Slow progress is still progress...

Once again, it's been another month with nothing to update on the build, due to work, christmas and having man flu. :(

Anyways, managed to get a little more done to get one step closer to driving it. The side panels from Saturn are now fitted and the suspension all bolted up tight.  The exhaust's finished, just needs a cover over the cat to keep Mr IVA man happy.  The wiring issue with the rear fog light is now sorted, was all down to a faulty relay!

I've got the main part of the roll bar now. Big thanks to Ash on the Haynes Roadster forum for sorting out a group buy. It looks spot on.  I'll upload some pics once it's welded and painted.

So things are finally looking up again.  Have a look at the pics to see how it's doing. :)

Still going.

Once again, it's been a while since i've posted anything on here. Been really busy at work, which is good, but haven't had much time for the build.

Work got cancelled today due to the snow, so i started work on my wheels - another job i've been putting off for a while :P  They're all rubbed down, one primered, one painted just waiting for laquer. Should look good when they're all finished.

Also, recently got some side panels from Andy at Saturn Sports Cars, so that's one of the next jobs to do and i've got a roll bar on its way soon too.

The list does seem to be getting smaller slowley.

Back on track.

A lot's happened since my last post. The reason it's been a while is because I lost my job for 3 weeks until a new site started up.  So the build was on hold until i started back.

Luckily, i've started back work - so the build progress can carry on.

So it was time to give the key a turn for the first time!! (still no fuel tank at this point, so the pipes are balanced into a jerry can)

It's running rough as it needs mapping still, and it sounds as if it's only running on 2 cylinders for some reason.

Anyhow, at least it started!

Today i got the fuel tank in and piped up and finished off a few bits and bobs that have needed doing for a while.

The future's bright.

Got the tub and one arch fitted today along with the rear lights.  Also bolted the mirrors onto the scuttle.

The Saturn boys have paid a visit.

Andy and HAndy popped down on Saturday to drop off my rear tub & arches and to have a look at my build.  I got the tub cut to shape and in place yesterday, but my plans of a full day on the roadster failed, as the exhaust on my everyday car decided to snap clean in half at one of the joints on the manifold!

Anyways, managed to catch up today, got the base map and all the sensors calibrated on the ecu, and started to fabricate the exhaust. :D

Waiting on a starter motor arriving in the post and need to sort a fuel tank soon!

Here's some piccies to keep you all happy...

Small update...

Got most of the wiring in place, so made a start on the dash. Not much more to say really, as pics of wires aren't very interesting. 

One step closer.

Popped over to saturn this morning to collect my scuttle. Andy also sorted me out with a piece of aluminium to make the bulkhead panel. Managed to get that cut to shape this afternoon and made a start on the wiring.

I've got the wires running from the scuttle to the back of the car and from the scuttle to the front of the car all in place and clipped. Also fastened the relay and fuse holders to the bulkhead panel.

2 Month anniversary.

Well, i got my donor parts delivered 2 months tomorow, and this is how it stands now...

Got the engine fitted today, the brakes are about finished, just waiting to get a couple of fittings. The seat's bolted in, rear transmision is all finished, suspension is all sorted.

Going to make a start on the wiring next.

Pipework's about finished.

Got the brake and fuel pipes plumbed in today. Put that many rivets in, i managed to snap my rivet gun on the last one, my arm feels like it's going to drop off!

Hopefully will be able to get the engine back in tomorow (need to finish shortening the sump first).

Whey! Got some wheels on at last!

The guys at saturn sorted me out with some diff mounting brackets, so i was finally able to get the diff, driveshafts, rear brakes and wheels on.

Quite happy at the pace it's coming together. I also ordered my scuttle from Saturn, which is getting made as we speak. :D

Engine's sort of in place

Had a full afternoon on the build today, but didn't seem to get much done for some reason :(

Anyways, the engine is in position, with the gearbox mount bolted in and i made up an engine mount on the exhaust side.

I was hoping to have it all mounted and finished today, but things happened a little slower than i'd hoped. Ah well, at least its a bank holiday tomorow :D

A little update.

Managed to get the paint off the nose cone, luckily, so it's now packaged back up out the way.

Also recieved a nice new set of gaz fully adjustable coilovers for less than they normally are, so fitted them yesterday.

Next up, diff and brakes to sort, then engine trial fitting time.

It's starting to look like a car now. :D

I've bolted the drivers side wishbones and hubs on and balanced the nose cone in place to figure out radiator mounts.

Looks great, i'm very pleased with the results.

Somehow managed to get some wet paint on the bubble wrap that protects the nose and it's got some on the front. I'm hoping i'll be able to polish it off when it dries :|

Just a small update to show how things are progressing. The drivers seat runner is finished and welded in, the last of the chassis plates have been welded on, the chassis has been fully painted and the driver's floor finished.

Finally started again...

