Body work in production

Some great step by step pictures of the Bodywork being created.

Project Cyana

Rob emailed me a number of photos of the process of producing the bodywork.

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Two sets of body work and and the sports kit.

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Engine mount issue

I while back I ordered up the engine mounts from Fury Sports Cars and other than taking them out the packet hadnt really done anything with them.

This weekend I decided to bite the bullet and get the engine properly mounted and drill some holes in the chassis mounting plates, and thats where I had a problem.

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The horizontal line going across the rectangle is the centre point for the engine mounts. Now unfortunately that line was also dead centre one of the chassis members! So it turns out that the chassis mounts supplied were actually about an inch to short on the passenger side.

After some deliberation the easiest and simplest method of sorting this is to create a spacer moving the mount away from the engine. Otherwise its a cut and shut job with Mr welder and Mr grinder and to be perfectly honest I just cant be bothered!

Ive mocked one out of 19mm Mdf and it works perfectly so the next stage is to get some 20mm aluminium bar and make the real deal.

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ST power

Just a quick shot to show how the engine will fit. Im surprised how high the zetec engine is, however I test fitted the bonnet whilst my brother in law was over, and it all fits nicely.

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How to remove a flywheel?

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How do you remove a flywheel without the correct locking tools?

As per the picture above you will need something that can hold the flywheel in place and stop it rotating whilst you undo the bolts.

Ive used Uni Strut as its like grownup Meccano and has elongated holes which means it lines up with the clutch bolts easily.

You could use anything, as long as it is long and strong enough to do the job.
You just nees to measure the holes where the clutch cover plate would attach and bolt it on. Then simply wedge your homebrew locking tool either against the floor or under your foot, and hey presto the flywheel is fixed in place allowing you to loosen the flywheel bolts. Simples

Finished Panels

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All interior panels are now completely finished. Unfortunately I have learnt the hard way that a sharp drill is imperative when drilling nice holes….although it seems ridiculously obvious having now written it down!

A couple of the holes have elongated a bit, but luckily they will be out of sight once body etc is in place.

Im not concerned about the knock on effect of the rivet holding properly in these places as I intend on tiger sealing all panels as well as the rivets.

Sloppy 2nd!

So you may remember from an earlier post that I bought the type 9 blind, as it had no gear lever. I bought a quaife quick shift and having bolted it in, found that every gear was really crisp and easy to find…except for 2nd!

I remembered this was an issue when the car had its original engine so decided to do some research into the issue. It turns out that the main culprits are either the synchro has failed or the plastic gear lever saddle has worn away.

Always keen to explore the cheapest option first I discovered you can get a replacement brass saddle, although not entirely cheap for what it is, compared to a syncro rebuild it was worth a try! Demon tweeks / merlin etc all sell them, but the cheapest I found was from Steve Perks at http:// http://www.spcomponents.co.uk £20 Inc Vat and postage.

You can see below that the plastic version I removed had lost its lug.

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Its simple enough to remove the saddle with a pair of needle nose pliers, leaving the following…

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I then put a little bit of grease on the inside of the saddle to keep it in place, and lowered it into place.

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Now the description says that the tips of the saddle should be crimped over slightly, however I couldnt for the life of me find either the space or strength to do so. Once the gearlever is on the saddle cant go anywhere, so ive decided to leave it as is, we’ll see what happens over the life of the car I suppose.

So the million dollar question, did it work? The answer yes! 2nd now comes nice and easily just like the others.