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Progress to date: Robert's Roadster

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  • #61
    Re: Progress to date

    I don't know if this will work...

    This is my spreadsheet list of tasks for the Marlin. it appears here so it may post?



    Chassis Tasks
    Completed
    Comments
    Create Rear Gearbox mountings
    YES

    Fit gearbox mountings
    YES

    Make inriggers for gearbox mounts
    YES

    Fit inriggers
    YES

    Make engine mountings
    YES

    Weld in the engine mountings
    YES

    Trial fit engine and gearbox
    YES

    Adapt rear chassis for raising suspension
    POST MOT

    Measure up for propshaft
    YES

    Shorten propshaft
    NO
    Original propshaft OK
    Make seat mountings
    YES

    Weld in seat mountings
    YES

    Make roll bar and mountings
    POST MOT

    Install roll bar and mountings
    POST MOT

    Cut holes in 4x2 screen X Member
    YES

    Make strut brace
    POST MOT

    Make rad support
    YES

    Make battery box
    NO
    Have material
    Weld hinges to ‘A’ posts
    NO

    Make brackets for temp fuel tank
    NO
    Have material







    Suspension Tasks
    Completed
    Comments
    Order parts for front suspension
    YES

    Fit rubber bushes
    YES

    Assemble front suspension
    YES




    Make dowels for Van back spring mounts
    POST MOT

    Clean and paint Van back springs
    POST MOT

    Assemble Van back springs
    POST MOT

    Final fit back axle using Car springs
    NO








    Steering Tasks
    Completed
    Comments
    Slot mounting holes in chassis brackets
    YES

    Clean and lube Rack
    YES

    Fit gaiters
    YES

    Fit Rack
    YES

    Fit track rods to steering arms
    YES

    Final Fit steering column
    NO

    Track up
    NO

    Fit steering lock
    NO








    Engine Tasks
    Completed
    Comments
    Strip and clean engine
    YES

    Get crank polished
    YES

    Strip heads
    YES

    Clean up heads
    YES

    Port old head
    POST MOT

    Clean valves up
    YES

    Grind valves in
    YES

    Re assemble head with new stem seals
    YES




    Get block back from LE
    YES

    Clean and paint
    YES

    Assemble short motor
    YES

    Fit head assy
    YES

    Lighten flywheel
    NO
    Some scope but deferred
    Fit flywheel and clutch
    YES

    Fit water pump and dizzy
    YES

    Fit engine to gearbox, mount in chassis
    YES

    Fit manifold and carb
    YES

    Fit starter and alternator
    YES

    Fill with oil
    YES

    Test start
    YES
    No water, needs timing.
    Clean and test radiator
    YES

    Fit radiator
    YES

    Fit coolant hozes
    YES

    Pressure test cooling system to +1 Bar
    YES

    Test run, check for leaks
    NO

    Fit oil warning lamp switch
    NO








    Clutch Tasks
    Completed
    Comments
    Clean pressure plate
    YES

    Clean centre plate
    YES

    Clean slave cylinder
    YES

    Clean master cylinder
    YES

    Get slave cyl kit
    Pending
    May be OK
    Get master cyl kit
    YES

    Fit kits
    YES

    Clean and lube release bearing
    YES

    Assemble actuation lever
    YES

    Fit master cyl
    NO

    Fit slave cyl
    YES

    Connect and bleed
    NO

    Test
    NO







    Comment


    • #62
      Re: Progress to date

      OK, it seems to work, but limit's me to 20,000 characters. Not sure how it counts more than 20,000 characters here but there you are.


      Gearbox Tasks
      Completed
      Comments
      Clean o/d filter
      YES

      Fit new sump gasket
      NO

      Obtain and fit hex drain plug
      NO

      Clean clutch housing
      YES

      Paint clutch housing
      YES

      Replace front oil seal
      YES

      Fit new Clutch housing gasket
      YES

      Fit gearbox
      YES

      Fill with oil 20-50
      NO

      Test operation of o/d unit
      NO








      Transmission Tasks
      Completed
      Comments
      Replace propshaft front joint
      In Progress

      Clean and paint propshaft
      In Progress

      Drain oil from diff
      NO

      Fill with new oil GL4?
      NO

      Fit new axle casing breather
      NO








      Exhaust Tasks
      Completed
      Comments
      Make and fit Downpipe
      In Progress
      Auto Perormance Morecambe
      Make and fit System
      NO

      Fit and test mountings
      NO








      Wiring & Electrical Tasks
      Completed
      Comments
      Adapt and check wiring harness
      NO

