Sunday, March 28, 2010

Well here we go again, I have now welded up the fuel tank. 3 times.

At the first attempt, I filled the tank with water and it leaked in 14 places. Actually, i wasn't too disappointed as it was my first ever go at making one.

Second attempt, It leaked in 5 places.

Third attempt, it now only leaks in 1 spot - and it's one I previously marked up but missed. Next go I'll have it sorted, I'm confident.

I have also painted the battery tray, and fabricated the fuel tank holding brackets. The last job i did yesterday was to line them with rubber strips, to stop vibration from the chassis when the car is in motion from damaging the fuel tank.

Next on the list once the fuel tank is leak-free is to paint it (I'll have to be expensive and use 2-pack paint for it that is resistant to petrol) and finally fit it to the chassis. Once it's installed I'm going to plumb in the fuel lines.

Sunday, March 21, 2010

Well apologies for not posting again sooner, but my home laptop has completely died.

The good news is I have made good progress. The one panel that needed fitting became 3, all done, as is the pedal box bulkhead. It's not my neatest ever work, but will be hidden from view anyway so I'm not too concerned. It's strong and does it's job.

Moving on from the paneling, I have managed to re-fit the engine and gearbox, attaching the propshaft along the way. It's all now tightly bolted into position - fingers crossed I don't need to take it our again! To me it marks a mojor milestone in the project, as the running gear is now completely assembled. It actually completely confused me yesterday, I needed to roll the car a few feet up the garage so i released the handbrake and pushed, it wouldn't go. It felt like I had left a chock by a wheel, but I looked around and no, I hadn't. I pushed again - won't move. ????? Oh yeah, it must be in gear, dopey prat.

Well I was a vey busy bee yesterday as I moved on to the next item on my to-do list and fitted the battery by fabricating a tray, welding it in position in the rear of the car (no room at the front - it's a big battery) and fabricating a clamp to hold it down.

Today I hope to make the fuel tank, indeed already this morning I have cut and folded the steel for it's main structure. I'll weld it up later on, and try to fit the pump/sender assembly.

As always, I'll post pics when i can.

Monday, March 1, 2010

I got some more done yesterday, and hit a problem or 2 as well.

I finished all the welds inside the engine bay that weren't accessible with the engine in place and ran and fixed the reamining front brake pipes. The front half of the braking system is now complete. The rear half just needs 2 more little flexi's.

I was then looking to see if I needed to do anything else bfeore refitting the engine. One thing has become clear, re-fitting the engine will be a 2-person job as the engine mounts, propshaft and gearbox mounts need to be aligned all at the same time, and it has to be done without hitting, snagging or otherwise damaging the lovely new brake pipes.

The other snag is that I need to fabricate and fit one of the panels for the gearbox tunnel, as it needs to be riveted on from the inside, which would not be possible with the engine and box in the way. I made up a template from corrugated plastic sheet - which was rubbish. I need to make another one. The difficulty is that the panel has to fit around the clutch master cylinder and it's pipe, without touching it.

I also need to panel in the end of the pedal box, which is a really complicated shape. I really have gone and made this difficult for myself.

I'll keep you all posted.