Dommo Posted September 18, 2011 Author Share Posted September 18, 2011 Seeing as CarbonMods have stopped making them, I thought I'd best order the dash early. I'd looked at alternatives but just didn't like anything else as much as the CarbonMods one. I'd wanted the mirror covers too but it seems they're sold out already. Ah well. Nothing like a bit of carbon motivation though... Westfield still haven't managed to get the drivers side footwell panel to me, so I thought I'd crack on with the underside instead. With the aid of a willing mate, we flipped the chassis and got drilling and riveting. Then it was on with the brake pipe fitting. First job, mount the pressure switch. Oh look, surprise surprise Westfield haven't given me an M6 bolt for it. It doesn't appear on any of the pick lists either. Temporarily held it with a longer bolt for now, using a nut as a spacer. I'd best remember I've done that come IVA time. Onwards. First pipe, primary port to front three piece. A few bends, more clips than I probably should have used and done. Pipes from the three piece to the flexi pipes. Pretty straightforward. Cunningly, I left the clutch master cylinder off to give me more space fitting the brake pipes. Idiotically, I didn't then check the fit and had to redo the front half of that pipe. Not particually happy with it, and I'm far from happy with the front to rear pipe. I think I'll get some pipe from the auto factors, get a flaring tool and make my own up. It's still good fun though! I should slow down really, else I'll run out of things to do before I've saved up the money for the completion kit... Quote Link to comment Share on other sites More sharing options...
Mark (smokey mow) Posted September 18, 2011 Share Posted September 18, 2011 I see you still haven't managed to seperate the diff from the PPF frame yet Good progress, just don't go drilling the dash in the wrong place, you've only the one chance and wont be able to get another no pressure!! Quote Link to comment Share on other sites More sharing options...
Cleggy the Spyder Man Posted September 18, 2011 Share Posted September 18, 2011 good progress being made - keep going at it Quote Link to comment Share on other sites More sharing options...
Dommo Posted September 27, 2011 Author Share Posted September 27, 2011 No pictures I'm afraid, but just a quick update. Attacked the front-rear hose last night. Much easier this time! The copper/nickel pipe I bought is easier to manipulate than the ones Westfield supplied and seeing as I had 25ft of the stuff, I could take a much neater route. The other two rear hoses were shaped fine, seems it's just the long ones I'm inept at. Ordered 20 of those clips yesterday to help me keep it all neat. Also deliberated with Westfield as to whether I'm supposed to have the fibreglass drivers footwell rather than the metal one. The technical guys were adamant that it doesn't clear the clutch slave cylinder but every build blog I've seen has it. It's even in the build manual! They were going to phone me back but haven't yet, so I guess we'll see if it arrives today or not. Also managed to get the fuel lines shaped. Well, two of them. For the first one, the wrong size was used on the pipe bender and it simply creased. Obviously, that was a friend that did that... I do different silly things like flaring brake pipes before putting the nut on. Diff is still attached to the PPF by the way Quote Link to comment Share on other sites More sharing options...
Mooch Posted September 27, 2011 Share Posted September 27, 2011 Hi, Dommo, Aaah, the happy experience of fitting the fuel lines and brake pipes. I managed to mess up the long brake pipe front to back, and one of the fuel lines. I replaced the fuel line with 8mm cunifer pipe, which was a doddle to bend by comparison. Fear not, you are not alone in having to rework these particular bits! I'm confused regarding the footwell side panel issue - surely that has to be the GRP one because it has the foot rest built into it. You won't have room for your tootsies if a flat alloy panel is used. Unless the 1.8 engine is wildly different (mine was a 1.6) the clutch cylinder shouldn't come into it - the only clearance issue is with the fuel lines which need to be fitted about 25mm inboard on the front bulkhead to clear the operating arm on the slave cylinder. I didn't have this panel supplied with my starter kit, either and had to hassle WSC for one to be sent. Keep at 'em until they give in - you need it! Mike Quote Link to comment Share on other sites More sharing options...
Mark (smokey mow) Posted September 27, 2011 Share Posted September 27, 2011 I'm confused regarding the footwell side panel issue - surely that has to be the GRP one because it has the foot rest built into it. You won't have room for your tootsies if a flat alloy panel is used. Unless the 1.8 engine is wildly different (mine was a 1.6) the clutch cylinder shouldn't come into it - the only clearance issue is with the fuel lines which need to be fitted about 25mm inboard on the front bulkhead to clear the operating arm on the slave cylinder. I didn't have this panel supplied with my starter kit, either and had to hassle WSC for one to be sent. Keep at 'em until they give in - you need it! ^^^^^ Quite correct The position of the clutch slave is almost in line with that of the master cylinders, i.e. in the engine bay and not in the transmission tunnel For info the 1.6 and 1.8 gearboxes are the same and IIRC the 1.8 engine is about 1" longer than the 1.6. Not the best photo but you can see the rough position of the slave cylinder in this pic. Quote Link to comment Share on other sites More sharing options...
