Indicator Light Switch

We have a saying in Portugal: "As a donkey looking to a palace". That's me looking at dash electrics!

Spent almost two hours on the car tonight (22h40 to 00h20). The focus was on dash electrics, having as a goal to wire up the digidash and minimum components to be able to initialize the Digidash ROM and turn the car on. But only managed to put the lights relay on the fuse box and wire up the indicator light switch. Wiring up the switch required creating some extensions since the loom's wires were not long enough. Usually people don't put a stalk, put some buttons on the dash, and for that it would work.

In between, tested the scuttle on the car to see how much space I had for the indicator light switch. It's always great to put some panels on the car because it really does look a lot better!

Let's hope that my next session can get me closer to being able to connect the Digidash.

Finished Brake and Fuel Lines, Airbox and Exhaust

Almost 5 hours today, interrupted by a long lunch. And many small bits got done!

I've been saying that only the brake fluid line was not finished but actually the fuel line was not completely done either. So today I attached the filler cap on the tank. The bodywork is missing but I plan to drive the car a bit without bodywork fitted, so it's wonderful!

Next task was to bend the small copper pipes to close the frontal brake circuit, possible since I attached the wingstays. Bending the pipes by hand, to fit the tight curves, was actually easier than I anticipated. This job was quickly done.

I had the idea of cleaning the engine. Someone told me I shouldn't do it because the grease and dirt prevented it from rusting. I forgot about the idea. But then, things don't rust in the garage space so the idea came back again. Grabbed a cloth and some petrol and started to clean the engine case, rubbing the dirt off. It was being too much work and sometimes I feel I make up these tasks to postpone starting up the car... Quickly abandoned the idea again and went on to attach the airbox to the car.

My initial idea with the airbox was to attach it with the intake pipes turned down to the interior of the car. Then cut the tubes a bit and link them to a scoop I would fabricate on top of the rad. But when I fitted the airbox that way, the intake trumpets on the engine did not slide adequately inside the airbox. Turned it the other way around to make it all fit nicely but it's temporary... I need to make my initial idea work so that I have less to cut on the bonnet.

After the lunch break, the only task accomplished was to bolt on the exhaust header. It was harder than I anticipated mainly because I was working alone. Had to tie one end of the exhaust tube (after the 4-to-1) to the chassis so that it would stay level with what I needed. then another piece of rope to tie the header part to the chassis to help me sustain the weight. After some wiggling and pushing, managed to get all tubes on the engine holes and bolt everything down. Two bolts were playing hard to tighten but I placed some grease on the threads and it slid a lot better. The wonderful look of the exhaust is not visible yet since I did not unwrap it, to prevent scratches and the likes. Will unwrap it before starting the engine.

Next task will be dash electrics or assembling the battery. And I have to go buy oil for the diff, the brake circuit, refrigeration fluid, fuses and some bolts...

Nosecone Grill and Attaching Wingstays

Another night shift on the car (from 22h45 to 00h30). And got some goals archived!

First task was to drill holes on the nosecone to attach the grill to it. Using the dremmel and a 1mmØ drill bit, punched 6 holes on the nosecone. Cut 6 bits of steel wire 7cm long and bent them in a U shape. Then it was just putting one "leg" through the hole, the other through the outside of the cut hole and twisting it together. Bellow a detail of one twisted inside and the grill attached. Later on I'll get to paint the wires...

Back on the car, attached the two bolts that I had left drying last Monday night. Before bolting them down, put some Nural 50 on them. Then removed the ones I did Monday to add Nural 50.

Afterwards, attached the wingstays to the uprights. This task consists of tightening 3 bolts, having each one 2 spring-washers and 2 nuts that hold onto the upright and to the stay, effectively ensuring that not only the bolt doesn't come out of the upright but also that the distance to the tire is correct.

This took me around one hour. The first one was hardest because I was trying to figure out how to reach the nuts to tighten them, so I spent 40m on it. The second one was a lot faster to get done; experience is priceless! The picture shows the upright on the front left wheel.

Doing these night shifts not only got the car build going again as also are giving me a morale boost. Very happy with this!

Refurbishing Bolts and Preparing Grill

Spaz had alerted me to the fact that the paint should be dry by now. And he was right! ;)
After three weekends in a row where other stuff got in the way and I couldn't work on the car, I was really frustrated. So, today I did a bit of work between 22h30 and 00h10. I hope the noise did not bother anyone (since there are 3 stores between the one I was working in and the first with apartments).

When I assembled the front brakes, the bolts that hold the calipers against the uprights were not reconditioned. They were quite rusty but I bolted them anyway. This has been in the back of my mind as something I should not have done. So, started by taking out a bolt on each side and scrub it with the driller and a steel scrub tip. After that, stuck them on a piece of cardboard and painted them black. After the paint dried, I bolted them back and took the other two. This was when I took the "before and after" picture below.

Scrubbed and painted the 2nd set of bolts and left them to dry.

While the paint on the first set of bolts was drying, I looked into fitting the front grill on the nosecone. Steve had told me how he usually does it, but when I asked I had already cutted the nosecone hole and Steve's way was no longer possible. So I was thinking about marking some spots to drill holes and fix the grill with plastic straps, as I believe MK does.
With the dremmel, cut the fixing feet off the grill, so now it sits perfectly on the nosecone. Did not get around to drill the holes, but in a way it was better. The idea that the plastic straps could get cut by the fiberglass was not conforting. And in the mean time I decided to use a bit of steel wire to tie the grill, also using holes. I can later paint the wire black and all. Something to do next time.

It was great to be back on the car!