudes into the tunnel). Matthew fitted the brake master cylinder and pedal. Spent about 20 mins looking for the clutch master cylinder, but now suspect the car has a cable clutch (this is not made clear anywhere, and even seems amibiguous when reviewing the list of supplied parts!).

13th & 20th March 2010 - Collection & the first panel!

20th March 2010

A slightly frustrating day, not helped by the need to spend half of it re-arranging the garage to allow the bodywork to be stored safely at the back. Identified and trial fitted most of the aluminium panels with a few issues noted:
The tunnel side panels don’t appear to need “bending around the tube” as stated in the instructions.
The driver’s footrest appears to be the wrong way up (is it for an LHD car?), although looking at the picture in the manual it seems like it’s supposed to be that way!
The rear panel (by all accounts a pig to fit anyway) seems to need some slots cutting each side to accommodate an “extra” chassis tube half way up each side.
Decided to start with an “easy” panel in the form of the drivers bulkhead, but made slow progress due to a cordless drill which went flat in minutes and a very old corded drill which was stuck in “hammer” mode and tried to enlarge all the holes. To add insult to injury, both of them were too big to get into all the holes. Eventually got the panel on, and it looks OK….. but not much to show for a days work. Now, where’s that tool catalogue……….?

13th March 2010

Collected the kit today after a delay of a week due to a problem with the chassis powder coating. The kit fitted easily in the Transit Luton and didn’t suffer any damage thanks to the expert way it was loaded by the factory. Slightly disappointed that there were a few parts missing, including the diff, but at least I was told they were missing rather than finding out later. There don’t seem to be as many boxes of bits as I expected, but I can’t think of anything that should be here which isn’t.


Welcome to Matthew (Aged 10) and Mark's build diary for our Westfield Sport Kit Car. We're first-time kit builders with limited mechanical experience and hope to be able to build a 2-litre Zetec Westfield Sport from a comprehensive (all new parts) kit. We're hoping to complete it in about a year, but it may take longer as we'll only get 2-3 days a month on the project.