      Fit rear lights inc rear fog
      NO

      Fit bracket for rear numberplate and lamp
      NO

      Wire back lights
      NO

      Adapt and Fit side lamps
      NO

      Repair and fit headlamps
      NO

      Fit front indicator lamps
      NO

      Wire Alternator
      NO

      Test Alternator
      NO

      Wire starter and solenoid
      NO

      Wire Radiator fan and switch
      NO

      Install Battery and main feed cables
      NO

      Mount and connect switch gear
      NO

      Fit horn and horn button
      NO

      Make bracket for front Number Plate
      NO

      Wire o/d and fit switch
      POST MOT

      Wire for speedo illumination
      NO








      Bodywork Tasks
      Completed
      Comments
      First Fit nose cone
      YES

      First Fit side panels
      YES

      Make extensions for side panels
      YES

      First Fit back tub
      YES

      First Fit back wings
      YES

      First Fit front wings
      YES

      Make and First fit hockey stick wing brace
      YES
      Need 4 Button M8 SS bolts
      Final fit Nose cone
      NO

      Final fit side panels
      NO

      Final fit back tub
      NO

      Final fit back wings
      NO

      Final fit hockey sticks
      NO

      Final fit Front wings
      NO

      Make step bracket under running board
      NO

      Adapt and fit screen valance
      NO
      Started
      Make and fit doors
      NO

      Make and fit dashboard
      NO

      Fit speedo
      NO

      Check speedo for accuracy
      NO

      Calibrate speedo
      NO

      Fit interior mirror
      NO

      Fit exterior mirror
      NO





      Comment


      • #63
        Re: Progress to date

        There, it's swallowed it and kept my formatting.



        Floor and Bulkhead tasks
        Completed
        Comments
        Modify bulkhead panel
        In Progress

        Patch Bulkhead to side panels
        NO

        Alter o/s seam in footwell to increase space
        NO

        Cut and fold floor panels
        In Progress

        Cut and fold Passenger footwell
        In Progress

        Cut and fold drivers footwell
        NO

        Drill and tap fixings for floor plates
        NO

        Cut and fold under seat panel
        YES

        Form panel for gearbox cover
        NO

        Final fit pedal box
        NO








        Brakes Tasks
        Completed
        Comments
        Clean and reassemble Master cylinder
        YES

        Fit Master cylinder
        NO

        Fit front flexy’s
        NO

        Make and fit solid brake pipes
        NO

        Connect up back brakes
        NO

        Bleed and test foot brakes
        NO

        Connect vac pipe to servo
        NO




        Install handbrake
        YES

        Connect handbrake
        NO

        Test handbrake
        NO








        This isn't going back to the start, just from when I had stopped pulling stuff to bits.

        Comment


        • #64
          Re: Progress to date

          A couple of photographs of the floor going in.

          [ATTACH]3464[/ATTACH]

          [ATTACH]3465[/ATTACH]

          I had the engine running last Sunday, it started at the first attempt after I got the oil pressure up. Running on all four and quite sweet, if noisy!

          Hoping to finish the floor tomorrow and start finishing the front bodywork, may be a bit optimistic with the shorter evenings now.

          Comment


          • #65
            Re: Progress to date

            oooh that's nice

            Comment


            • #66
              Re: Progress to date

              Hi Robert

              It may be the angle of your photo, but couldn't you have fitted your engine quite a bit further rearward, to help take the load to the back wheels for hill climbing?
              (It made me smile as I can barely get a cigarette paper between my rocker cover and the bulk head, and the servo has to be limited in diameter, whereas you have acres of space!)

              Mike

              Comment


              • #67
                Re: Progress to date

                Hi Mike, I have room for a V8 in there! It grieves me when I see Land Rovers in breakers yards with good fuel injected V8 lumps, going for scrap. But then I think of the fuel they would guzzle.

                Moving the engine right back occurred to me when I first saw the car again, I could see the potential for moving the engine back best part of a foot, why stop at the bulkhead? In fact the bulkhead is about in line with the front of the gearbox, since the clutch housing is 200mm I could easily have gained eight inches without touching the bulkhead.

                However... The National Trials Association regs state that to be eligible for class 7 the No 1 spark plug must be no more than 410mm behind the centre line of the front axle. I don't believe moving a 1275cc engine back even 12 inches would even begin to make me competitive in class 8 (Which are mainly special rear engined, high powered cars), so I decided to stay legal to class 7 (hopefully). I have made the engine mounting brackets with space to move the engine back about 45mm but that would also entail altering the gearbox mounting, so not that easy. Adding the overdrive gearbox has increased weight significantly and I am hoping all the weight I have added in the 'A' post and bulkhead area isn't too much of a penalty. I think I have saved some weight in other parts so perhaps it has evened out? The test will be to weigh it when I have finished. Hoping for 650Kg unladen but it may be a bit more... I am hoping for a 40%-60%, front - rear ratio, laden, we will see. The seats are heavy, with their integral seat belt mountings, the seat brackets are heavier! but at least they are near the back...

