Mike's Zero Build

SVA day

2009-05-12T04:48:00.000-07:00

Last night I worked till 10.30 on the kit trying to get it finished for the big day...

And this is how it looked at 06.30

Exhaust Bracket

2009-05-12T04:46:00.000-07:00

I then fitted the exhaust bracket.

Mirrors

2009-05-12T04:43:00.000-07:00

With the seats in you can then fit the mirrors.

Nose and Bonnet

2009-05-12T04:37:00.000-07:00

Next was to fit the nose, and trim the bonnet and fit.

Trimming the kit

2009-05-12T04:07:00.000-07:00

The fun part was trimming the carpet and fitting it....

I glued the carpet in with contact adhesive (don't do this in the garage)

When the carpet is in the seats and harnesses were fitted.

Filler cap

2009-05-12T04:00:00.000-07:00

Fit the fuel cap to the body.

I fitted mine this way as I didn't want problems filling the tank (common fault with this kind of setup is the bend in the pipe wont let you fill it quickly without splash back)

Fuel pump

2009-05-12T03:56:00.000-07:00

Next was to fit the fuel pump so i could start it!

With a few false starts it went.

Expansion tank

2009-04-10T13:53:00.000-07:00

Well this was to be a oil breather kit but I liked it so much I'm going to have to get two...

So with a modification of fitting a tube into it to reach the bottom then fitted it as a "spit and suck" bottle.

SVA looming

2009-04-10T13:38:00.000-07:00

This is how it looks as of the 9/4/09 and I have just been given a date for the SVA. The 28/4/09.... That's just 19 days away..

Things I still need to do is....

Finish fitting the fuel setup.

Trim the car.

Map the ECU.

Fit the seats and harnesses.

Fit the dash.

And several other things to do

I BETTER PULL MY FINGER OUT!!!

Fuel cap

2009-04-10T13:26:00.000-07:00

After reading a post I decided to make mine a vented one, as I didn't want to drill more holes in the tank.

I dismantled it and found the best place to drill a hole in the body of the cap.

This is the part to be drilled in, if you look inside there are two slots (drill through one of them)

Then put it back together and it will vent through the lock.

Front wings

2009-04-10T13:12:00.000-07:00

Next was the front wings, I trimmed and fitted them.

After that was the front indicators, the wiring was put through the wing bars.

Horn

2009-04-10T13:07:00.000-07:00

Next I fitted the horn and tried it!! ( then wish I had'nt )

Horn button boss plate

2009-04-10T12:58:00.000-07:00

This is a plate I made to fit in the boss to stop the wiring getting trapped as you turn the wheel.

The black bit is a small hole to put a wire through then fit the plate to the column, the wire is then wound loosely in the gap between the plate and the boss.

As the steering is turned the coil is tightend or slackend.

Air Filter

2009-04-10T12:50:00.000-07:00

With the Jenveys fitted the backplate and filter was fitted.

Pipes

2009-04-10T12:43:00.000-07:00

With the rad fitted I then did the pipework (what a nightmare!)

I don't think I did a bad job though....

Need to keep it cool

2009-04-10T12:29:00.000-07:00

The radiator was placed inside the nose and measured on fit.

The nose was then taken off and the rad was fitted.

Nose ( I thought I was building a car... Not a frog )

2009-04-10T12:22:00.000-07:00

Next was to trim and fit the nose cone.

Take your time with this as it will show if you don't...

Rear Lights

2009-04-10T12:12:00.000-07:00

With the rear wing on it's time to fit the lights.

Keep the underside neat and tidy and it looks good.

Rear wings

2009-03-03T13:17:00.000-08:00

My next challenge was to fit the rear wings.

So I marked and drilled the holes.

I then marked out the holes on the body then drilled and then fitted the wing.

Does'nt it look good!

Fuel pressure regulator

2009-03-03T13:12:00.000-08:00

With the Jenveys fitted I fitted the fuel regulator.

I don't know if it will stay there yet, I might need move it.

Jenveys

2009-03-03T13:00:00.000-08:00

I got the Jenveys today and made a start on fitting them.

The pipes just to the left of the engine are the fuel lines (if you stop them there they just need fuel hose to fit to the Jenveys).

This was a fun bit to do....

Fitted the Jenveys and the fuel lines to them.

Oil pressure sender

2009-03-03T12:57:00.000-08:00

The next job I did was to fit the oil pressure sender and sort out some of the wiring.

