Celebrating One Year

Small note to celebrate the first anniversary on receiving the kit. One year ago around this hour I was returning home after delivering the rental van on the depot, feeling completely drained of energy but very happy.

Looking back, I'm sorry I haven't kept a clear record of hours spent on the car. It would have been enough to write down how many hours in each post... Probably have spent around 250 hours so far, but it's more of an educated guess. Could have spent a lot less if I had done the right thing 1st time, had all the proper tools on the 1st attempt, etc. But it's all part of the learning process and one of my goals is to learn a bit about mechanics.

All in all, a wonderful adventure, that allowed my to meet new and great people, learn, have fun, have a project. Thanks to all that helped, supported or inspired!

Additional Cutting of the Bodywork

I'm loving the dremmel. But since it is borrowed, I thought it would be best to perform as many jobs with it as possible until I have to return it. So, instead of drilling for the radiator, I thought it would be best to trial-fit the bodywork so that I could shave off excess to make it fit well and also to use the dremmel on the bulkhead (specially so that I can have a throttle peddle).

The scuttle had to be cut on one side, in the interior lip, to accommodate the arch where the steering column attaches to. This was a quick job.

More cutting had to be done on the nosecone to make way for the nosecone attachment parts and also to clear the way where it was hitting slightly the radiator mounts.

In the end couldn't mark the bulkhead's final place since the engine cover part lost it's curve after laying on the floor for a year. I had heard about glass fiber loosing a bit it's shape after some time. Being kept on a room that exceeds 35º in the summer... I guess I should expect it. Notice the picture where it looks too "straight", without the curve.

Although I didn't mark the bulkhead's location, I noticed that it needs some trimming specially in front of the drivers. After trimming it, I'll hold the nosecone and scuttle in place with tape and then, even if the engine-cover is not with the right shape, I'll be able to check where the scuttle shall lay. But that will have to wait for the next weekend.
Oh, and holding the nosecone and scuttle in place with tape will really be a must. After taking this picture I tried to get the engine-cover roughly in place and ended up pushing the nosecone. It dropped on the cement floor, and it now has scratches in two different (and visible) places. :( I hope I can get some wax and/or another material to cover up mistakes I'll be doing along the build.

Cutting the Nose Cone

Got home from work, kid is away, wife celebrating something at work... Got myself on car-clothes and went to the balcony with the nosecone and the dremmel. Cut loosely the big air opening on the front. Then 2 small cuts on the back of the cone, where it meets the engine cover, so that the chassis supports can fit through. These supports are where the cone bolts to, once in place.

Very happy that last weekend I bought a professional air mask from 3M, certified to work with small dust particles. There was lots of fiber glass powder flying around and I bet it wouldn't have been good for my lungs to get a share of it.

Only after having cut the big opening I thought how will the grill bolt on it all. I hope I haven't cut too much or too near the "edge"...

In the end, it took me a bit over one hour to cut it all and almost 30m to clean afterwards.

Fuel Tank and Level Gauge

Since the work I had planned for today didn't have to be done in the car, I took tools and parts to a balcony. Fresh air, sun... It was a good decision. Better photos too, due to better lighting.

Spent some time reading an email Steve from Aries had sent me with instructions regarding the fuel level gauge and the tank. He mentioned ETB's manual (Digidash company where all these parts come from) so I also read it. Since the level gauge was too big, I finally grabbed the dremmel and cut the wire in two, shortened it and used (as recommended) an electric connection thing. Used the larger ones (5A?) and used lots of the Pattex Nural (threadlocking stuff) on the bolts.

Then I used my new contraption on the driller to cut a circular hole with 40mmØ on the fuel tank. With some cutting oil and patience, it was done with great results.

I still have to drill 6 holes to fix the level gauge on the tank, but it was lunch time. Still have to figure out how to bolt the gauge in place since I have no way to hold the bold inside. Should I use something different than bolts?

Radiator trial fitting

Had to do a couple of small tasks first. Small tasks end up taking a bit of time and also got to talk a bit about the car to the building caretaker. But in the end, besides talking, I attached the braided hoses on the rear brakes and to the pipes and put some ptfc tape on the oil pressure sensor (for the brake lights).

The big task was holding the radiator in place and trial fitting the nose cone to see if all was OK. It took some time and several tries, since there is not that much space under there. The car looks wonderful with the nose cone attached.

Stored the nose cone again. The radiator is in place held by 2 clamps. I'll drill for that later.

Water Pipes and Bulkhead

Found by accident a store that sells braces for the water pipes. Bought a couple and replaced the ones that were a pain and made me "suffer" last week. It wasn't as easy as I would expect since I bought a size too small and had to struggle to make them fit, but 45m later both were in place!

A friend borrowed me a dremel-like tool and I prepared the bulkhead to have a hole cut for the steering column to go through. I had never used such a tool. It was great but cutting the ally was a long task. After a hour I had the hole cut and could trial fit the bulkhead. I think that the hole is not big enough to cover all the steering column travel course since it's quite adjustable. I'll probably have to enlarge it later, but for now it serves it's purpose.

Next I'll have to take the nosecone, scuttle and bonnet to trial fit them all and figure out the final location for the bulkhead. And were to cut for the throttle peddle. And also where to drill for the radiator.
And it seems I'll not be able to run away much longer from the electrics...

Rear Brake Calipers and More Pipes

After a weekend without car-time, today I had the whole morning. Unfortunately, it didn't work out that well, so not much accomplished.

Started by finishing off the rear brake assembly. After spending some time trying to understand how to connect the pads with the calipers, I swapped some emails with Steve, from Aries. He really is a great person! I had some difficulties understanding what he was saying but still he kept trying and I finally understood how to assemble the breaks. Fitted the pads on the caliper carrier, placed the caliper on top and bolted the caliper to the sliding pins (with the rubber gaitors). Notice the fact that the oil pipe and bleed nipple are at the top and the handbrake lever is at the bottom.

I noticed after taking the photo that the springs on the pads were out of the caliper, so I had to undo it all and redo with the springs inside. Then did the same operations on the other side. Just didn't connect the flexy brake pipes from the chassis connection point to the calipers because I left the flexies at home.

By the way, after some trial and error trying to assemble the things, I understood that the slots on the caliper piston need to be "straight" so that they slot correctly on the pads. Using pliers, I rotated the pistons slightly.

Went back to the cooling circuit. Finished connecting the pipe to the Y piece near the oil filter. Then did the connections from that hose to the header tank and from the carbs T piece to the header tank. These were easier since I figured out applying some spit on the hose and the connection point helps it slide. But lost over two hours struggling with the braces to hold the pipes in place. The big braces were very easy to use, the small ones are a pain. Left both on the header tank undone and considering buying different ones, like those on the big pipes. Very nice looking header tank, by the way!

(2011/10/08) EDIT: It would have been easier to drill the four holes on the header tank attachment tabs (6mmØ) prior to fitting the water pipes, since they are stiff and limit movement.