Build day 9

Steering rack

The remaining components for the steering rack arrived this week.

Removed the bracing plate from the cross-member that also bolts to the upper wishbones and carries the headlights.

...and then fitted it all; I used the steel spacer plate underneath the chassis and the aluminium one between the "u-mounts" and the brace plate.

Steering is in.

Pedal Box

Having measured the distance between the holes in the pedal box as 43mm between centers, I filed the master cylinders to match and fitted them to the pedal box.

Tomorrow I intend to grind out the holes in the pedal box so the boots on the master cylinder will fit.

Build day 8

Fuel sender

I installed the fuel pump and sender to the fuel tank; not particularly difficult except the one bolt is under the pump outlet and needs to be tightened before the rest.

Rear Brakelines

Also I connected the rear brake hoses. Both the holes in the brackets that the hoses fit to were too small so I had to file them out with a rattail file.

Clutch, flywheel and pressure plate

I have taken photos of my clutch, flywheel and pressure plate.

There is an ulterior motive here...I am keeping a visual record of the build in case the QT inspector wants to confirm that I am the constructor and didn't have it done for me. Although how that matters is a mystery to me.

Master Cylinders

I spent some time trying to nut out my pedal box and how the master cylinders fit and found the following:

1. The kit comes with large and small reservoirs and brackets and plumbing to mount the reservoirs "remotely". The pedal box is too small to fit them on the cylinders but I need to ask whether I should use the large or small.

2. The three banjo bolts supplied seem to be too long for the outlet of the master cylinders. I need to check that my assumption for assembly is correct, but I may need to replace these.

3. The two mount holes that run across the top of the cylinder are too long to all fit square on the pedal box so some filing is required.

4. The hole in the pedal box is just too small for the boot on the front of the cylinder so more filing.

While I was looking at the hydraulics I had a look at the front callipers and found that one banjo bolt has three holes in its shaft the other only has two, I'm guessing that these holes aren't the limit for the fluid flow but I want to ask the question of Frank@Birkin anyway.

Build day 7

Wheels and Lights

I wanted to get an idea of the offsets and other measurements needed to spec the wheels so I fitted the front and rear wheel arches. Also I took the opportunity to fit the spare wheel holder to get some photos so I can think about how I am going to set out my lights and what lights they will be.

The gas bottle in the background of the second photo is for the water heater I had to install this morning for wifey so she can properly shampoo her horses hence the pitiful build progress today (plus I am short some parts but I felt she needed the guilt).

Distance from the outside of the rear wheel arch to the face of the hub is 105mm. The rear spigot diameter is 57mm and the distance from the center of the hub to the outside of the calliper is 150mm.

Distance from the outside of the front wheel arch to the face of the hub is 75mm.  The front spigot diameter is 60mm and the distance from the center of the hub to the outside of the calliper is 150mm. The arch itself is 220mm wide.

Oh, and Happy Star Wars Day, May the Fourth be with you.