KP's Build - Final Assembly

[Andy888]

Really impressive build Kevin. Love seeing your updates.

[Kevin Patrick]

Finished up a few more engine-related items.

Installed a new thermostat


Heater Bypass


Reinstalled valve cover

(went back and forth on painting/polishing/powdercoating it… think I'll wait til later)

[Kevin Patrick]

Finished installing the front brakes and fabricating aluminum brackets for the front stainless steel brakes.

Installed the front brakes


Ran the new stainless steel lines


Bent some aluminum for the front brake line bracket


Used a drill press and step drill bit to drill out the hole for the brake line mount


Painted the brackets


Riveted the brackets to the front subframe



I also rotated the rear brake distribution box per the April 2011 version of the Exocet Build Manual. My stock line was in good condition so I retained it and installed p-clips with M4 rivnuts in the holes where the original plastic clips were located on the rear subframe.

[Kevin Patrick]

Tackled the rest of the wing stays. I followed Stuart's advice and used a lock washer along with Threadlocker Blue for the wing stays that mount using the top caliper bolt. For the rearmost wing stay, I chose to drill two holes and use M8 1.25 x 40mm bolts with lock washers and nuts.

Front Corners (Left side pictured below)






Front Left from the top


Front Right from the top


Rear Corners (Left side pictured below)

[Kevin Patrick]

Suspension is on!

Front



Rear

[Kevin Patrick]

Time for spacers, wheels and tires. She is really starting to look like a car now...

32mm Spacers installed


Then the first wheel


Then on to the rest of the wheels




Front Left Corner


Front Right Corner


Rear Left Corner


Rear Right Corner

[alan87]

Wow! Great stuff as usual Kevin!

[Andy888]

This is a superb build. Am sure everyone on here building one of these is grateful for your detail and pics.

[Deleted]

This looks fansatic Kevin, Love the detail and level of quality going into it. makes mine look shabby now!!

[bouns]

superb build kevin!and some very helpful photos.

[Kevin Patrick]

Made a little more progress on the Engine/PPF.

New NGK spark plug wires arrived and installed


New PCV valve installed


Installed three new rivnuts and p-clips in the PPF to hold the wiring harness. (I broke a few of the plastic clips during disassembly.) Also installed the speedo cable. Ran and hooked up the rest of the harness that goes from the battery to the starter/alternator

[Kevin Patrick]

Bought some stainless steel self tapping screws with black oxide finish to install the side panels.

[Kevin Patrick]

Started work on running the brake and fuel lines in the tunnel. Ended up buying a cheap $24 close quarters drill from Harbor Freight to drill the holes inside the tunnel. I broke my M4 rivnut mandrel (for the second time in 2 weeks!) while installing rivnuts and am now waiting for the replacement to arrive before I can finish the job.





Sample of how the brake and fuel lines will be mounted


To mount the fuel line, I had originally purchased some stainless steel/rubber cushioned p-clips. Unfortunately, their overall size was a bit too large to fit both fuel lines and the brake line on the bar that runs inside the tunnel. I also had some nylon clips lying around that were smaller overall, but still slightly too large for the fuel line. I ended up harvesting the rubber cushion portion of the stainless steep p-clips and installing them in the nylon. Fits perfectly now.

[Kevin Patrick]

Warmer weather made it a good time for cleaning and painting of some additional donor parts. Clutch pedal assembly, brake booster/master cylinder assembly, and steering column were finished over the weekend. Need to finish up the brake/accelerator pedal assembly next. Used some of the Rust-oleum Hammered finish that can be applied directly to rusted metal - worked well for this application as there were plenty of surface imperfections. www.rustoleum.com/CBGProduct.asp?pid=159

Brake booster/master cylinder before and after




Clutch pedal assembly

[Kevin Patrick]

The replacement mandrel for the rivnut tool arrived today and I finished running the fuel and brake lines through the tunnel. I used 3/16" brake lines and 5/16" Goodyear fuel injection hose www.goodyearep.com/productsdetail.aspx?id=5144.