browno's Exocet build

[p2tav]

really good,

impressed with your build hope to see the final result i'm sure it will be fab  
what size wheels are you using and did you have to alter the cycle wings ?

regards paul 

[browno]

Thanks for the positive comments Paul - I am really enjoying the build so far (although I think that might change when it comes to playing with the loom!).

I am using 15x7 et25 Team Dynamics pro-race 1.2 wheels with 195/50 15 Federal RSR tyres, to which I have added 25mm spacers from Freaky Parts to take me to the required et0 offset. I haven't modified any parts so far - but the wheels clear the wing stays (front only are fitted so far), and should fit under the standard cycle wings (if you want wider than a 195 tyre then Stuart can now do wider wings, but I know that MX5's can be easily over-tyred by going too wide or heavy, and I assume, being so much lighter, that the Exocet may exhibit this also - so wanted to stick with a sticky 195 and a light wheel).

I have made a little more progress over the weekend - I have bled up the brakes, and they all seem to work ok (it is very nice to be able to bleed all 4 brakes with the car on the ground and with the wheels in place!) - just need to p-clip the hoses into place now to make sure they are all ok for IVA.

I have also taken a look at what I want to do to fit the radiator. I have the MEV brackets, but since everything else on the car is either green or black, I wasn't sure about having bare alloy on show, so I had a go with teh carbon vinyl - which I am quite pleased with, but am unsure how the heat might affect it. I think I might go with this to begin with and if it looks ropey I can always whip them off and give them a lick of paint... ( I am assuming that I may also need some edge trim to finish this off too)



radiator bracket on Flickr

[aterro]

Good work. Really good for a newbie like me to read.

Your floor, do you think the carbon wrap will be hard wearing? As surely it's a pig to redo if it wears down quick?

[browno]

Thanks Aterro - on the floors, I debated a number of finishes from paint through powder coat and even truck bed-coat, but a lot of folks on here have used vinyl with good success, and I figured that most of the floor isn't going to really get a lot of traffic onto it (and if the worst comes to the work I can always put something over the top) - for now it certainly gives a good effect.

I have not been doing as much as I would have liked over the last couple of weeks, but have got a few bits done (I have also been getting my mini prepped for a rolling road setup, which has involved swapping carbs over and tweaking some bits).

Firstly, having bought a rivnut tool, I fitted the radiator, which looks good - with the vinyl working well (we will see how that lasts once it has got hot):

Radiator fitted on Flickr

Radiator fitted on Flickr

and I have been working on figuring out the 3-D puzzle that is the tunnel and bulkhead panelling! This is where the loss of history from photo bucket has really hurt, as many of the threads I looked at on here and elsewhere had great descriptions, but no pictures to be able to really visualise what was going on. I began with trying to sketch out templates for the panels that need modifying/making. having started that, I then realised that I really needed to cut the hole for the gearstick and get the tunnel in place and the front end trimmed up before I finalise my templates.

So tonights job was to do just that - and some measuring, double checking and marking was followed by a first conservative cut that was then gradually opened out to fit.

Untitled on Flickr

This then allowed me to put my templates into place - so I can start to refine the shapes to ensure that i get tabs in the right places to hold the front of the tunnel and also mark where the front needs a trim.

Untitled on Flickr

Untitled on Flickr

Not masses of progress, but still moving forwards - I now need to order more aluminium sheet, as the offcuts from the floor aren't quite big enough to make the panels as I have them templated - I might even try to make the passenger side and upper panel into a single piece - anyone got any thoughts on why that might be a good or bad idea?

[browno]

A bit of a gap in updates here as I have been off travelling with work and busy with other things - but have got back onto making a little more progress.

First job was to do a little more cardboard fabrication to finish the bulkhead and also work on a first draft of a wiring tray... One question on that - how deep have people made their trays, and did you feel that was right or could you have done with a bit more?

Untitled on Flickr

but I am not sure that cardboard will quite be suitable for the IVA man, so I marked out and trimmed off the front end of the tunnel, and then began transferring the dimensions into something a little more suitable!

Untitled on Flickr

Untitled on Flickr

then started offering up the panels (and progressively adjusting them!) to get a decent fit:

Untitled on Flickr

Untitled on Flickr

which looked ok - but I wasn't keen on the pointed edge floating on the centre panel, so then had a go at remaking an improved shape to drop the join below the tunnel and neaten things up.

Untitled on Flickr

this version is still a work in progress as a couple of bits aren't quite straight and need a bit of tweaking - but it is looking like a good start! Having been hesitant at the start that this was going to be a very tricky 3-d jigsaw puzzle, I am very pleased with the progress to this stage - and am confident that I can get these fitted up nicely with a little adjustment (or in the worst case, making another iteration!).

So, progress has been slow, but I am still working on it, and hopefully I am now properly back on it, so will be keeping things moving along!

[jgilbert]

Great use of the cardboard templating. Looking very good. Takes a bit of time, but the results as can be seen from your build are well worth it

I ended up doing 3 dimensional templates for my build - fuel tank shown below. Amazing what can be made with card, scissors and a hot glue gun.




and then turned into metal.