It's been a while since i've posted as the project's been on hold as i had no electric. Finally got the generator back the other day, and it seems to be working fine. So i can hopefully now make some more progress.

Yesterday i got the rear upper wishbones made up and this evening fabricated the driver's seat runners and welded them in the chassis.

Not long now and hopefully it'll be on it's wheels.

No pictures today. :(

A day off from work and a day off from welding.

Got a day off work today, but the genny's still in for repair. So i decided to put a few bits together that i've been buying over the last few weeks :D

Throttle bodies...

(the standard trumpets have 2 smaller (i'll be getting them all the same size)

Engine hoist...

Generator's playing up again :(

Once again, my generator's decided to cause me problems. It just dies every time it's under heavy load (welder).

I've dropped it off at a local machinary place, who hopefully can fix it tomorow, fingers crossed.

Take a look at my rear end.

It's been a few days since i've posted, as i've been busy at work, so haven't got a lot done on the car. Still... Small progress is still progress, the chassis is about finished now all the framework is done and the suspension mounts etc are all fully welded; just got the seat runners and a few plates to weld in, then ready for painting properly (it's half primered at the moment).

Not often i post pictures of my behind, lol, but may as well tease you with one. (excuse the lighting, it got dark when i'd finished)

Front suspension brackets are on.

Made a jig for the suspension brackets and fitted the front ones today. The rears are in the jig now too, ready to be welded up next time i do some work on the car.

Another small update.

Was hoping to get a full day on the car today, but my grinder packed in this afternoon, when i got home found that it was just a wire had snapped inside the flex. So can crack on again tomorow.

By the end of tomorow i hope to have the rest of the wishbones cut (and possibly weld one or two) and get the suspension brackets and seat rails welded on the chassis.

Then i'm waiting to get some M8 nuts for the roll bar mounts (i've only got stainless ones at the moment) which means i can get the back end of the chassis finished, then some 7/16 unf nuts for the seatbelt mounts (the shop that sells them is only open mon-fri 9-4.30 when i'm ususally at work)

After that, the chassis is about finished, besides engine mounts and headlamp brackets :D

Now fully welded.

The frame's now fully welded, unfortunately the build table had warped in the middle without me noticing, so the middle of the chassis is a few mm lower than the 2 ends - which shouldn't cause a problem with the suspension/steering geometry, just the side panels will probably need some modification to fit.

Next on the to do list is welding all the chassis plates, suspension brackets and steering column supports etc.

Almost there with the frame work.

The chassis is just about fully welded now, but I ran out of wire again getting the last few upside down. The rear diff cage was a nightmare, as most of the chassis tubes for it had been cut wrong; so nothing lined up. Took a little longer than i'd hoped but got it sorted in the end.

Excuse the pic, it was taken in the dark with my phone camera.

One step closer to a finished chassis.

It's getting there now.

The gas ran out on my welder yesterday, so i put some gasless wire in; I've found that although the welds don't look as nice, it runs much smoother off the generator - so i've decided to do the full chassis gasless. Once it's had a skim over with the grinder then painted you won't be able to tell the difference anyway.

Have a look at the pic to see how it's looking.

A Little More Progress

Today i cut out the welded bend in the front frame (the person i'd bought the chassis pack from had welded it wrong) So I re-welded it at the correct angle. This now ment that i could cary on progress with the rest of the chasis. Also made recently made the rear lower wishbones.

Front lower wishbones are finally done.

Finally managed to get the welder working and running off the generator at last, so i can finally crack on with the build.

Unfortunately, the front frame of the chassis with welded angles has been welded wrong by the person i bought it off, so the chassis is on hold until i can get that sorted.

So I've decided to do some of the suspension components. Got them all set up ready to weld in the jig, then the gas decided to run out on my welder - so packed up, went to get some more gas and started again. Then the petrol decided to run out on my generator, so once again packed up and went for petrol. 3rd time lucky, managed to get the 2 front lower wishbones welded up and painted at last.

Next up to make the rear lower ones.

The build so far.

As it stands, i've currently got a dismantled sierra, 2.0 blacktop zetec engine, a few random boxes of lights etc and a big pile of metal ready to make the chasis.

Unfourtunatley, my new welder seems to be having problems, so my build is at a stand still really until it's sorted, which is my next step.

I've got the base of the chasis layed out on a build table and tacked together, i've cut all the angles on the lower wishbones and cleaned up and painted some of the donor parts.

I've also got hold of some Triton race seats which arrived today. :D

The blog is here.

As you'll probably know, if you're reading this - I've started building a Haynes Roadster kit car, based on the book by Chris Gibbs. (the pic is of Andy's at Saturn Sports Cars - Have a look at their site, great guys and very helpful)

I've decided to set up a blog of my build's progress, rather than posting updates on various forums.

So here it is..

Enjoy and don't forget to come back to see how it's going.

Dave