Dommo Posted September 27, 2011 Author Share Posted September 27, 2011 No panel here, but thanks for the photo. That makes it perfectly clear - now I can do a good job of pretending I know what I'm talking about when I phone them up tomorrow! Quote Link to comment Share on other sites More sharing options...
Mat Jackson Posted September 27, 2011 Share Posted September 27, 2011 Sorry, have Carbonmods stopped making dash blanks? Quote Link to comment Share on other sites More sharing options...
Dommo Posted September 27, 2011 Author Share Posted September 27, 2011 Sorry, have Carbonmods stopped making dash blanks? It says discontinued, but looks like they're still in stock at the moment: http://www.carbonmods.co.uk/Product....01.aspx Quote Link to comment Share on other sites More sharing options...
Dommo Posted September 28, 2011 Author Share Posted September 28, 2011 The panel is no longer part of the kit and comes supplied with the zetec sport only. So I've bought one at £15+VAT Quote Link to comment Share on other sites More sharing options...
Captain Colonial Posted September 28, 2011 Share Posted September 28, 2011 No panel here, but thanks for the photo. That makes it perfectly clear - now I can do a good job of pretending I know what I'm talking about when I phone them up tomorrow! The Parts department do read these boards - refer them to this thread. Quote Link to comment Share on other sites More sharing options...
TIG Brother Posted September 28, 2011 Share Posted September 28, 2011 That's a bit cheeky not giving you the GRP panel for the drivers side. This is a must have. You have very little room for you're feet without this. Quote Link to comment Share on other sites More sharing options...
Mooch Posted September 28, 2011 Share Posted September 28, 2011 That's a bit cheeky not giving you the GRP panel for the drivers side. This is a must have. You have very little room for you're feet without this. Outrageous that you should have to pay extra. This panel should be part of the kit as it has been for all SDV builders that I'm aware of. As TIGBrother says, it's not very roomy down in the pedal dept without it. Make a fuss and point the Tech department to this thread. Tell them the SDV brotherhood will be outside with placards and flaming torches if they won't play ball Quote Link to comment Share on other sites More sharing options...
Mark (smokey mow) Posted September 28, 2011 Share Posted September 28, 2011 The panel is no longer part of the kit and comes supplied with the zetec sport only. So I've bought one at £15+VAT yeah right and what's the betting that line get's used for all the other parts which get supplied wrongly by them or they forget to include in the kit. If it's in the build manual then I'd expect to receive it or an equivalent too, not be charged extra. Quote Link to comment Share on other sites More sharing options...
Dommo Posted October 12, 2011 Author Share Posted October 12, 2011 Progress has been a bit slow recently whilst waiting for bits, and trying to ensure I don't run out of things to do before I've got the money for the completion kit! First things first though, I'd like to introduce my new best friend: I swear I need my head read for not buying that at the start of the build! It's reduced the rivet:swear ratio substantially... The footwell panel finally arrived at the start of the month: It looks different to what I've seen in other builds, I was sure it was going to be fibreglass. Anyone care to comment? Build wise, I replaced the front-rear brake pipe and the front-three way pipe. Still not perfect, the pipe I bought came coiled and was quite difficult to get a straight line. Either way, I got it to look vaguely neat and use the original fixings. I then ran out of P-clips. With five and a half metres of fuel line supplied, and a recommendation of fitting a clip every 20cm, Westfield saw fit to only supply 20 clips. I ordered another 20 and fitted them a bit more often to try and keep it as tidy as possible. Whilst waiting, I decided to give the hydraulic rivet gun another play and so fitted the passenger inner footwell panel. After drilling the holes for the other panel of course! The P-clips arrived this morning, so it wise time to get these pipes done and dusted. Shame it took until the 3rd fuel line for me to get the hang of making them tidy! Fortunately the rear was much tidier, so it's just the front letting the side down. Whilst the chassis is upside down I'm going to paint the welds to ensure they're fully covered (as mentioned earlier, the powdercoating isn't great here). Then it's time to put the chassis back up the right way, finish off the panelling and start on the wishbones. It might start looking like a car soon... Quote Link to comment Share on other sites More sharing options...
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