Monthly Archives: September 2016

More assorted bits… boot box cover, harnesses, seats, carpets, grill and a trip to the garage

40+500 = 540


Wow, another 3 months have passed and no updates… doesn’t mean no progress though 🙂 Albeit slow progress, so a bit of a brain dump and a selection of pics to keep everyone up to date. It’s been a good few months for visible updates, sometimes (wiring!) you spend an age and feel like you’ve nothing to show for it – in this block of time adding the rollbar, carpets, seats etc has made a very different looking car – the rollbar specifically really “balances” the look of then car IMO. Anyway, here we go on a little summary of my garage adventures…

Last post I had a few pics of the beautiful carbon fibre sheet that Mark at Carbon NV made for me, and a few pics of how I’d started chopping it up. As im sure I mentioned, I oped to go straight to a carbon panel (my ultimately plan) rather than utilise the WF boot box because I thought it would be easier… silly me. Anyway, after a lot of measuring, chopping, measuring and general fettling and I do not know how many hours I’ve a 3 piece CF panel that fits nicely in the boot box area – does it look like a new BMW panel finish? No, but I’m really quite happy with it given it’s hand made, hand finished (by me), nothing is symmetrical etc.

What was fun and games was doing the bootbox cover, the rollbar, and the harness eyebolts – you can’t really fit one without consideration of the other, nor can you really fit them all at the same time. What made this whole process 10x easier was a set of small ratchet straps, this meant I could pull in the rollbar stays and drop the rollbar in and out relatively easily, something I must have done 10+ times through increasingly big holes in the boot box. So after a lot of fiddling, some bulky drilling in the lovely Playskool MSA bar they’re all fitted. And I should callout the fitment of the Playskool bar is excellent, very little tweaking needed and very sturdy feeling – and it looks great. Somewhere I have a nice Playskook MSA sticker, god knows where that is – perhaps in the same safe place as the other safe bits I keep!?

With the bootbox cover in and rollbar in you need to mount harness eyebolts. For what I’m doing with seats (JK compsites both sides, driver side on runners – this is not uncommon) I need to raise the harness eyelet height a little to meet some IVA height requirements, this means some spacers – sourced through the WSCC! So a pedant will see one seat is a little higher than the other, they will also see the eyebolt is sat higher (but still threaded enough into the chassis)

Carpets… another nice job. One that did not take an age and make a nice aesthetic job. What did surprise me was how heavy the whole carpet set is, there is quite a thorough set too giving a good finish. And when I say good finish you’ve got to be impressed with the tunnel carpet, there are a lot of undulations in the tunnel – the carpet fits brilliantly. What I did have to do was make some holes in the carpet for gearstick, handbrake and holes to get seat mount bolts in, this was a job for the Stanley knife and it turned out that rough cutting and shaping to get it in place was the key, not super accuracy! And to add to the weight of the carpet I used 20m of heavy duty Velcro to secure it all down, it’s definitely stuck.

What I do need to work on are some surrounds for the gearstick and handbrake, the leathers came with the carpet set and need something to secure them to the carpet, I toyed with stitching but after seeing some amazing jobs of doing this I know this will not play well to my strengths – surrounds it is.

What’s next? dash tidying so that I can seal it all up, but first an annoying problem. After testing my wipers with a little watering can I found 2 things… 1. the wipers want to wipe down, i.e they are going the wrong way, towards the scuttle, not cleaning the windscreen – argh! so the solution here to some stupid oversight on my part is to turn the wiper boxes the other way up (or do something clever with a cam in the wiper motor apparently. Now the wipers were annoying the first time, let alone again. And to add to my frustration was point 2. the wipers leaked water into the scuttle – conveniently over the ECU and the imobiliser! So after a bit of fiddling to redo the wiper boxes, with a  lot more sealant and another stab at the wiper rubber bits I have a better seal and there is no torrent of water into the scuttle. I say better seal, speaking to those on WSCC getting no water in is pretty tough, and that’s what I found, after several attempts with sealant I had some in – but my testing did involve using a watering can over the wipers, so pretty artificial.

Next dash in, wires all finally bound up, and secured down – that was nice to do a few things up, rather than keep putting the steering wheel on and off to take the dash on and off. Something Gary KugaWestie had done was add some connectors to the dash wiring to enable him to remove the lot with a couple of big connectors – when I do any form of dash upgrade this is a must!

Nose cone grille, I ordered some nice black mesh from car builder solutions, I hoped this was going to be an easy task, wasn’t too bad. chopped easily with wire cutters, one can attach to the inner nosecone with holes and small cable ties, I wanted to do so with no visible cables ties. What I did try was cable tie saddles silkaflexed to the inside of the nose – but these ripped out when I tightened the cable ties up 😦 Then after a search I made little blocks of wood around 3cms sq, drilled in the cable tie saddles and then silkaflexed the wood to the inside of the nose, a much better bond and it doesn’t pull as much on the silkaflex, much better! mesh in!

Harnesses went in a the same time as the lovely seats from JK composites. They are indeed very comfy as everyone says, especially when sat in your lounge – not done any long journeys yet… The harnesses are playschools RaceLidsz ones, are nice and wide FIA approved and tighten up by pulling “in” which is handy in such tight confines. I am sure I will get used to this, but getting in and out is a skill im sure, currently I keep sitting on bits of harness, or when in can’t get them easily, sure there’s a knack…

Currently I’m mid way with the cycle wings. There were two options for me here, either the book way – bolts through the wings into the stays, or using fibre glass and “big heads” to make securing not visible externally. My plan all along was to go the “big head” route, however with time going on, me quite liking the black annodised hex bolts and one day wanting carbon fibre cycle wings I’ve gone the bolt route. One is nearly done and looks fine – the stays did need a bit of a bend, after a bit of reading the solution was levering them with a big long bit of wood – everything else I tried (elongating holes, hitting, etc did not work 🙂


Final comment on this post is the day the car left the garage 🙂 Thanks to the very helpful people at the local Ford garage the WF had its second go on their flatbed (first was moving house you recall). This time down to the Ford garage for headlight aim, brakes and emissions. “2 out of 3 aint” bad as has been said. Headlights were promptly pointed in the right direction, if a little down by default. Brakes were – and I quote “spot on” – which I was happy with given I refurbed the calipers with new everythings – and I am on a very steep learning curve! Anyway, breaking evenly in all corners.

Emissions… it did not pass here, no matter how many goes we gave it, HC, Lambda were fine, CO2 not, and only at “fast idle”. See here for the full story

What I suspect was the issue was either that the lambda sensor was not at all tight, only finger tight at best, and that there were some takeoffs on the intake side that were not in terribly well. What I am deciding (rightly or wrongly) to do is have another go on the emissions machine before IVA, it was a bit of a pain getting the garage to get the car, so with the steps taken hopefully I should be okay!






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