Tuesday, 26 April 2016

Suspension Overhaul

So I cracked on at the weekend greasing up the suspension. I also decided to fit the heavier springs at the front due to the suspension maxing out sometimes.

I fitted a 5kg spring to the front rather then the 4kg spring I currently had. First thing i noticed was seeing as I used the car all last summer and stored it over the winter it was still very clean in the arches.

So I removed and greased up the suspension as well. I used a Lithium grease as the bushes are polyurethane and not rubber. I had to remove the lower arms, the front of the arm is a threaded rod so under breaking pushed on the bush and as the suspension would moves up and down cause the squeaking. I then refitted to move on to the coilovers.

It took me about 2.5hrs per side, not rushing and getting plenty of grease in there and setting the correct ride height.

The difference is like night and day, the suspension on the car is now handling like what a production car would feel like. I don't have to dodge drain covers, large holes etc... the car just glides over them. Its firm but still comfy. The new seats will of no doubt have helped in this with more padding as well.

So for the next week or two hopefully i'll drive it a bit more and just enjoy it and confirm everything is how I want.

If it is I can move on to meshing around the exhaust and continuing to build the wing I want to use on it.

Thursday, 21 April 2016

A couple of Journeys, so what issues?

So I've had the car out and the good news is no major issues after doing around 70miles. I've put a new exhaust tip on which Ill show soon and Id been having a problem with it staying still but I've solved that. Ill detail more on that next time.

So I headed over to see my uncle and he noted that he could hear some squeaking and it was quite loud! This will be the polyurethane bushes, when I fitted them I thought there wasn't really enough grease with them. Well its been over 2yrs now and they need re-greasing, so ill do that. At the same time I'm going to fit heavier springs at the front. The suspension is just bottoming out and a bit more resistance should stop this or at least help a lot, I still don't want it too hard though.

Thursday, 14 April 2016

Dashboard in and seats test fitted

So the dashboard had to be put in over the centre tunnel. It was a tight fit but in some ways that is good as it wont move. Ive only had to secure it to the cross member with 1 sturdy bolt just to hold it there and being honest I dont think it needed it other than for safety.

Once In I tested the dials and gauges all worked as well as the stereo.

All worked well and the look felt more natural. Next i made the vanity panel to go over the dials and the stereo. I actually mucked this up and got dirt under the wrap as I put it on the wrong side so it will need to be done again at some point.

I also put the buttons too far forward and only the hazard is accessible, lucky I can just drill new holes further back and move them.

The seats also go well with the dashboard and feel much comfier, however I will have to get rid of the seat rails and making them fixed, the extra cushioning has raised the position and the 25mm drop will be a big gain to have.

Wednesday, 6 April 2016

An update... a long time coming

So the work on the car has continued over the winter but as well as that I've been busy with other things in my personal life. So lets catch up!

The lights got fitted and are working and I had moved on to the interior, making it out of foam...what a disaster. I covered all the foam to stop the resin going through and started to fibreglass etc... but the shape was horrible, so I went back to wood.

As well as this I wanted to give the tunnel piece a lip at the top to make it easier to cover and fit any other panel pieces I might want to fit. I next moved on to making the skeleton of the dashboard. as it was from scratch and was going to be fibreglassed eventually I could use relatively thin wood.

Following this I made two pieces to go on the rear firewall and covered in leatherette. I decided to get rid of the carpet rear firewall as it wasn't easy to secure and I wanted to try something different.

Next I got some cloth and stapled it down on to the dashboard frame. This was to form the base structure. I soaked it in resin afterwards to give a good firm structure.

As well as this I made mounts for the dials and headunit (covered later on). Next was on to the filler, well I used a fair amount to get it to the shape I wanted but suits the car a lot more and when I make the piece to sit over the dials it will cover the ignition as well.

Next was to remove the pieces from the car and cover them in material. So i started with the tunnel and the speaker pod at the rear.

As well as this I've got car mats as my feet were wearing out the carpet quite quickly as it happens! Also I created a vanity panel in the centre console, which holds the 4 previous buttons that were there and a new button to do with a rear view camera. The interior is looking a lot cleaner and more professional like this.

I'm currently now working on covering the dashboard itself with the same material then will fit it and finally the seats.

