Rear end work

As well as fixing the handbrake cable in, we also installed one side of the drive shafts into the diff and bolted the hub to the hub carrier. Before we installed it we replaced the CV boots on the drive shaft. We were unable to do the other side as euro car parts had supplied the wrong CV boots and they were too big. Therefore I have to take these ones back and get some of the smaller ones. Next job once I have these will be to install the other rear corner drive shaft. The drive shafts just push into the diff.

Handbrake cable installed

Today I installed the handbrake cable a threaded it though the holes in the chassis in front of the diff. I now need to fix it permanently in place once I am happy with the exact location. I need really to have the fuel tank in place so I can make sure it is in the right place. The fuel tank is on order.

Another view of the diff

Here is another view of the diff from the side of the car.

Diff mounted in chassis

It took me some time to work out what to use to mount the diff on the diff mountings on the chassis. The manual said either use 220mm M12 bolts or threaded bar. Therefore after much debate I decided to pop to screwfix and buy some threaded M12 bar. I got back and cut this to size ready to install. The installation proved quite hard as the diff is quite heavy and so needed a few persuasions from the old rubber mallet to get the threaded bar through. Anyway it is now bolted in safe and sound and looks great.

Rear suspension fitted

I spent almost all day on Sunday in the garage and after many hours it didn't look like I had achieved much. However I did manage to build up the rear suspension, and the pictures show this. The only thing left to go on are the shocks and the drive shaft through the hole in the rear hub. What didn't help on the near side was the fact that MK had given me a bolt which was too short so I need to call them to get another. Therfore I used the shortened bolt until the new one comes.

New brake drums

I have now received my order from euro car parts and included in this is the new brake drums.. Picture shows the new drum.

Diff now finished

I took the diff to Phil Jones to get get it rebuilt and reconditioned, he has done a great job and now it is ready to be bolted onto the car. I hope to get this completed on Sunday.

More reconditioning

In my last post I had mentioned that I had taken the brake drums apart to install new components, as well as this I also have painted the back plates ready to fit the rear brakes bake together again.

New parts ordered

Today I ordered the replacement brake drum parts that I need. I ordered new drums and slave cylinders and also new CV joints to replace the existing ones I have that are shot.
I have also spoken to MK and will be ordering a radiator and brackets.
I have also ordered some shim washers and various size P clips for attaching the final parts of the brake pipes. Just need to wait for all of it to come now...

This picture shows the contents of the drum brakes post me taking them out of the drum, these are what I need to replace with new parts. I will also need to refurbish the clips and fixings and clean these up.

Brake drums inspection

I decided to take the brake drums apart to see what condition the shoes and the slave cylinder were in so I carefully took it apart and decided that I would be better off changing the shoes (already bought some replacements) and also the drum was in a rough state covered in rust so for the sake of £30 I could get some new ones. I also decided that the slave cylinder needed changing and so took this out. I will pop down euro car parts this week to order up some new ones so i can fully refurbish the drum brakes. The picture shows the back plate with the contents of the drum brakes taken out.

Another pic of the steering rack

This picture shows the steering rack from the side installed on the car.

Its been a while - steering rack added

Its been a while since i worked on the car the summer has gone, and due to holidays, illness and enjoying ourselves most weekends I haven't had the time to work on the car. I decided that this sat I would dedicate a day to working on the car and managed to do a number of things. Firstly I cleaned up the steering rack and installed this. Then I did some pre planning and worked out a shopping list for the coming phases of the build. I then thought I would install the diff and I undid the plug and drained the diff of oil and the rubbish that has been in it and at this point I noticed it was leaking quite a lot of oil to the underneath ofthe diff. After some thought I decided that I either needed a diff that wasn't going to leak or I need to recondition the diff I have. I am currently researching what to do on this as there are diff recondition packs you can buy and I think this would be the best option.

More brake pipes

A further image of the brake pipe install.

Brake pipe install

Mark came over tonight and after having a look at the new loom from premier wiring that came today we set about fixing the brake pipes to the master cylinder and then attaching them to the chassis via the brake pipe clips. 6mm holes were drilled for this and then the clip inserted into the hole with the pipe then fixing into this. We then had to use the brake pipe bender (what a gadget) to bend the pipes in the relevant directions to make a neat and tidy job. I found I was missing some pipes on the rear so will need to contact MK to get these ordered. I still have some further work to do to P clip some of the pipes, which I will do this weekend.

