Ian's build thread

[ian360]

Ybot19 - interesting. Were you using the MEV supplied lights? Surprised that they aren't suitable coming from HQ. Also mounted in same position as show display car - I took pictures and had discussion to make sure. They do still need lining up correctly haven't done that yet.

[Stiggy]

Aug 31, 2017 9:10:54 GMT ian360 said:

Ybot19 - interesting. Were you using the MEV supplied lights? Surprised that they aren't suitable coming from HQ. Also mounted in same position as show display car - I took pictures and had discussion to make sure. They do still need lining up correctly haven't done that yet.

Hi Ian, your build looks great, well done chap.
Only point I noticed was the rear lights, the edges at the rear need a rubber ring around as the lights do not have a 2.5 mm radius on them.

Headlights.

Flat beam pattern is permitted for IVA so no issues there.
See section 25 Headlamps in the IVA manual quoted below;

Headlamps producing a flat dip beam are acceptable, and

will not have to meet the aim criteria for “break point”.


Dominator lights have a flat beam pattern if mounted with the bolt at the base.
The side lights and indicators lights need to be seen from the opposite side of the car to where they are mounted.
Examiners often say to 45 deg. THEY ARE WRONG.
If this is the case please ask the examiner in the nicest possible way to refer to the manual he is working from. It clearly states that if the light is below 750 mm from the deck then it must be seen be only 25 degrees on the opposite side.
Quote for the manual in section 20 Installation of lights;

Where the front indicator lamp is positioned less than 750mm from the ground the inward angle of visibility may be reduced to 200 when viewed between

the vertical angles of visibility shown in Figure 2 ‘a’

In the case of headlights mounted on the chassis front corner plate they will need a right angle bracket. This will lift the light to offer improved angles of visibility and also hold the beam pattern flat. Dominator lights come with cheap bulbs and occasionally we have noted the the plate in the bulb is not angled correctly to give a flat beam pattern.

When mounting the indicators on the Dominator housing ensure that it does not protrude internally to stop the headlight rim going back on. The 10 mm hole needs to be back as far as possible, close to where the steel bowl starts to curve.

[ybot19]

I though that was the case (angles of visiblity) but couldn't find in the manual on the day. I do have the mev lighting kit and did replace the bulbs with better ones but still had the kick up on the off side. Had no issue with the rear lights with the little lip. Examiner just put his finger over them and said yep that's fine. I did have to trim the reflectors supplied as these protrude more than 5mm. My Examiner was very good and said if I have any issues to call him and ask questions so I'll be asking about the angles of visibility before I go back for a re-test.

[ian360]

Bit of help again please!

Was looking at refitting the headlights last night and as I switched the car on noticed the ABS warning light didn't go out. Hasn't happened for a while, but having had a problem with the rear sensor in the build ran some quick checks. All fuses are ok so not a problem there. Ran the diagnostic test and came up with the following codes

12 - Left Front Wheel Speed Sensor Open circuit or Short to power supply

42 - Left Front Wheel Speed Sensor Rotor Short to ground or Disagreement with other sensors is detected

63 - ABS Module Power Supply Malfunction

If I am reading the 'flashes' correctly!

Checked the front left sensor and it has correct resistance reading, and power to it. Sort of ran out of time then, but checking wiring diagrams there aren't any earths from the sensor, and the ones from pump unit and ABS module both check out fine.

Where should I be looking next?

[ian360]

Very close to finishing now!

The ABS problem was sorted, it was a loose connection on the module simply fixed by taking off and reconnecting, no problems since.

I have submitted my IVA test application and all has been approved, paid and booked for Nottingham! There was a three week wait for appointment and it's for 8.00am so will be an early start that day.

Time to go over everything and triple check things in order.

Feedback was correct that my headlights would fail the visibility angles so made up a bracket and lifted them, rotating the fixing put the indicator on top of the headlight though!

but both now easily comply with the viewing angles

They passed the 'MOT' test I had done for beam direction and strength, so think they are now good to go?

Fitted the lockable filler cap as required

Wasn't happy with the look of the rear as the exhaust was sitting at an angle, so dropped it a few cm to get it level

Emissions checked out fine ( as they should with new system and CAT). Needed to turn the centre section slightly to stop it rubbing on the prop so that is all now sorted.

The MOT check was passed but of course lots more aspects that aren't included need checking off. Still finding nut and bolt heads that need covering and edges which seem to appear that need blunting. Have a couple of weeks to do it and figuring best to be overdone than underdone! 

Was struggling to find a way to get the brake fluid sticker placed within 100mm of the reservoir, and was working on using the manufacturers plate in conjunction with it, but it seemed to just present another piece of ally in places I didn't want it. Took a step away (and Shanes thread!) to realise just stick it on the container and put the plate somewhere more suitable! Overthinking sometimes misses the most obvious solution?

