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-   -   Welsh Kiwi's Build Thread - 275GTB (http://www.madabout-kitcars.com/forum/showthread.php?t=6476)

Welshkiwi 7th May 2019 07:28

Fuel filler - Final location
 
Quote:

Originally Posted by Lucky@LeMans (Post 100286)
I think it will spoil the clean lines of the car having it sticking out that far. Could you set it in half way at least ?

Very difficult without getting into the chassis needing being cut to accomodate - see below the only way I could get it to fit.

Quote:

Originally Posted by molleur (Post 100294)
Not the best location (albeit, a little easier to connect).
Put mine on the top of the rear wing, recessed, as close to the door as decent. Had to segment and weld up pipe sections as needed to make the bends . No issues filling.

Thanks Molleur that looks really smart and stylish - appreciate the pictures.

Quote:

Originally Posted by Egdik (Post 100297)
Farina was so keen on keeping the lines clean, that he put the filler in the boot.

The standard Z3 flap cover is quite discrete.

Fully understand Kidge, good thing for me is I am keeping away from a replica and now am fully into the "homage project". It does get in the way of the lines but hopefully you will see below what I have settled on as a compromise at least!

Measured and measured tonight and there was only a few locations that it could go with being able to get a 90 deg bend on the filler and out of the way of the chassis structure. This was the best and looked the least "out there" so picked this. I like it, no offence taken if anyone doesn't but I have made the best of a tight situation. Have lined it up centrally with hub of the rear wheel. Will have a small scalloped flat shelf to sit on once glassed/changed.

https://live.staticflickr.com/65535/...bacb161b_z.jpgIMG_20190507_180353

https://live.staticflickr.com/65535/...eb453a96_z.jpgIMG_20190507_180343

https://live.staticflickr.com/65535/...58b8044b_z.jpgIMG_20190507_180412

DaveP 7th May 2019 08:50

Given the constraints you have I think this is the right place. If it is recessed a bit will look very tidy.

Dave

Lucky@LeMans 7th May 2019 18:43

Have you thought about a more modern Aero cap style filler, flush fitting and low profile. If the regs over there are so strict I'm surprised you can have a sticking out in the breeze filler cap anyway.

molleur 7th May 2019 19:01

I managed a somewhat gentle "ess" shape tubing to achieve a more direct fill flow without splash back. Avoiding 90 degree bends.
Works a treat too.

Welshkiwi 8th May 2019 06:59

Quote:

Originally Posted by Lucky@LeMans (Post 100312)
Have you thought about a more modern Aero cap style filler, flush fitting and low profile. If the regs over there are so strict I'm surprised you can have a sticking out in the breeze filler cap anyway.

Hi LLM, definitely hearing you but got to be the classic racing cap for me. The only part of the regs that I am making sure I dont step on is the chassis. I cant cut anything out with going through structural cert. I think where it is should be ok as it is no further out than wing mirrors etc. The modern one would fit but just wont look right for my eyes. Ill get there!

I may be able to put gentle bends in Molleur where I have put it so fingers crossed!

Paul L 8th May 2019 18:49

WelshKiwi Given the rules you have to follow, I think you are doing the right thing with the filler cap.

If anything, rather than try to blend it in with the body work, perhaps you should make it stand out more?

Sorry these photos are not great, but there were the first ones I could find.

Id be tempted to add a full metal surround to make it look more like something bolted on.

Something like this

https://lh4.googleusercontent.com/-T...o/DSCF4309.JPG

https://lh4.googleusercontent.com/-4...o/DSCF4477.JPG

Or this

http://www.autochron.co.uk/images/bo...ry%20large.jpg

Good luck, Paul. :)

Welshkiwi 9th May 2019 05:51

Quote:

Originally Posted by Paul L (Post 100324)
WelshKiwi Given the rules you have to follow, I think you are doing the right thing with the filler cap.

If anything, rather than try to blend it in with the body work, perhaps you should make it stand out more?

Sorry these photos are not great, but there were the first ones I could find.

Id be tempted to add a full metal surround to make it look more like something bolted on.

