Chris's Build Thread - Northern Ireland

[scooby1929]

No probs Andy hopefully reading this might give you some motivation to finish yours

[scooby1929]

So I have applied for my IVA test anu d panic has begun. It got off to a bad start when I received my forms back in the post saying i had sent them to the wrong place. There is actually different forms to fill in and amateur build form is also different if you live in Northern Ireland even thought we are part of the UK so anyway I hand delivered the forms to the Mot centre in Boucher Road Belfast.

Anyway I finished by binnacle cover I was never to happy with just a single bracket supporting it so I added some stud bar and bonded on a couple of brackets to the chassis.





So this completely stopped the binnacle from moving. On the cover itself previously I had drilled the plastic but it had cracked so this time I bonded on some brackets and used some more stud bar to secure



Some orange plastic paint and some vinyl wrap and final result is a very secure binnacle and cover



I could not get my binnacle perfectly flush with bonnet because I can't lower the steering column any more as my buckets seats sits higher than the mx5 seats and my knees would hit steering wheel.

I made a manufacturers plate and added the compulsory but rather daft Iva sticker regarding dot 4 brake fluid.

I still need to fully weld my Vin plate





I have fulled trimmed all the wishbones and thanks to John I got some electrical grommets in B&Q and used these to cover the track rod ends and used nut covers everywhere.



I also added some extra brackets to secure the brake lines





I then labelled every earth and relay for example





My Ecu was previously cable tied in so did not think Mr Iva man would like that so cut existing brackets which I kept and bolted in place. I also used somme 3 mm rubber under ecu to cushion it



I removed unnecessary connectors. Be very aware of shared earths I came across 3 of these and when you cut them weird and wonderful things happen. Cable tray tied up



I removed 2 full bags of connections here is one of them



I also made a bracket for the diagnostics box



I also read on John and Lukes build they had an issue with the low level brake fluid so I prodded mine and it works so happy with that.

I then decided I need to sort this drip tray to stop fuel in the case of a leak from the tank onto the exhaust so I removed the tank. I have made a template and I will then bend some alloy to suit and using a few self tappers I will secure to the subframe. It needs a few bends as the diff sits higher that the subframe




I have also added a fuel tank earth.

One wee piece of advice is when you fit the front wing stays make sure they sit horizontal. One of mine was sitting way up and when I fitted the wing it did not sit right. I can't believe I did not notice it but I had to bend the stay to horizontal. This then resulted in the holes etc no longer lining up and as a result a scrap wheel grp cover. Also don't forget to torque front hubs nuts to 140 lbs ft and re ident then replace cover



On the rear wheel stays I replaced the caliper bolt with a 10 mm longer one. The bolt is a m10 metric fine and I used a spring washer under the head





Big thanks to a couple of people in helping me get this far John Gilbert, Trident Chris and George Gymwar, others and this forum otherwise I would of been completely beat

[scooby1929]

Today I made my drip tray from 0.03" steel plate





Now I have to bolt it to subframe and bracket that supports the fuel tank

[jgilbert]

Chris,

Sorry, I'm way behind on replies.

Build looking very good. on the wheel arches, why do you need a new arch? I understand you have had to bend the arch strut, but this shouldn't change the position of the holes unless the you bent the strut arm instead of the just the the top bend.

Picture to illustrate my thinking.



Liking the labelling of earth points. I would fit more nut covers to your suspension bolt/nuts, I know there is a hypothetical area that is exempt, but for a few extra pennies I reckon it shows you have thought it through, you can even say you know the area is exempt by have added them anyway to demonstrate your knowledge of the manual.

For difficult sized nuts use a bit of self amalgamating tape on the nut then add the nut cover.

Good luck.

[scooby1929]

John I see exactly what you are saying but I had also got slightly carried away with the file on the main hole on the grp arch that the stay slides into and it looked terrible so I bought a new one.

I have ordered more nut covers for suspension.

What would you do with the rubber hoses running across the tank. Would you encase them in conduit? I have them cable tied together but not sure that's allowed For IVA?

[trident]

I encased mine in split conduit especially where they might rub on the tank edges . i also used some edge trim on the tank seem where the pipes came between the chassis and the tank.

[scooby1929]

Chris I have fully edge trimmed my tank. If you put the fuel pipes in conduit can you tie wrap the pipes together?

[scooby1929]

Tonight was not a good night for my powdercoat. First job was in my opinion this daft rule that the Vin plate must be fully welded so out with the grinder and welder.



Needs a few licks of paint but at least Iva man should be happy.

I had also another issue that I was getting a small vibration on the front wheel grp covers so my poor powder coat got grinded down again and I welded in a stiffener to triangulate the wheel stays



I also was not particularly happy with my fuel pipes it looks so much better if they run parrallel to each other from front to back so have made a start to correct this.I will put little clips between them to stop them rubbing / fretting on each other. You can see in the pic below that the fuel pipes sit above each other and all bends etc are parrallel the length of the car as previously I had them all shapes. I also need additional p clips on the fuel lines.



I seem to spend more time changing things that I should of done right / different first time round. At least I am learning plenty...

[scooby1929]

Well after 3 years and a few ups and down mostly my own stupidity my Exo is finished with a few small things to do with an IVA date booked for the 20th July. I was getting a bad vibration through the wing stays but as soon as I increase the revs the vibration stops completely so going to attempt to increase the idle.

I need to add the wing mirrors and mesh in a few areas to stop Mr Iva man's balls getting in.

I have went with a decat as it's a 93

Using a decibel meter at 4000 rpm my exhaust with cherrybomb exhaust is reading 98 decibels so not a lot of margin as it has to be under 99.

Iva panic has begun

[jgilbert]

Chris, looking very good, can't see any problems. Figures crossed for you on the 20th.

[trident]

Good luck for tomorrow mate.

[scooby1929]

Cheers Chris I a mixture between nervous and excited that I am going to drive the car on the road for first time. I have done my best. Used some mesh that I had for my fence to cover the areas around the engine to keep Iva man out and covered all nuts, bolts etc

I think part of the reason I am nervous is the fact that if you suffer a break down etc on route you lose your £450 fee.

Also praying it does not chuck it down

[dave]

Fingers crossed for you tomorrow.

[jgilbert]

Your be fine! but fingers crosses having been then.

[scooby1929]

I have made it here but first problem filled the tank to the neck and she is only reading half full fek sake.

It says on the form to arrive with a full tank...