New brake drum shoes purchased

I have decided to refurb the rear brakes before I fit them and ordered new brake shoes to go inside. I ordered them from euro car parts and I got a set of 4 for £24 which I was pleased with. The picture shows one of the new shoes ontop of the drum.

Brake drums cleaned up

I spent some time clearning up the brake drums and finished off by painting them. I also need to refurb them ready for going onto the car.

A bit of cleaning and some donor part refurb

I spent some time today cleaning up the front hubs and also the rear brake drums and axles. I cleaned them up and then painted them

Floor on and riveted

This weekend I finished the floor but it didn't go as smoothly as I had wanted it to.
I started by putting the sealant onto the chassis and then lowered the floor onto it, lined it up and then put the rivets into the holes ready to rivet it. I got my lazy tongue riveter out to use and on the first rivet it broke. It just would not spit out the rivet redundant part. I then had to make a decision either to carry on and use a hand riveter instead to rivet the whole floor before the sealant went off or go and get another lazy tongue riveter from somewhere. I thought I would use the hand riveter but after having done about 20 rivets (my my hands shaking from the effort required),on a boiling hot day I gave up and quickly visited machine mart in Bristol and bought another lazy tongue riveter. I managed to then use this to complete the job. The picture shows all the rivets inserted at gaps of around 5 cm's.

Floor continued

I was joined in the garage today by Mark a friend who has built his own MK Indy blade recently and I really appreciated his advice and guidance. We both worked on getting the floor attached by continuing the prep work needed to do this.
Next we placed the aluminium floor on top of the chassis and clamped it in place. We then drilled 3mm holes in the floor into the chassis (every. Once we had done this we then increased the size of the holes to 5mm with a larger drill bit. We then went round each hole and got rid of any rough edges from the holes.
We also drilled 3mm holes in the transmission tunnel and various other areas which would be hard to get to once the floor was in place. This was an excellent piece of advice from Mark, thanks Mark.
Now its time to attach the rivets and get it attached.

Floor work

It was time to get the floor attached to the chassis, so initially I turned the chassis upside down and I was ready to drill the holes.

Missing parts turn up - at last!

After many frustrating weeks the 2 missing parts have arrived and now I can get on with the build. The missing parts were the floor panel and also the interior panels. This weekend I hope to do some further donor part refurbishment on the brake drums and also start riveting the floor to the chassis.

Steering rack and Propshaft refurb

I also spent some time today cleaning and painting the steering rack and prop shaft these now look quite tidy and ready to go onto the car.

I also visited euro car parts today in Filton to spec up the bits I need for the refurbishment of the brake drums on the rear, i will be getting some new shoes and also new drums.

Diff Refurbish

I spent some time today cleaning up the donor parts, I started with the diff and cleaned and painted it, picture below.

Refurb work this weekend

I plan on spending some time this weekend sand blasting the donor parts and getting these into a nice tidy condition ready for fitting on the car. I can use my sand blaster kit I have which attaches to the compressor. I also plan on painting the donor parts once they are clean and tidy. I may also pay a visit to euro car parts in Filton to but some new parts for the brake drums i.e. new shoes.

Lost parts delivery

After what seems an age the parts that I need to start the build should be on my way to me. MK forgot the interior panels and the floor so have couriered these to me, but they sent them the first time with the wrong postcode on, I should get these Monday and can then get going.:-)

Kitcar and donor parts arrive part 2

The photos for the arrival of the kitcar and the donor parts can be found at the following link:
http://www.flickr.com/photos/jes100/sets/72157619118738011/

Kit arrives

Finally after months of waiting and preparation the kit arrived today (well minus the aluminium floor which they forgot!). I need to get going now on it, but guess which is the first part that needs doing, you guessed it the aluminium floor!!!!. Its being posted out to me on Thursday.

Compressor ordered and arives

I decided to get a compressor in the end after much deliberation and found a good one on ebay for not allot of money, it has a 50 litre tank and is powerful enough to run my air riveter and various other tools. Here's to trying it out very soon.

Kit Delivery

MK confirmed today that the kit will be delivered with my extras next week. Cant wait to get started now. More garage action required this weekend if I am allowed (wife is dragging me to see some of her friends).

Air compressor?

Today another delivery of rivets arrived, different sizes to the ones I had ordered previously. These are 5mm v 16mm and are to be used to rivet the kit floor to the chassis.
I have been debating whether to hire or even buy an air compressor so I can use an air riveter to put all the rivets in, will certainly be easier on the hands and arms and make a long and tiring job that little bit easier. Compressors are quite pricey but they are one of those tools that you can keep for years or even sell and get most of your money back when you have finished with it. I need to do some research to help me make a decision.