Good luck, Paul. :)

Hey Paul thanks for these photos, I will certainly look into that as it might be a good feature to supplement the look. Good news is just saw the cert guy and he is happy with filler position both external and under shell proposed pipework. Got some Mocal fuel elbows coming from Demon Tweeks and have the continental (Contitech) fuel tube ready.
Also caught up with the exhaust guy, he is all ready to go in the next month when I get the rear body position finalised and bonded on. We are planning the ansa style 4 sloped tips and noise up to the 95db allowed. Break in to the pipes at the rear of the cat. Really pumped now to get this thing going!

Barber 9th May 2019 15:04

Glad to see you are back on the case and enjoying yourself. I saw Kidge's 275 at Stoneleigh, and very fine it was too. If yours comes anywhere close in finish, you will be a very happy lad.

Welshkiwi 11th May 2019 04:04

Fuel cap out and aerial changed
 
Hey guys, good progress over the last couple of days, and a few games of rugby watched as well so happy boy!

Back end is back off and working through structure and brackets/under stuff.
Managed today - Split the front roof/frame support that had misaligned during fitting - Perfectly happy with the bonding agent cos that was a bugger to get back off! Need to re position/bond and fibreglass strengthen before the roof fit.

Fitted the sharkfin powered aerial in place of the original (Cheers JagTVR for the idea) works well and looks tidy even though it will not be seen.

Fitted the rear light R/H bus for all my earths and started blanking off the rear light holes that aren't needed.

Removed the fuel cap which proved to be pretty easy, I used a method that I am familiar with in aero engineering (splitting it/slotting it). Worked really well. See from the photos if you are yet to do it, pull up the Qty 4 tangs with a flat blade screwdriver and using a die grinder high speed burr I cut the bracket that is attached to the rivet/cable and then slotted the outside of the cap metal assy. Just be very careful of heat/sparks. I left the cap on for most of the cutting, but also put rag down the fuel fill pipe to minimise any fumes coming out/material going in. Worked really well, once split you only have to gently lever the two parts wider and pull the assy of the o-ring that is underneath.
Back on it tomorrow......

Fuel filler split
https://live.staticflickr.com/65535/...b6ef47e3_z.jpgIMG_20190511_135835

Fuel filler rivet bracket cut and tangs raised
https://live.staticflickr.com/65535/...03fdbec3_z.jpgIMG_20190511_135851

Sharkfin aerial fitted
https://live.staticflickr.com/65535/...74415642_z.jpgIMG_20190511_103600

Welshkiwi 12th May 2019 04:37

More progress today - backend wiring and tidying
 
Managed a good few hrs on the car today, primarily wiring extensions and conduit work as well as manufacturing brackets for the rear body lower arch support. It was nice to start putting bits back in the car and making visually some changes.
Now know exactly how I am going to brace and support/fix/bond the rear body on so will photo that as I do it. The angle of the rear body doesn't match the angle of the boot extension so I need to do a bit of fibre-glass build up to get those to match and support nicely. The boot extension also doesn't sit on the boot line rear very well either so I will scarf and re-glass that to build it up and that will sort that out.
Good news with the front window frame/roof support - That now fits nicely and when I put the rear body back on the forward roof line is now correct - Happy days but would have been better first time around!

A couple of pics of the boot wiring extensions and conduit/earth bus fitted.
https://live.staticflickr.com/65535/...117e3335_z.jpgIMG_20190512_120242

https://live.staticflickr.com/65535/...18826c1f_z.jpgIMG_20190512_120249

https://live.staticflickr.com/65535/...5d64715e_z.jpgIMG_20190512_120302

https://live.staticflickr.com/65535/...1d69e0d9_z.jpgIMG_20190512_120313

Welshkiwi 14th May 2019 09:05

Tonight's mock up
 
Hey guys, a bit more progress mocking up the back-end and putting in lights and positions of lights etc.
Reversing light and fog need brackets made to sit vertical and number plate lights may need a small plinth or recessing due to the slope on the rear bumper. All fits together reasonably, the bumper though will need a small bit of work for alignment and extension in places.
Got a crowd setup to chrome wrap all the bumpers next week, but with some work to do that may extend out by a few weeks.
Got a company ready to bend some BA stainless to make the side trims like the original, then over to me to finish it with welding on ends, tabs and bolts for the fixings.
Also dropped off a E46 rotor to a local machinist tonight. He is dropping the rotor (disc in UK language) from 280mm dia to 272mm to match the Z3 original then I can fit the Z4 hub /better offset wheels and narrow the track at the back.
Some pictures in the dark, heading back out in the man-shed for a few more hours after a cuppa!

