Sonic 7 build diary

[jonb2010]

Looking very good. Have you got any pics of the radiator fittings ? I presume you moved it forward to get the fuel tank in.

Is the hole in your tank in the centre ? I'm trying to work out how to fit the pump and allow the float to move through it's full motion.

[daydreamer]

Yes , I moved it forward to make space for the fuel tank. Here are some pics of the radiator instrallation. The radiator is a Mk4 Golf , it is avery tight fit. I have supports at the bottom and restraints at the top.






My fuel tank hole is in the centre. To accommodate the float bar on the sender unit in the tank I turned the float bar around by 180 degrees. I don't have a picture of this. You do have to keep the float bat at an angle where it will work smoothly. Wish I'd taken a picture as it is difficult to explain. This could have been avoided with the hole in a different position.

[jonb2010]

How did you turn the float round ? Did you just bend the bar it's on ?

I like your idea of fixing the top of the pump to the tank. There is such a small amount of tank to put screws into if you go through the top of the pump housing itself.

[daydreamer]

Yep, we just bent the float bar. One of our considerations when bending it was to make sure that the bar would operate in a similar way when lifted by the float and not put excess stress on the sender rheostat. When adjusting the float bar position consider how it will impact on the pressure placed on the sender rheostat at the base of the bar. The sender rheostat could wear out prematurely if the bar presses the pickup into the rheostat back plate with too much pressure.

This picture, from someone else's blog about a F150 pickup which I have shamelessly linked to, shows how it can wear out. You can see on the left how the circuits have been worn through.

[daydreamer]

Almost completed .

Only tasks left now.

Fill up fuel tank
Fit tie wraps to steering rack gators
remove protective film from windscreen
Adjust headlamp alignment.





My top tip from the last 48 hours. Fit edge trim to seats before you fit the seats to the car. Edging strip is hard to push on by hand. It helps if you can tap it on with a hammer.

Taking it by trailer to RTR on Friday.

[mabbs]

Job well done Love the colour combo. Good luck with the IVA, should be on the road soon !!

[daydreamer]

Hi Mabbs, thanks for the comment on the colour scheme although it will look better when the decals are put on. A lot of my friends are divided on the colours but I don’t pay much attention to them as they mostly drive cars that should have been heavily discounted as the manufacturers seems to have forgotten to paint them after putting the primer on. Way back in the sands of time just after to ordering the kit when I had to make my colour choice and send that through to MEV , I spent hours considering different colour combo’s and in part I wanted it to be visible so that ruled out darker colours. I bought a RAL colour swatch set, boy those things are expensive for what they are, to help with choosing colours. ( If anyone wants to borrow my RAL K5 Classic colour swatch set let me know and I’ll post it through on the understanding that it’ll get posted back to me. )

I made it to RTR last Friday with the Sonic on my trailer. A bit later than expected due to bank holiday traffic and leaving late. I spent an hour wrapping it up as it was raining.




I saw Avantkiwi’s car at RTR and the Mevabusa, both looked very good. I do like the Black and Blue on yours Avantkiwi.


Paul had a quick look over the car and I was disappointed that he pointed out the following in no time.

• Steering wheel, original ford item is too hard, but RTR can fit a foam pad,
• Rear fog light is wired through donor light switch and this does not comply unless front fog lights are fitted. I’ve given RTR a set of fog lights that they’ll fit as I have all the wiring already installed for these but had not fitted front fog lights as I thought if they’re not there they can’t be tested.
• Side repeaters a bit marginal on position. RTR to fit an alternative set that I’ll supply.

I’ve asked RTR to:
• check and adjust suspension level, camber, toe in and tracking as I’ve had a go at these but I’m sure it can be improved upon.
• Adjust the steering rack height as this is an early kit and prone to bump steer. I believe this is now fixed on the new kits.
• Adjust and lock the brake bias bar.
• Supply and fit chassis plate
• Check and adjust headlight alignment.

I was gutted to discover the day before going up to RTR that the gearbox driveshaft seal was leaking so I’ve asked them to change that as it I expect it’ll fail if it leaks gearbox oil on the IVA examiner.

Apologies to Paul at RTR for keeping him late on a Friday.

Lessons learnt
• Focus light switch does not comply as regards rear fog light operation, unless front fog lights are installed.
• Standard focus steering wheel does not comply as regards surface hardness.
• Don’t promise that you’ll do all the outstanding DIY when the car is finished, that day does come.
• Waiting for test results is never fun.


Hoping to be on the road soon and going to events like Curborough and the bring em home days at MEV. I won’t make Newark as I’m away that weekend.

[andybaird]

Hi Daydreamer

You must be getting excited now the car is at RTR for it's IVA
Not long till you are on the road.
I'm booked in with RTR on the 1st June and looking for them to do the same work to the suspension Steering Brakes & Lights.
I have hired a self drive car transporter for the day so looking to have the car down at RTR for 2pm.
Has RTR said how long it will take to get the work & IVA done.

Andy

[avantkiwi]

Thanks for the comments, my colour scheme choice was the opposite to yours, I wanted mine understated to let the car standout on its own. I am with you on the waiting! Mine has been away almost 2 weeks now, my wife doesn't know what to do with me at home in the evenings.
RTR also has 1-2 things to "adjust" on mine, the fog light also being one of my items.

[daydreamer]

Hi Andy,

The temptation to call RTR and ask if they have test date yet takes some controlling. When I dropped it off with them they said that they should hear back from the test centre in 10 - 14 days with a date. So still a little while to wait for the test date.

Paul at RTR thought that they would be able to fit the work in the time spent waiting for the test date to come through.

I'm hoping that it'll all be done and registered by mid June. I just hope that summer arrives before then.

I might pass the time by building a cover for the trailer.

[Stiggy]

Fantastic to see all these Sonic7's coming together, they all look quality. Bring on those summer evenings. I had great fun in mine, so cool, my favorite moment was when I met Lewis Hamilton, he loved it!

[andybaird]

Hi Mate

How did your IVA test go today

Andy

[daydreamer]

Well, the result was a FAIL.

On
Emissions
Top seat belt harness restraints - radius
Steering Wheel - too large.

The emissions were just out and this is due to an oxygen sensor being out of calibration, not completely failed but not working right. RTR have ordered and fitted another.

The radius issue on the top seat belt restraint is an easy fix.

The steering wheel too large and interfering with driver legs is a surprise, RTR have not seen that before with the standard Focus steering wheel.

Should all be fixed this morning and back for a retest at lunchtime if they can squeeze it in.

I'm hoping for positive news re: re-test today.

[avantkiwi]

Not a positive week for 1st time passes on Sonics. Lets hope lots of positive 2nd time passes. Seems to be a run on O2 Sensors this week. Mine also failed on that!

[daydreamer]

Zip-a-dee-doo-dah, zip-a-dee-ay
My, oh my, what a wonderful day



Many thanks to Paul and the RTR team.

And Stuart and Julie.

( When I bought the kit, a couple of years ago now, it was all handled by MEV directly )