New steering wheel and boss ordered

I saw a very nice car at Stoneleigh that had a suede steering wheel with a paddle shift system on the back. I have decided to order one of these wheels with a ford fitment boss for my MK, picture attached.
I will need to order the paddle shift system from Mk directly later on in the build.

Acewell arrives

The Acewell dash unit arrived today and looks very nice indeed, I am glad I went for the carbon case, just need to work out now how I wire it up and how I integrate it into the dash. Boys and their toys.

Temp Wheels purchased for rolling chassis

I have decided to purchase some old allow wheels and tyres to enable me to roll the car in and out of the garage. So rather than buy some expensive new black alloys which is what I want the Indy to have eventually I will use these wheels for now. Not a bad purchase off of ebay for £40.

Kit delivery date

MK have confirmed today that the kit delivery date will be w/c 25/5 - so just 2 weeks to wait I hope.

Acewell in operation

This video shows the digidash in operation
http://www.youtube.com/watch?v=VLX-41D70Z8

Digidash purchased

Well after much deliberation I have decided to install a digidash into the MK rather than a standard set of clocks. After much research I have decided to go for an Accewell 3351. I decided on this one for a number of reasons, 1. It has the warning lights I was after and need for IVA and 2. I have read a number of very good reviews for this model from kitcar owners and 3. It is well priced for such a unit.

I enclose a pic with the carbon fibre dash attachment and the link below provides more information on the unit. That will be the last shiny bit I purchase for a while as I need to concentrate on the actual kit and the consumables required for the build.

http://www.acewell.co.uk/en_uk/kit-car/index.htm

Seats purchased

I also purchased 2 carbon fibre seats at the show and I am very pleased with them. They are very light and perfect for my car where I am trying to keep the weight down to a minimum.

Exhaust Manifold purchased

These is the exhaust manifold which I picked up at the Stoneleigh show, its very shiny and I am looking forward to putting it all together. Mind you there are plenty more jobs to do before I get that far!

Steering rack reconditioned

My donor steering rack got an overhaul today with a sandblast and a few tweaks to bring it up to standard. I am very pleased with it.

Engine Arrives

I picked the Honda Fireblade engine up at the show on Sunday and am very pleased with it. I also picked up the carbs and exhaust system which looks superb.
Now the hard work begins :-)

Stoneleigh Pics

These are a selection of pcitures from the Stoneleigh kit car show.
http://www.flickr.com/photos/jes100/sets/72157617589067499/

Stoneleigh Show 2009

Well I have just returned from an amazing kitcar show at Stoneleigh near Coventry. It was advertised as the largest kit car show in the world and I wasn't disappointed, there must have been well over a thousand cars there all looking lovely in the May sunshine. Together with the owners cars were a whole host of show stands with parts suppliers, kit manufacturers all vieing for your business. I went with a large wad of notes in my wallet and came home a whole lot lighter. I purchased a whole host of new tools and also purchased both my engine and carbon seats which look stunning (I will post pictures of these on Monday). I also came across a car on the MK stand that is a similar spec to what mine will be once built, it had a blade engine and was orange with black cycle wings the same colours I have gone for. Anne wasn't convinced by the colour but I thought it looked superb and will certainly not be missed with these colours.
The show was great but what made it so good was the people and the great weather, it was nice to wander around in short sleeve and enjoy the sun.
I will be spending bank holiday Monday (if I am allowed), finishing the garage, I have bought so many bits I need to find somewhere to put them now so they wont interfere with the build until I actually need them. Off to the pub now to enjoy the sunshine, until next time.

Cool build diary site found

I today came across this superb MK indy build diary of a chap called hellfire, have a look its brilliant: http://www.mkhellfire.co.uk/

This weekends activities

On Sunday we are attending the worlds largest kit car show at Stoneleigh. I have already purchased a number of parts which I will be picking up at the show. The main part I will be collecting will be my engine, its a 900cc Honda Fireblade (blade) engine with only 10k on it. I have also ordered some very light carbon fibre seats with runners and a steering rack.
I am also in the market for some further tools and consumables. It should be a good day, lets hope the weather is good so I can threaten the world with my legs by wearing shorts and my very 1960's new pair of sunglasses I bought in Canada.. :-) Anne wont be seen with me wearing those.. LOL.

