Author: paulyork2004

The Master Cylinder…

…has it’s adaptors in! Hurah!

After many hours swearing at the impossibility of getting the Dax adaptors into the cylinder, the job is finally done.

In the end I had to take the adaptors sharp lip back by 1mm, rounding it in the process. Altered version on the left…

The plugs we’re taken back with a file, emery paper and a drill. All very professional…

The plugs still didn’t want to go in but with some brake fluid and some gently applied heat to get the rubbers softer they finally wriggled in. I think it was the heat gun that finally did the trick followed by much wiggling. Using a vice didn’t really do much except try to squash the rubber bungs futher back in the cylinder.

The plugs are now set in place nice and flush…

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Spot the difference

What 3 posts in less than 2 weeks!  Shock horror but I managed to slip away to the garage for another few hours this afternoon!

You may not be able to tell at first glance but the pictures below are very satisfying!

 

The pipes are hanging there without the heater and¬†any blocks of wood propping them in place! ūüôā Woo Hoo! ¬†What should have been a quick job with two holes to drill for the passenger side bracket turned into a bit of a pig as my drill bit that I use to do the pilot hole snapped in the hole and I couldn’t get it out. ¬†The only way I found, in the end, was to blunt another three bits with brute force and drill the drill. ¬†I now need to buy a few replacement bits but it makes me happy that the side pipes are now in place with all the gaps symmetrical on each side thanks to the rubber head of a rubber screwdriver for hand gap gauging.

The next job I thought I’d tackle was adding the hinges to the boot. It’s being lying in place for what’s most likely several years but I’ve never added the hinges. ¬†With this new found gusto I’m on a mission to use up all the parts I’ve bought in the past before buying any more. ¬†Hopefully this will mean that the garage naturally tidies itself in the process! ¬†We’ll after re-introducing the second hoop, lots of measuring and marking and tying a string in place on the nose and waiting it using a lump of wood at the back all the centre lines ¬†have been marked but there seems to be one minor issue… ¬†…I’m not sure that I ever bought the rear hinges. Doh! ¬†At the time my idea was to have a hidden hinge at the back but I’m not sure I have the skill to achieve this and Dax and DB don’t seem to sell a kit that I can buy that would achieve what I’m after so it’s back the traditional external hinges. ¬†I’l leave things marked up for now and hope as¬†the garage starts to tidy itself a bag of hinges will appear or I’ll confirm that I don’t have them and get some ordered.

Lastly, the oil cooler has been bolted in place. ¬†Coated with some foam shock dampening tape on the bottom and with the aid of the centre line¬†it’s been bolted to the Cobra’s fireglass nose. ¬†I wasn’t sure¬†that this would be acceptable but after looking at a few “in-progress” builds at the Dax garage a few weeks ago this is exactly how they have done it so it just leaves things to be plumbed in now to move the engine bay area forward.

Till next time…

Build Time : 220 Hours (possibly)

Doors!!!

What a difference a few bolts make! The doors are on, plus one side pipe is mounted at the rear to the chassis (just not on the pics) and the other is ready for mounting.

The bolts of the door hinges are a pig to tighten because of the limited space within the door and because the studs are sooooo long meaning you spend more time in that limited space grating your knuckles for as long as possible. I chopped one set down to ease the pain but I could have taken another 10mm off the stud happily. In the end a 13m angular rachet spanner made the job more bareable.

Cutting a 3mm steel bar into small sections and sticking them around the door opening provided some simple consistent spacing to sit each door on and with a little bit of sanding for the drivers door both lined up with suprisingly little pain.

One top tip for those that buy their exhaust pipes from the good man that is Dave Brooks – your rear brackets, bobbins and bolts are packed inside one of the pipes! Mine fell out as I fitted the second side pipe and I’d shelled out money for the bits from Dax! Doh!!

Build time: Another six hours on…

Side Pipes

Both holes are now cut and opened out correctly in the body. The collectors have been on and off half a dozen times or so trying to get the clearance neat and equal all round, but the holes now seem to be correct.

There have been issues on both sides trying to get the collectors far enough onto the headers to allow them to run parallel to the car. After tightening up the header bolts, and pushing, shoving, swearing and employing the carpet and hammer trick I still couldn’t get them closer than comming out to corner just over 2 and a half inches from the body whereas I needed that gap to be about an inch. Looking for alternative suggestions I found a forum post that recommended just chopping a little off each header pipe’s end from the man that made them so after doing just that, they’ve gone on and now fit perfectly.

They need to have a self tapper put in place on each side, from the headers to the collectors to stop them dropping during use and I need to pick up a couple of powder coated brackets from Dax to allow me to tie the back of the exhaust to the chassis using two large rubber bobbins as vibration dampers.

Now onto the pipework for the engine and getting the thermostat in place and water-cooling all linked up…


Build time:???

Power Issues

My last two trips to the barn have been cut short with power issues. In sub zero, with no lights, power or heating I must admit I’ve bailed early.

Today it was a little warmer and whilst I had the use of a temporary extension it was enough to run a heater from for an hour. Rigging up the reversing light and a small LED battery powered unit gave me enough for a late but welcome hour in the shed cutting the exit for the driver’s side quad collector for the headers.

The hole is now cut and collector through. It needs to be opened up and tidied but the next step is to ease them on… …Or wrap them in a carpet and hammer with all my might as another tipped.

Catching up…

I’ve managed to spend possibly 12 hours on the lockup since the engine went gone in and whilst no great big steps have been completed a few key bits have been started including getting the header pipes in place (not finally fixed) and the exits through the body marked on one side and cut on the other. 

Another small thing but big relief is that it looks like the steering shaft cuts through from the bulkhead through the header pipes without fouling anything. I had thought that I may have had to move the bulkhead bearing further inwards which would have been a massive unnecessary faff but it all looks good at this point which is good. I’m sure it has time to go wrong too though.