Whilst doing all this I decided to get a double din headunit. The unit I've gone for is a 7" unit which is pure android. It has a lot of features like bluetooth, usb, sd etc... also GPS maps and wifi. This means I can pull up outside the house and on the spotify app download all the music locally that I want to play or of course make my phone a hotspot.

Once its all back in I can start to use the car again. I've continued work on the rear spoiler although this is 2nd to the dashboard.

Sunday, 8 November 2015

Rear Lights & interior progression

So i continued work on the lights and got all 4 units made, I wanted them to be smoked but not take away too much light. the camera gives a relatively good idea of how they look at this stage

I then tested all the wiring works as expected.

with that complete I set about putting them on the car. Im not the biggest fan of the look with the lgihts off but still is an improvement and with a wing etc... completed at some point in the future it will look much better again. however as ill be running with the lights on anyway I think it looks much better.

So I started on the interior, first of all making a Tunnel cover out of MDF, its 9mm thick and with the correct spacing etc... is very sturdy. It is braced throughout and a lid out of MDF put on to a part of it, I will continue the wood down the edge to give a large border.

As well as this I started to mould the area where I will fit speakers to out of foam

I'm happy with the design, however when I covered the foam with felt and soaked it in resin, it just came away from the foam as I was unable to staple to it, So although its given me the rough shape it would be alot of work to sort out.

So what I will do is make the 2 side panels out of MDF and brace it across the middle with wood a few times to give a sturdy piece. I till need staple foam across the curves edges and soak in resin to make it hard this should then give me the finish I want with less work to be done to the piece.

I will use a router on the MDF parts to curve the edges neatly. Hopefully by the end of next weekend I can have the back piece that will hold the speakers finished in terms of shape.

Tuesday, 27 October 2015

rear lights Evolution v1

So whilst I continue to design and decide what to do with the interior I've been working on the rear lights. I wanted to replace them with a more modern look but still plug and play type of drop in to the current fitting.

The lights are currently a round cylinder and when you take the front cover off it has a normal bulb. So first was to go for a more modern look with two rings either side of the car and keep it within the same housing. The design involved making a metal holder for LED COB rings (80mm and 90mm) and a 5 watt LED in the centre for the indicator on the two outside ones and fog and reverse on the two inside ones.

So first of all the metal holder was made and test fitted with the LED rings and 5w LED and that it sat flush in the holder.

After this the ring itself was Anodised black, the side walls of ring area would then be polished back to reflect light.

Following that the 1st set of frosted light covers were made. These light covers were to ensure they gave the light look I wanted.

so it was time to test them, at this point they are just frosted covers with horrible screws and no profile. So how was the look...

Overall I was really happy with the brightness and the look with them on. They are bit brighter than normal lights but once they are smoked that will dull slightly. If you want to see a video of them I have one on my instagram account @iwanabeaferret.

Now the current stage is making the lens covers to a high standard and similar in profile to the original set so first a test lens has been machined and you can see the profile change and finish better. The next stage is to do this in a 15mmm perspex block and then spray them smoked. I will then decide either to leave them matt or go gloss depending on the look when they are finished.

i'll cover the electrics next time as some regulators and other parts had to be used.

Monday, 19 October 2015

work has started (interior)

So first of all I got one last local meet in before the end of September and the weather changed. the cool evening air gave a nice crispness and punch to the engine as well.

So within a few days I was on to the job at hand...the interior. I'm in no rush to do this and will do it right rather then fast. So previously I had ordered my new seats. The criteria was I wanted small ones in terms of height and width and also reclining. Reclining was simply because there was a small amount of space behind the seats but with a fixed seat you simply cant get in there. With a reclining a hand luggage suitcase would fit or other bags you may want to put in out the way.

Luckily these were also one of the cheapest seats as well, which is rare to happen. The comfort of them compared with my current ones is like night and day so I'm very happy. They raise the seating position a little but I can counteract this by removing the carpet and sound deadening from underneath the mounting points so there will be little difference but more comfort, the seats also feel like they hold well for their shape.

so I test fitted one of the chairs, you can see even though they are the smallest reclining seat I could find there is little difference in size but they are slightly smaller, in theory they will probably be easier to get into as well.

So on to the interior and it came out easily enough, as I took it all out the dust from the bodywork was everywhere so ive done a fair bit of cleaning already and then moved on to tidying the new wires I had added once on the road. (tv screen, electric door opening).

Since then I've been measuring areas of the interior to start designing the new centre console between the chairs.