Alternator

2009-03-03T12:49:00.000-08:00

As the space on the proper side of the engine is tight the only other option was to place the alternator on this side.

So Myself and a fellow builder made up a plate to attach to.

Happy birthday to me... :o)

Making light of things

2009-03-03T12:45:00.000-08:00

With the rear panel fitted I then fitted some of the rear lights.

Dashing

2009-03-03T12:37:00.000-08:00

Over the past couple of weeks I made the dash and wired it up.

Rear Panel

2009-03-03T11:45:00.000-08:00

Next was the rear panel (loads of fun!)

Take a lot of care on this as It takes a fair bit of time to get right, and the part from the top of the rear to the side panel really is a nightmare to do.

Boot boxing

2009-03-03T11:35:00.000-08:00

With the tank in place I had a go at fitting some panels in the boot.

I bought some sheet aluminium, made a template and this is the result.

Both shock turrets plated with access holes for removal of the bolts later (Should the shock need replacing).

Fuel tank

2009-03-03T11:20:00.000-08:00

The next job I done was to fit the fuel tank.

Engine mount part 2

2009-03-03T10:49:00.000-08:00

This is the lug that needs to be removed.

And now with it removed.

As you can see with the lug removed the mount bolts closer to the engine.

Engine mount

2009-01-24T14:22:00.001-08:00

With the engine mount inplace you can see there is too much of a gap between the mount and block.

So after chatting to a fellow builder we decided to cut the fowling peice off.

Will have new pics of this when complete.

Remote oil filter

2009-01-24T11:51:00.000-08:00

With the space between the engine and the steering shaft too small I fitted the remote oil filter kit.

More wiring

2009-01-24T11:44:00.000-08:00

With the relays rewired I then fitted them.

The next task was the fuse box, witch I made a square hole to just poke the fuse box through.

Now does'nt that look better...

Boot

2009-01-24T11:38:00.000-08:00

With the boot put together and test fitted to the kit I drilled the holes for the rollbar to boot stays.

Battery

2009-01-24T11:35:00.000-08:00

The next thing I did was to fit the battery.

Washer bottle

2009-01-24T11:30:00.001-08:00

As I don't want to get through the SVA then fit the screen, demister and wipers, I fitted the washer bottle.

Wiring

2009-01-24T11:19:00.000-08:00

Whilst waiting for parts to arrive I took the time to sort out some of the wiring.

I riveted the top panel on the tunnel wit5h a hole near the firewall for the wiring to come through into the car.

Starter

2009-01-24T11:15:00.000-08:00

Starter in place.

More panels

2009-01-24T11:09:00.000-08:00

The next job I did was to fit the crecent panels.

Ground clearence

2009-01-24T11:05:00.000-08:00

Now the sump looks like it might last the first pot hole.

Sumpthing old, Sumpthing new....

2009-01-24T10:56:00.000-08:00

With the engine removed I fitted the new sump.

With the new sump fitted I refitted the engine.

Sumpthings wrong

2008-12-12T14:00:00.000-08:00

Now whilst the engine was in the kit I noticed the sump was very low. (the front chassis rail was on blocks to gain height to get the engine hoist under the car)

One quick call to Scholar engines and I now have a lowline sump.

Test fit the engine

2008-12-12T12:53:00.000-08:00

After bolting the gearbox to the engine I test fitted it to find out where to drill the holes for the engine mounts.

There is a part of the bell housing that needs to be cut off to clear the passenger side footwell.

The near side engine mount needs to be spaced of the engine due to a bit that sticks out.

With the engine in place I marked the holes that needed to be drilled.

The next move was to remove the engine, drill and bolt the mounts in place.

Helpfull tip: If you can't get your hand between the mount plate and the stainless panel, take your spanner and place a bit of masking tape on one side of it at the ring end, place the nut in the ring and then place the washer on top of the nut, then fold over the masking tape to just stick on the edge of the washer. Now the nut and washer won't slip or fall off.

Rolling chassis

2008-11-30T10:33:00.000-08:00

With all the those jobs done I can fit the wheels and get it off the stands.......

New problem....

How many times can I trip over it??

Note. The board on the front of it is my work table.

Dash and Scuttle

2008-11-30T10:16:00.000-08:00

Between a few of the previous jobs I had a go at sorting out the dash, scuttle and front Firewall.

