Best day of the project (so far!)

It's been quite an exciting week on the build, lots of pics and a big update ahead...

It started out a little frustratingly having to un-do the inlet manifold. I was sorting through some of the old bits from the donor car, and coincidentally reading up on the fuel injection system, when I realised that I'd taken off the idle speed control valve and the oily mist seperator - both key systems which I'd earlier mistaken for secondary systems such as evap and seconday air injection. So I had to remove the inlet manifold (in istelf no small task) and with a fair amount of effort, hassle, research, forum reading etc. I managed to figure out which way around it was all plumbed in. (thanks to those who helped me, particularly Trev and Dave Rodgling from gkdoc.com)

earlier removed ICV, and hose from the manifold  that I'd already blanked and filled with gunk, will have to be re-made

ICV and Crankcase Ventilation reinstalled - lucky I kept all the brackets etc. from the donor

Then on Saturday morning at 0927... this happened...

Hasn't got a shiny nose, a sleigh or even a cheery disposition... but it might as well be Christmas

I seem to have had quite a few Christmases already this year, but this was an additional one - all the remaining components to get me to a rolling chassis. (thanks GKD! Particularly for rushing it through for the weekend for me)

Rear Track adjusters, front uprights, steering shaft, rack extensions and column bush, fuel tank straps and fuel cap - Thanks GKD!!!

 So it was straight up to the workshop and on with the goodies. Pressed the bearings onto the stub axle, didn't really require any effort at all, and then tightened up the hub nuts 250ft-lbs... that's mega tight to the uninitiated and took a good dose of grunt and the almightiest of my torque wrenches:

I then did the rear track adjusters. No pics because it didn't photograph very well, but all didn't go quite as a planned. There was quite a bit of powdercoat in the threads, and it was difficult to get anything in there to clean all but the first two or 3 threads. With hesitation I gingerly wound in the rose joints, and then my worst fears were confirmed when they went tight after the 3 threads. I took them out only to find that even after only a finger tight application of torque, the threads were a little bit chewed. They are also left handed threads so it's not the sort of tap you carry as in stock... so a little bit frustrating, but I decided that there was not much else to do except shove them in and worry about it later. Think I'll end up buying/making a new set and perhaps painting them instead. But, rear suspension complete(ish) for now.

 Next up, front brakes. My mate Trev came up to offer a helping hand, initially more for the brake bleeding and the big event coming up shortly, but an extra pair of hands was most welcome and allowed us to team up and get more done.

Trev building up the front caliper with new seals

 Finally, all four wheels attached and looking awesome... (the car, not you Trev) it was time to bag the first major milestone - Drop it on its wheels!

Pre-flight checks

 Started by lowering the rear, in the end settling to use a strop around the diff

 We then did the same on the front, note the use of cleverly positioned blocks of wood to prevent the crane fouling on the suspension

Heave...

 And then, finally, she sits on her own wheels!

The Legend has Landed

 This took a fair while, and we wanted to ensure we did it safely to risk damaging the fragile fleshy extremities that we humans have grown quite attached to, and also, risk damaging the car. (According to Emma has actually now reached the point where it can be referred to as a "car")

So after a monster tidy up session, it was time to go home and call it a night.

The next (Sunday) I found myself in the fortunate position of having 2hours before the official functions of the day were due to kick off... plus I was told to "disappear up to the unit" instead of moping around on the Internet and reading kit car magazines. My new wife does indeed know me well.

I decided that the steering should be easy to tackle in this gifted time period.

I attached the upper column to the lower column and got the steering to actually steer - that was another exciting moment. I then had to fine-tune the position left and right between the top UJ hitting the crankcase, the steering wheel being roughly centred in the cockpit, and the lower fabricated column fouling on the suspension upright. Think I got it roughly right, but there's a bit of a kink in the lower fabricated shaft. Might have to come off again at some point to be straightened, most likely done by the grumpy postman who either isn't paid enough to care, or just hates people.

It also looks interestingly close on the exhaust manifold, haven't yet fitted that... could be some interesting manoeuvring in the not-too-distant future

Steering actually working!

As that didn't take too long, I decided it was high time to get her outside to see the sunshine. Plus pose for a few photos, and give me a chance to properly sweep the floor which had been covered up since February-11 when I got the chassis, so I used the trusty Landy to help pull and shove and did a bit of pulling and shoving myself;

using one of my favourite mantras "Pics or it didn't happen" I'll let them tell you the rest:
 

 There was also a method in my madness - I was able to winch it up to the top of the yard and "drive" it back down into the workshop, to test the brakes and steering. It was quite possibly the world's dullest, least powerful and slowest test drive, but a test drive nonetheless. Hence this being the best day so far!!

I did learn a few things from the exercise

• Wheel setup needs to happen - at present all four wheels point in different directions and even at 0.005 mph you can feel the tires scrubbing. Will be able to set them up roughly, but the geometry will have to be done properly at some point.
• Footbrake works really well, initial travel is a bit spongy, but they bite good and firm. Happy with that.
• Handbrake - not so great. It works but only just and at 8 clicks is no good. Will have to adjust the cables and see what happenes, although the adjustment is only supposed to be for cables stretching over time. Will see what happens with that.
• Steering is fine - very smooth and precise.
• 20mins of effort for of rigging/dragging cars around for a15second roll... means I have to get this engine running ASAP! Or cancel the gym subscription...

So all told, pretty awesome week. I'm happy with everything that I've achieved, really grateful for the help and support from friends and other builders, and GKD pulled out all the stops to ensure I achieved this milestone. Only fair that I actually made it then! The car is also starting to look awesome, which makes it all worthwhile.

Next I'm going to turn attention to the manifold and cutting the aperture for the exhaust primaries, and fuel tank. I believe I'm about 50% through the build now, although with the wiring loom, ECU and engine start I reckon I've got some interesting times ahead.

I've also been told by Peter that there's a slight change on the cards ref. IVA and how the foglamp is activated - has to have a buzzer to tell you it's left on when the key is out of the ignition, or not be latched by a "hard" switch. Only a minor thing but it technically means my loom will have to be modified, and therefore I'll have to wait a bit longer for it... Still, never mind, plenty to be getting on with.

Thanks for reading!



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