                I am very un-decided about the windscreen frame, which weighs a ton. For the MOT I am not going to fit glass, meaning I don't need wipers or washers. That will give me an opportunity to assess whether running without a screen reduces buffeting. I am going to fit a rear roll over bar once the MOT is done and the car on the road, I could replace the original ultra heavy screen frame with a steel tube hoop which could arguably be more effective than the original solid frame and definitely much lighter and could still be glazed if I wish.

                Comment


                • #68
                  Re: Progress to date

                  Originally posted by cameronfurnival View Post
                  oooh that's nice
                  The aluminium checker plate does look good! I just hope I can make a nice job of installing it. There won't be any carpets, so any blemishes will be plain to see. I am really looking forward to making the gearbox cover, that WILL be a challenge.

                  Comment


                  • #69
                    Re: Progress to date

                    Shes really coming together then. Looking great That list is gonna take a day or 2 tho. Should work out really well.

                    Comment


                    • #70
                      Re: Progress to date

                      You dont want to be class 8. Wise move. I would keep a little quiet about what youve done tho. Cause they can be picky when everything is ok. You want that heavy windscreen frame. Its the roll bar! And you will be grateful of the windscreen when its minus 9 at 3 o'clock in the morning. Plus it will keep mud water and stones from hitting you in the head and face. If your worried about heavy seats just go a diet lol. The previous owner of mine had tractor weights behind the seats. Iv fitted mine to the wheel carrier to keep the weight back.

                      Comment


                      • #71
                        Re: Progress to date

                        Steven -dont you mean three oclock in the afternoon - there isnt a three in the morning is there?

                        Comment


                        • #72
                          Re: Progress to date

                          I find having two, three O'clock's in one day very puzzling.


                          Two more tasks ticked off, I have finished the floor and made and mounted the battery bracket today.

                          Today has been very hard, according to the forecast overcast but fine, in reality overcast with short but heavy showers. I got the gear out three times and then had to run for cover, no joke with welders, grinders and drills to protect and rescue from the rain. Ended up welding the battery box on in heavy rain before retiring wet and tired.

                          I have tried a variety of devices to remove the paint from the fibreglass parts of the body, none very successful, usually marking the gel coat. Today my neighbour offered me a little Makita palm sander to try. It worked very well even with some very worn paper installed. Five minutes and I had cleaned up half a rear wing. I would say a nice day with a good supply of paper will see the job done.

                          Not expecting to do anything tomorrow due to heavy rain forecast all day. My next target is to do a few small tasks at the front and mount a temp fuel tank 'borrowed' from a Yamaha Quad just for the MOT. I think I have the new aluminium fuel tank organised, got an eMail yesterday about it but I doubt I will be able to afford it this year.

                          The stainless front pipe has been collected from the exhaust fabrication people, just needs a short flex coupling welding into the down pipe then I can fabricate my own system. I should have the pipe tomorrow.

                          Comment


                          • #73
                            Re: Progress to date

                            I normally sleep through the early hours but the navigator keeps telling mr directions lol. Your fine once the suns up lol. When i was navigating for father we were far back in a que and fell asleep The car behind us had to get out and wake us up. Ther was only 2 cars left in front lol.

                            Comment


                            • #74
                              Re: Progress to date

                              I seem to be under budget but also building to a reduced spec, just to comply with the basic MOT.

                              Just for interest...

                              Comment


                              • #75
                                Re: Progress to date

                                A minor milestone, I completed piping the brake system and the fuel pipe today, will hopefully have them bled and the clutch working over the weekend. Weather permitting.

                                The exhaust is almost complete. Seem to have spent a lot of time doing very little but it's that part of the build which consumes a lot of time with not a lot to show for it. All of a sudden I will have a car instead of a lot of boxes of parts!

                                The floor panels are all made, the handbrake is finished, the radiator mountings are complete, although the radiator is leaking like a sieve, I will have to get a new core fitted or find another radiator. @ £10 a time for a rad from my local breaker that seems favourite at the moment.

                                I have discovered that my local Halfords stock GL4 EP 80W-90.



                                In handy squeezy containers I think.

                                So I seem to be on track at the moment although the dark evenings are curtailing the time I can spend on the car, I managed to work until 5 today but it was more by feel than sight! lol

                                Comment

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