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Post by lemans75 on Dec 3, 2019 15:57:40 GMT
I just finished up my headlight covers and realised after the fact that I didn't take any photos which is a shame because I think I came up with a way of doing it that might help others.
So here's an after-the-fact photo that shows my method:
After some mockups I found that the width of the paint on the cover is the same width as my standard electrical tape so I did the following to get a perfectly consistent width.
- Apply electrical tape to the outside (yellow tape)
- Apply painters tape to the inside, following the electrical tape.
I used plastic "sharp edge" tape rather than the paper painters tape because it stretches around curves nicely.
- Spray paint the inside edge in multiple light coats to prevent runs
One last thing to be careful of is drilling holes to receive the cover in/on the headlight bucket. I am putting 4 screws (top, bottom and on either side) and three are fine and easy to drill but the outside screws (on either side) are a little tricky. Since you want to drill horizontal to the cover, if you go too deep you'll pop-out into the bucket (I found out the hard way). So use a small screw on that edge! Here's a photo of the offending screw hole I'm referring to:
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Post by lemans75 on Dec 8, 2019 23:30:43 GMT
Another headlight trick I haven't seen posted elsewhere but that's maybe because it's a given, is applying a small seal to the headlight bucket.
The added benefit is that it prevents the distortion of the plastic that I've noticed on other builds.
The stuff I used is basic adhesive-stripped draft seal neoprene:
And here it is with the lens installed:
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Post by ancsportscars on Dec 9, 2019 8:43:58 GMT
Very neat, James. Did you sort out your emissions issue in the end and are you now fully road legal? Appears to be a good colour match on the paint for the lens edges - what colour code did you use?
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Post by lemans75 on Dec 9, 2019 13:24:48 GMT
I got very lucky with the paint, it's called "Forest Green" from my local hardware store. I took the disk I cut out for the headlights shopping with me and used that to find a match but I didn't expect to get it so close.
I've been given a temporary waiver on the emissions front. I still have a rejection sticker but have been told to "keep driving" which is exactly what I plan to do once the snow melts. To be clear, it's the evap and EGR readiness that are holding things up and apparently those are notoriously tricky and there's a convoluted set of steps that is supposed to get those cleared.
If anyone has experienced the same thing, please share!
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Post by R2S on Dec 9, 2019 21:28:35 GMT
The headlamp finish is really clean love it.
On the evap and EGR issue did you remove the under bonnet canister or any parts of the system?
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Post by lemans75 on Dec 9, 2019 23:18:16 GMT
That's the mystery, the only piece I removed was the catch can which on the NB is not a charcoal canister (it is empty and I can blow through it in both directions quite freely). The charcoal canister on NB cars is moved to the rear of the car near the tank and I have retained it along with the assorted hoses and solenoids.
I also removed the cruise control which has a hose going into the intake manifold but I capped that using the rear light rubber grommet method.
I don't have a check engine light and no other codes are present.
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Post by R2S on Dec 11, 2019 23:15:27 GMT
Main reason I left everything in place with plan to remove as and when post IVA was to avoid any surprises, glad i did because even leaving vac pipe off the servo initially resulted in cars refusal to turn over for more than a few seconds, lots of head scratching connection of only pipe missing (said vacuum pipe) and everything ran smooth.
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Post by lemans75 on Dec 12, 2019 13:53:43 GMT
I tried to approach the build the same way and only removed what I was 100% sure would not result in a CEL or other issue. The car runs and drives perfectly with no issues at idle or at speed so I think all my vacuum lines are in the right place but it won't hurt to triple check...
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Post by lemans75 on Feb 10, 2020 0:46:06 GMT
Winterized and immobile, it's time to finish up some much neglected bits and pieces. First thing to do is the "gills".
Since I don't need to vent the engine, I'm going to make them "functional" to simply provide some foot well venting. Not wanting to rivet into the fiberglass, I went for hex bolts that I countersunk for that aero look. I'll be removing the backing so that at some angles you'll be able to see through the body.
I think they will look better color matched to the body.
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Post by mtparnassus on Feb 27, 2020 13:11:29 GMT
Fellow enthusiast here in Mystic CT and seriously considering importing a Kit. I'm hoping you'd be willing to share a bit of your experience with getting your kit here. I've been in touch with Andy and Jase, BTW. Thanks for any advice you can offer. Your blog is spectacular - really nice job with the build! Brian mtparnassusvineyard@gmail.com
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Post by R2S on Feb 29, 2020 14:44:38 GMT
Take a look at build thread 'Replicar for Arizona'
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Post by lemans75 on Mar 26, 2020 22:50:20 GMT
Some progress being made on the side vents. Right hand side is done... Here's the final cut-out stage before re-spray:
And here's the shot after paint and fin install:
Next comes the much awaited inner fenders because I'm sick and tired of having road crap thrown in my face
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Post by R2S on Mar 27, 2020 15:23:25 GMT
looking at your photos has given me an idea, rather than using the existing glass as a back frame could the glass be cut then swept inwards to form the 'gills"?
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Post by lemans75 on Mar 31, 2020 15:13:20 GMT
I think it absolutely could. I'm not all that confident with my glassing skills so I would love to see someone try that and post some results. Other ideas I've had on this front is to have a simple slider on a set of glassed-in rails above and below to open/close the openings (with my setup).
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Post by R2S on Mar 31, 2020 21:05:44 GMT
Like the idea of a set up that can be opened and closed. I templated up some copies of the original gills but I am so far away from IVA, and currently in lock down 10 miles from my workshop, that these will be a very late, probably post IVA addition (snowbird 1 used some of my templates for his build).
Thing that is bugging me is they will be totally for show and not functional as route to flow air away from engine is blocked by the sweep of the front wheels.
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