So now getting a much simpler and small plate engraved ready to rivet into place.

I'm using the replies to Shanes question to double check everything but any other pre test advice more than welcome here.

Thanks

[miket]

You've mentioned you're still to do final edging etc so I won't cover them in detail, but you can get a 100mm polystyrene ball from 'craft' places to use to simulate the IVA test for sharp bits.

[jgilbert]

Sept 26, 2017 8:26:12 GMT ian360 said:

Very close to finishing now!

Still finding nut and bolt heads that need covering and edges which seem to appear that need blunting.

Buy some self- amalgamating rubber taper from ebay.

Use it to cover nuts/bolt threads or take it to the IVA with you for any unforeseen issues.

example below shows it covering my upper front wishbone washers. 3 years on still in place.


Good Luck.

[ybot19]

If you are using mx5 seatbelt the reel can be contacted through the triangle in the side of the chassis with 100mm ball make sure to cover it with mesh or something of the sort.

[ian360]

Doesn't that area fall into interior fittings chapter 12 'exempt area' ?

[ian360]

Few more Iva jobs ticked off.

Copied Mr Gilbert's idea to cover the rear suspension mounts with bottom of drinks bottle, painted and nut covered.



I found an old inner tube in the shed and cutting across it made some very good circular rubber which stretched nicely over the edges of the light tubes




And also the suspension arms



Finally the new headlight bracket edged



Attached the manufacturers plate



I've been round the car several times now and think I've covered or blunted as much as I can. Fingers crossed?!

[noobie]

Drinks bottle. Great idea !

[ian360]

It’s a brilliant idea - and one I can take no credit for!

Stole it from John G build but unfortunately the early pictures from that thread are victims of photobucket.

[ian360]

IVA test done on Tuesday - FAIL

Of all things the big one was exhaust emissions which did for me, CO levels too high.

I had this tested a few weeks back as part of an MOT assessment to check things looked good, and they were fine then. Car has been driven maybe 15 miles tops since then, engine run a few times as well so not much chance for anything to have changed. To be fair my inspector was surprised as the whole exhaust system front to back is brand new - in fact he did the test three times just in case it was his machine that was playing up!

There has to be too much air in the system and can only be -

1. Hole somewhere in the system (our visual checks couldn't find an obvious one)

2. Failed CAT (unlikely)

3. Failed Lambda sensor (most likely)

4. Failed ECU (again unlikely)

Whatever, I had no means of diagnosing and correcting on the day so at that point knew I had a fail on my hands. Took the pressure off but we still had to complete the inspection, which up to that point had been going quite well!

Few other minor fails I had which would have been able to be corrected on the day -

My 'IVA compliant' locking fuel cap turned out to be not so compliant! The key could be removed whilst cap was off, as it can be locked out of position. Simple answer to tether with a cable tie.

Sidelights were too low for the 5% angle. As they were fixed on side mesh just needed to move them up a couple of inches to correct.

Handbrake warning wire was 'floating' in the tunnel. Needed cable tie fix to the conduit.

Rear flexible o/s brake pipe was touching the chassis. Needed turning round slightly.

Rear n/s flexible brake pipe needed clipping more securely.

Some general trim issues - a nut cover on the suspension had come off, exhaust hangers, side repeaters were outside of the exempt area and needed blunting, rear reflector edges (oops!)

Side panels I had filed and blunted but not well enough. Needed extra filing or suggested put some trim on them.  

All of these were easily fixed, and in fact my examiner said if I went to their cupboard I would fine trim to use!

He even tried to guide me to a local garage to see if the exhaust could be sorted, but on reflection I said it was a lot of hassle to tow around and best to just take away and sort out.

I would say my examiner was really helpful, and genuinely seemed to want to pass rather than fail the car. The test lasted about 3.5hours, which goes surprisingly quickly! Without question it helps to show that you have at least read the manual, whilst not specifically tested on it's contents it is a bonus that you can refer to sections and why certain things were done certain ways. I took all my build photos but was never asked to show them!

So disappointing that I don't have a pass certificate, frustrating that it is an issue I seemingly couldn't control, satisfying that excepting a few oversights what I had done was acceptable. I have the car booked for diagnosis at my garage to sort the emissions, and then I can resubmit with all the above tended to and hopefully get the pass.

On the positive side, how much was the car going to be used in the next six months anyway!!

[mikeeyboy]

The exhaust seems to be a really annoying thing to fail on as it sounds like there are some unknowns with how the results will display. I would have presumed you getting it tested at an MOT station before would have guaranteed a pass.

The other issues sound like easy ones to sort.

Lots of useful information for those of us looking to book the test soon, thanks.

[miket]

That's a shame when you were otherwise so close to passing.
Had you glued on your nutcaps?