Another delivery and Stoneleigh

The security guard at work is now getting very fed up with me as he has to call me each day to tell me there is a parcel for me. Today I received another box from screwfix with circa 2000 bolts and nylocs, kind of essential really when you want to build a car. The only problem now is I need to lug these to the car to take them home... my poor back.
Its the national kit car show this weekend at Stoneleigh and hopefully with good weather this should be a great show, will be after a few bits that I still need and hope to chat to a few MK owners to get some tips and tricks.

Evening class

Last night I started my college evening class and had a great time. It is held at the city of Bristol college in stoke gifford and is split into 2 phases. The first phase teaches you the basics of car servicing which is the course I started last night. The second part is the advanced part which is probably the part I will get the most from for the kitcar build. The class was very relaxed with an equal spread of girls and boys. Last night we took the tyres off our own cars and had a look at our brake pads and discs. Then we used the college car to change the pads and discs, it was a great first night and I look forward to the next installment in 2 weeks time. At least this gives me 2 weeks to do my homework :-)

Garage prep finished

Didn't get to spend as much time today on prepping the garage and finishing a few jobs as I had wanted as it was the last Swindon home game of the season so was at that until mid afternoon and a good result of 2-1 against Bristol Rovers means Swindon are safe for another season in league 1.
Anyway back on to kit car matters, I visited Machine mart today and purchased a tool trolley and a new pro socket set, I also bought some more racking for the garage to store the donor parts on. I put all this together today and now the garage is finished and ready to accept the kit in 10 days and counting. The only job I have left to do now is move all my tools into the new tool chest, but that can wait until Sunday after the GP.
Good to see Lewis in 5th place on the grid just behind Jenson, lets hope one of them wins the race on Sunday.
Until next time.

New drill purchased

I decided that considering the amount of drilling I am going to be doing in building the MK that I ought to get a decent drill so decided to put yet another order in at screwfix, decided on a Dewalt cordless to replace my old black and decker which is on its last legs.
http://www.screwfix.com/prods/73596?cm_sp=AOVDriver-_-Cordlessdrills-_-Dewalt18V&ts=19235.

It should be here on Thursday so will test it out this weekend.. I never thought I would get so excited about buying a new drill, shows how sad I really am.. :-)

More bits and more money

I have spent the last few days assessing my tools and bits I will need for the build, and worked out that I am not very well prepared. So to counteract this I decided to put a large order in at screwfix. I ordered : Plastic P clips for brake and fuel lines, heat tubing wrap, 50 piece titanium cobalt drill sets (x2), more nylocks, sikaflex 221 PU sealant (x10), more rivets (closed end type) and about 500 washers of various sizes. I feel sorry for the poor courier's back when he delivers this lot on Wednesday. Until next time.

More domor parts ordered

Today I decided to order another batch of Sierra donor parts which will arrive with the kit in early May, I also ordered some PU Adhesive and a box of rivets and riv nuts. I am trying to establish an essentials list which will make my life a bit easier when the next part of the kit arrives.

Donor parts start to grow

I have managed to source some Sierra donor parts already, I have front hubs, brake disks, drive shafts, brake calipers and a steering rack. I just need a chassis now to fit them on.. Pic attached to show my collection of donor parts building up.

Garage cleared ready

I spent several hours today sorting the garage ready for the kit to be delivered in a few weeks time. I never knew I had so much rubbish!, I cant believe I used to fit all this stuff in a single garage in our last house.

I also went to B&Q today and bought another saw horse that I will use to stand the chassis on prior to getting the wheels on. These can accept 2 tones so I should be OK. Also ordered a couple of axle stands just in case I need some further stability.

A pic of the newly tidied garage is enclosed here.

Until next time.

This is what it will look like

I thought I would add a "this is what it will look like" picture for inspiration. So here is one.

What Diff

I am trying to get my head round sierra differentials and which configuration is best for me. I think after much research that a 3.62 diff with a limited slip diff will be a good choice. Now I need to find one, there is one on ebay but the guy wants £179 for it which is far too expensive. Time to start emailing a few scrap yards I think. Until next time.

It's been a long time!

Its been a long time since my last post and in this time I have been debating whether I have the time to complete the work so I cancelled the order, but I am glad to say I have now decided to forge ahead with the work and re-ordered my kit with MK. The next phase of the order will be with me in early May and I cant wait.
Here's to a good build and I am glad I have talked myself into this mad world of kitcar building once again.