[browno]

Thanks again for the encouragement, and some serious pro-grade cardboard fabrication there jgilbert! It is good to keep things moving along for now (albeit more slowly recently!)

I have managed more progress - having made up all of the panels, I then neatened them all up, and then it was time to get them all ready for fitting. Having pondered how to finish the bulkhead, I decided that I wanted them in body colour to tie in with the frame - so after some searching, I was able to find some vinyl in the correct (RAL6018) colour to match, and wrapped the panels - which match nicely.

Untitled on Flickr

Untitled on Flickr

Then it was time to get everything lined up and drilled for riveting (and all of the holes cleaned and deburred.

Untitled on Flickr

Untitled on Flickr

Untitled on Flickr

Then it was finally time to apply a generous bead of tiger seal to ensure good bonding and prevent vibration/drumming of the panels and start riveting into position.

Untitled on Flickr

Untitled on Flickr

Untitled on Flickr

Overall, I am happy that it is looking pretty tidy as a finished job, especially with the tunnel in place (next job is to sort the tabs that located to the front of the tunnel and get that fitted).

Untitled on Flickr

And since I am making progress - I decided that I was overdue some time to play in my other toy, so headed up to Blyton with Mazda on Track for an unseasonably sunny trackday at the weekend - which was very enjoyable!

Untitled on Flickr

Untitled on Flickr

[jgilbert]

Interior looking very clean. Liking the stainless? dome head chassis bolt. Nice detail.

[browno]

Long time, no update! I haven't forgotten about my build - but have in fact been busy doing various things in the garage - only some of them on the Exocet.

After the previous update, I had started templating a wiring tray to hold the ECU and electrics neatly - so I cut out a sheet of ally and got it folded in the workshop at work - which left me with a neat tray that just need a little adjustment to fit into place:

Untitled on Flickr

Untitled on Flickr

Untitled on Flickr

Then I took a break away from the Exocet as I wanted to finally get my mini sorted and running right - this has been a very long (23 year!) build, that I finally got MOT'd in March, but needed to get setup - so took it off to Peter Burgess to get sorted on his rolling road. It was a very steady drive over with a badly set engine meaning I couldn't drive over about 35mph without serious spluttering! Having worked his magic (and had a good chat), Peter has transformed the drive - and it now has a whole 51BHP (ish!) and drives much better, pulling happily now. This meant that I could take it out for its first proper drive - and then put it to bed for winter!

Untitled on Flickr

video on the rollers:

and since that, I have been starting to work on the Exocet electrics - firstly plugging the loom back into the key areas to get the engine to fire again, and then starting to strip out the unneeded wiring... so I currently have a car covered in large amounts of multi-coloured spaghetti - and lots of removed wiring!

Untitled on Flickr

Untitled on Flickr

Untitled on Flickr

So I have now removed all of the wiring that I can see is unneeded (and that I dare remove!) and the engine still fires - so that's good! Next is to re-wrap the loom and then begin getting everything refitted and neatened up. However (as ever, there is always a challenge!), my brother has caught the trackday bug and has bought himself a clio 172 cup which we need to fettle a bit - and so that has been taking up some garage time too!

[gwnwar]

Nice work so far.. Do all the lights and gauges work after wire work.. You might want to check them before you wrap up the harness..
Maybe use slip ties so you can still see the wire colors till all are checked..
Taking time off to do other jobs is good to clear your head.. Mini looks nice..Keep it on the road till the first snow fays..

[browno]

Time for another delayed update - as the clio mentioned previously has needed rather more attention than planned - a lumpy, missing idle wasn't solved by swapping over engine sensors, and so deeper investigation was needed. It turned out that the cambelt that had been done by the previous owner had been fitted slightly out of time (the 172 uses a floating cam setup and timing (and belt replacement in general) is a pain - so we had to open it up, get it all retimed and put in a new cambelt, water pump and aux-drivebelt, which have resulted in it running much better!

Untitled on Flickr

So with that sorted and back out of the garage (for now - we have a full set of new springs and dampers to fit to it next!), I could get back onto the exocet. Thanks for the encouraging words again Gwnwar - I have been using slip ties on the loom to keep everything broadly in place - and have had the engine firing but haven't checked the lights yet (as I haven't bought most of them... they will be coming soon!) so for the moment am keeping my fingers crossed that they work! 

First challenge was to check where the loom could run best and then cut holes in the bulkhead for the big wiring grommets (which required a decent holesaw!)

Untitled on Flickr

and then with the nearside also done, position the wiring tray and drill that too...

Untitled on Flickr

and with that done, it was then time to wrap and secure the wiring tray in place.

Untitled on Flickr

Which I think now looks quite tidy from inside (although I know I will need to sort a way to radius the lower edge rather more for IVA - I am thinking some kind of tubing stuck on might do the trick) - so the next job is to get in with routing and tidying the loom up - I have already planned and rearranged the wiring for things like the engine fusebox to move into the wiring tray, so there may be some more creative work required to make sure that it all looks neat and is routed with minimal wiring on show.  (and I also need to get a knife and ruler to tidy up the edges of the wrap too!)

