Thursday, 31 October 2013

Delivery Day

So today was delivery day... Ill write a more detailed account of the day and some closer photos over the weekend, but here's a teaser of some of the days photo's.

Friday, 25 October 2013

Delivery Week...

Just to say the blog will get updates probably once a week (maybe twice) but I've decided I'm going to tweet pics along the way more regularly than the blog, with blog being a build diary which will have useful updates and pictures.

The tweets more along the lines of pictures and comments. I do tweet my thoughts on other things as well but nothing OTT. if you want to follow me for the delivery pics you can on

I will start the DDR tweeting from the moment the delivery truck arrives next week :)

Sunday, 20 October 2013

Little bits going on while I wait...

Well the wait is almost over! Boat comes into Dock late on the 25th. It will be a few days after that for delivery.

In the meantime I've been ordering other little bits I know I need and that I don't require the car to measure to ensure they fit.

So I've ordered a new water washer jet system, its a small unit holding 1.4litre which is plenty and gives me flexibility on where I mount it. I was going to use the MR2 system but it was dirty and old and for the price of £15 i'd rather have a new looking system to give it that better look. I will use the current wiring loom and then it can still work off the steering column stalks.

As well as this I decided the fans and metal shrouds for the radiator were just to heavy and not looking as nice still as I hoped, so I bought some new 12v fans with a high CFM of 2000. This should be plenty and help with cooling, I will be making some ducting later on in the build which should aid this further.

I've also ordered a new horn and some little side lights to meet IVA requirements.

I previously gave a quick guide on brake pipe flaring, although they were coming out well it was hard to get it right 99% of the time and if its not right and wont seal it would need to be cut off and re-done. They were not coming out flat and the reason is as you screw the die in further to create the flare it wants to twist the claw round, giving you an uneven flare.

So I bought a 2nd tool, this tool has not produced one bad flare. same principal in clamping but easier by just pushing the handles together, but the screw sits on a flat plate platform which cant twist meaning it goes down flat and even every time. The tool was not expensive at about £30 as well. The tool model is a Sealey AK5063

Monday, 7 October 2013

Throttle Pedal

The car requires willwood clutch and brake pedals which match nicely together and look professional. The gas pedal that's suggested was by a different make and to be honest wasn't too my styling (all other areas black and this pedal was bare silver metal) but that's the advantage of a kit car you can make the car your own as well. So I've been looking into pedals a lot based on what will fit the area and also the look I want.

So below is a comparison of the pedal I've bought and the original;

The pedal will actually fail the IVA test in its current state as its a requirement to have an anti slip surface, so i've ordered some self adhesive anti slip tape for that. The photo below is with me holding the brake pedal in roughly the position it will sit next the throttle pedal.As you can see I think the styling goes well and should work well together.

The pedal can be adjusted for the amount of travel so I will be able to configure it to open the throttle over the full pedal movement range if required. I plan on sound proofing and carpeting the floor so that will move the feet's natural resting position higher up the pedal which will make it more comfortable as well.

Saturday, 5 October 2013

Brake pipes and double flaring

As part of the IVA test, all brake lines / fuel lines including hoses must be securely mounted to the chassis. I will be using the below, these are clips which have a collar which when pushed into a 6mm hole, flares out on the other side of the hole, holding the pipe line secure.

To get a professional finish and better pedal feel. I will be using Kunifer pipe throughout the car's main body for the Brake lines and clutch and using braided hose to attach to the callipers and the clutch cylinder. Kunifer pipe should ideally be used instead of standard copper, Kunifer pipe is slightly different to copper and has better corrosion and fatigue properties to just copper alone.

One of the problems when buying some pipe is that it comes coiled up so unwinding by hand can leave you with no perfectly straight piece of pipe. The easiest solution for this is a bit of 4x2 and to drill a hole that is slightly wider than the pipe. In this case a 5/6mm hole for 3/16 pipe (A good mix of metric and imperial there!). Pass the pipe through it and this will make the pipe straight and give a good look finish.

Brake lines require flaring for unions and the joining to hoses. so my flaring kit and some pipe arrived so I decided to give it a go. This was my first ever flare, so it can only get better from here with some practice.

First of all cut your pipe with a cutting tool, this is the easiest tool to use and will give the best cut, it will also leave only a little de-burring to do.

Once you have cut the piece you want, you need to clamp it in the flaring tool, with a piece sticking out above. The amount sticking out will depend on diameter of the tool and it should be the length of the base of the first flaring piece as shown below.

You now need to turn the piece over and place the thin end inside the pipe and put the clamp on ready making sure everything is lined up.

You now need to tighten the tool ensuring the flaring tool is squashing in an even fashion across the tube or the flare will be poor. this should be done so that no copper pipe can be seen between the clamp and the flaring piece, then undo the flaring tool, leaving the piece in the clamp and you'll be left with the below;

Following this you now just redo the flare again with the clamp and tool itself (shown above) but this time be careful not to go to far, this should not be squashed flat but be done firm. This will leave you with a flare like the below;

This was the first ever flare I've done so they will get better with more practice but for a first go to understand the principle it was good enough.

* Make sure you de-burr the pipe before flaring
* Use a little bit of brake fluid on the piece so that the flare tool doesn't grip and creates the flare smoothly and hopefully produced a better flare.