With it put together all I need to do now is fit it to the chassis.

We need brakes..

2008-11-30T10:09:00.000-08:00

Next fit the rear brakes and new drums, Don't forget to shorten the handbrake cable.

Diff and shafts

2008-11-30T10:06:00.000-08:00

After fitting the diff and driveshafts it now looks like this.

Next time the rear brakes.

Driveshafts are driving me crazy!

2008-11-30T09:45:00.000-08:00

Now the fun part!

My driveshafts had nackerd gaiters so I changed them.

Prob 1. What sierra did they come from?

Prob 2. How to take them apart?

Prob 3. Split gaiters (glue style) or std ones.

Well I could'nt get the split ones so had to go to ford and get the right ones from them.

For a small fee £9.68 each I now have replaced the old gaiters.

If anyone needs help to do these gaiters email me on mac801123@lycos.co.uk and I'll send you a file on how to do it.

Gearing up !!

2008-11-30T09:37:00.000-08:00

At last I have my gearbox and diff back!

So next job was to fit the diff and prop.

Down under...

2008-11-03T14:12:00.000-08:00

At this point I turned It over and riveted the underside.. and received a hernia for the trouble...

Go kart...

2008-11-03T13:57:00.000-08:00

Now we have a kit that now resembles a go kart.

And If I might add I'm quite pleased with myself..

Front Suspension

2008-11-03T13:36:00.001-08:00

Fit the front wishbones and components.

The top wishbones are tight but they do fit If fitted at the rear first and then pulled forwawd Into the front mount.

Once It's all together It should look something like this...

Remember to leave the bolts loose till It's on the ground. I have test fitted the steering rack to see how well It fits.

Rear Suspension

2008-11-03T13:21:00.000-08:00

Fit the rear wishbones, Shock and back plate with the spacers provided.

As I am still waiting for the diff and gearbox to get back to me I have tried to do other jobs to keep myself busy, that's why there is no diff or drive shafts fitted.

Remember to drill a hole In the hub carrier for the bottom shoe retaining pin.

Make a wish! or 8

2008-11-03T13:04:00.000-08:00

Now for the worst job I have done on this kit....

Fit the bushes and sleeves into the wishbones without damaging yourself or your equipment.

I broke my vice twice and now It's going to the bin (age 6 weeks).

Sorry for not having the pics of the bushes going In but my camera was missing the day I built them..

Outer panels

2008-11-03T12:20:00.000-08:00

Now that I have the Footwell, tunnel and rear panels fitted the next job was to fit the outer side panels.

Note: Look after the drill bits, make sure you have plenty and most of all If they snap try not to hit the panels (as I did twice) BUGGER!!

Starting to fit the panels

2008-10-17T13:24:00.000-07:00

Next It's time to fit the panels......

Test fit the panels and see if they need trimming or adjusting.

Mark out and drill the rear panel, tunnel panels and footwell panels.

Fit to chassis, drill and rivet.

Starting to fit parts

2008-10-17T12:52:00.000-07:00

Nows the time to throw away those bloody paint brushes and start to do the proper stuff.

So fit the brake master cylinder and brake pipe from front to rear making sure you attach it at the proper distances.

Fit the handbrake and handbrake cable.

Fit rear brake pipes, 'T' peice and rear brake flexi hoses.

Steering column and steering bush.

Grind and paint chassis

2008-10-12T11:58:00.000-07:00

Grind the welds that need to be done then paint with rust converter, primer and then top coat.

Clean and paint donor parts

2008-10-12T11:36:00.000-07:00

Wire brush the old rust off the parts.

Paint with rust converter (left side)
Then paint with Gray primer (right side)

Then paint with top coat (I used international 10 year garage door enamel)

Donor parts

2008-10-12T11:23:00.000-07:00

First job Is to sort out the donor parts so strip, wire brush and examin.

With that done send away the diff and gearbox.

27/09/2008 Collection day

2008-10-09T11:28:00.000-07:00

After a 4 hour drive, 3 hours at Great British Sportscars and another 4 hours to get back home I am the proud owner of a Zero Superspec in Kawasaki Green with stainless steel panels.

Oh what have I done, I now have a garage full of bits and pieces nuts and bolts. All I have to do now Is make a cup of tea (or several) and start building. I mean it's just a big meccano set right? Well over the next few weeks we'll find out.