Untitled on Flickr

[browno]

So I think it is new year, new update time for the Exocet, as I have been busy with lots of stuff (including lots on the clio mentioned previously - completing a full suspension refresh and exhaust replacement) - but have managed to find some time to make a little further progress.

Having fitted the wiring tray, I then started to feed the (still unwrapped) loom back into place - which left me with lots of spaghetti!

Untitled on Flickr

So in order to try and clean things up and look more organised in there, I started adding some conduit, which started to improve matters.

Untitled on Flickr

As I had to move things around in the garage to accommodate the clio on my ramp, I had to shift the nosecone (which had been suspended above my lift) - so briefly put it into place to see how it looks with the car on its wheels.

Untitled on Flickr

Then I started wrapping the loom (with the hope that I won't need to access the wiring, so fingers crossed the loom thinning has worked out ok!), starting in the engine bay...

Untitled on Flickr

Then I have started fixing things down in the wiring tray - with the ecu riveted down and the large fusebox secured to the chassis with a couple of rivnuts, and also getting some of the earth points located and bolted in, and I have started to locate the conduit also - using self adhesive cable tie bases (which will be securely riveted in place for IVA - as it seems that is required).

Untitled on Flickr

Untitled on Flickr

So with this at this stage, I thought I'd better check that things still work, and I am glad to report that it still turns over and fires - and now that I have the earths properly fixed actually runs without cutting out after a couple of seconds - I think that the immobiliser wasn't properly earthed as I was stripping the loom and was killing the engine as soon as it fired. The horn even works too!

I have also been busy shopping for more bits and have ordered most of the lights that I need along with hazard and foglight switches - so can get some more of the wiring completed. I will also be heading to the Autosport show in a couple of weeks, so will be on the lookout for some seats that might tie in with the car well without breaking the bank (currently thinking a pair of Corbeaus might be right), along with any other bits that take my fancy!

[hammy3601]

Wow, I've just read your whole thread start to finish! Excellent read.
I like you am in two minds about using my current 5 (1.8 nb) as I love it but Im going to give the sills and arches a good inspection and make my decision from there.
Hoping to visit MEV soon and place an order for a GType

[browno]

Thanks for the comments hammy, and glad my ramblings have proven interesting - let me know if you have any questions!

It is time for an update again - and some more progress (but it is certainly getting to the stage where I there are a lot of jobs to do that have less to show for a lot of time!)

First of all, I got some deliveries - including lights, so I roughly connected the wiring to test that all worked - and was pleased to see light!

Untitled on Flickr

I also tried the wiring for my savage switches for the rear fog and hazard lights - which work and light up in a nicely coordinated colour...

Untitled on Flickr

the only significant wiring issues have been sorting the earths on the panel lights and also discovering I had a dead instrument panel - which appears to be down to a broken track on the circuit board - which I will sort - but just want to check that the track hasn't broken due to high current leaking through the panel before I do so...

Untitled on Flickr

I then started trying to tidy up some of the awkward bits that I hadn't got to and get some extra p-clips in some of the spots the IVA-man will be looking for - having bought myself a new drill and flexible drive to reach those tricky spots!

Untitled on Flickr

Handbrake cable and fuel lines

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Rear braided lines

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Front braided line across the bulkhead behind the engine

I then had a short break while I did a bit of work on my NC - service, replacement Lambda sensor and new front pads.

Untitled on Flickr

Then it was time to finally get the cooling system hooked up with a new bend in the bottom hose (which will be secured for IVA) and get some coolant into my (temporarily held) Hyundai Getz header tank....

Untitled on Flickr

Untitled on Flickr

Next, I bolted down my fuel tank (I went for M10 bolts at each corner with Nylocs underneath - I expect this counts as secure enough for IVA) - and then tested that the rear bodywork fitted correctly.

Untitled on Flickr

Untitled on Flickr

I had deliberated about seats a lot and had swung between bare GRP and something more upholstered (like some corbeau/sparco buckets) but eventually settled on the lightweight approach and picked up a pair of MEV GRP seats, which I think will suit the minimalist nature of the car (and be a bit more weatherproof!)

Untitled on Flickr

Then the latest fun and games - I started fitting the o/s rear wing stay and as I was tapping the hole in the hub, the M8 tap snapped off flush in the hole (just about visible by the driveshaft below)

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So, I had to whip off the hub and get it onto the bench - where thankfully, I was able to access the flutes in the tap and move it - and with some gentle persuasion thankfully managed to get the broken piece removed.

Untitled on Flickr

Untitled on Flickr

With the messing around, it meant the hole was a little mangled, so I then drilled and retapped it to M10 to ensure that I have a secure fit, and got everything rebuilt.

So that's as far as I have got for now, and the next plans are to get the wings mounted and get the lights all fitted and working as the next step towards being ready to go!

[Stiggy]

glad you managed to remove the broken tap !

We just drill and 8 mm hole and use a lock nut on tother side.

You will need thread lock if your not using a nylock/spring washer out to ensure they don't vibrate out.