https://live.staticflickr.com/65535/...4878e480_z.jpgIMG_20190514_174552

https://live.staticflickr.com/65535/...2a31a155_z.jpgIMG_20190514_174603

https://live.staticflickr.com/65535/...471f37e9_z.jpgIMG_20190514_174613

Barber 14th May 2019 09:13

Good work chap, keep it up and you will soon be able to take it for a drive.

Welshkiwi 15th May 2019 08:45

A few bits on the back-end fixing
 
Quote:

Originally Posted by Barber (Post 100424)
Good work chap, keep it up and you will soon be able to take it for a drive.

Thanks Barber, can't wait for "d day"

For anyone yet to do the backend or a project and just looking at what is involved here is a bit on my decisions on fixing the backend structure. Can't guarantee it will all work yet but will post my success or fail anyway!

The rear body fixing will be:

- Front screen top frame bond (with possible U Brackets on Roll cage, but not looking likely)

- Side brackets (as pictured blanks for size/form) will be bonded to the outer skin (with strengthening embedded in them) and bolted to the car brackets with a rubber dampener.

- Lower arch brackets have been fabricated (as pictured) and will be attached to a bolt coming through from the boot area. Will be attached to the lower wheel arch on body in some fashion to stop lower "flapping" with rubber dampening.

- Standards fixings @ B pillar in door area

- Screw and Bond to boot extension sides and rear areas

- Bond to parcel shelf (which is attached to roll bar cross member and car original roof rear surface.

Rear arch side bracket form for fabricating final bracket
https://live.staticflickr.com/65535/...8d37bc2f_z.jpgIMG_20190515_191603

Rear arch lower bracket connection (bend galv steel riveted together and galv sprayed).
https://live.staticflickr.com/65535/...a863a160_z.jpgIMG_20190515_191625

Welshkiwi 19th May 2019 05:57

More progress - I am knackered!
 
Hey, been working hard in the background over the last few days.
Been working on:
- Boot extension shape and glassing
This needs a bit of fettling and material added to get it to fit nice to the body structure.

- Finishing parcel shelf and high level brake light extension
Fitted the parcel shelf and "end fillers" screwed and bonded to the body and bonded to the roll cage support. Just need to fit some p clips and standoffs on the outer edges (from the roll cage) to support firmly on those ends. The shelf will be carpeted. The original high level brake light is being placed on a mount that is being 3 D printed. The lower surface of the OEM light has been 3D scanned so we can 3 D print a mount to cover with carpet.

- Fuel filler tube. Have fitted the fuel filler extension and you will see from the photos fitted with epoxy tank repair kit putty. This has gone off solid and holds the tube really solidly. I scalloped the lower end of the tube so that the breather tube as standard will work comfortably. Only need to fill the upper part of the pipe with a fuel resistant sealant (even though it is sealed from fuel now anyway) and then fit the rest of the pipework.

This week will be taken up with trying to get the fuel filler finally done, Z4 hub on and seeing if the track reduction mods give me enough for what I am looking to do with the style 5 wheels......Also of the humidity plays nice will start glassing the bigger bits of the rear shell I need to.

Rear glassing required!
https://live.staticflickr.com/65535/...7a20040b_z.jpgIMG_20190517_160727

Parcel shelf
https://live.staticflickr.com/65535/...57bf5a74_z.jpgIMG_20190519_112011

Fuel tube scallop and 90 deg tube
https://live.staticflickr.com/65535/...feb6fc41_z.jpgIMG_20190519_132854

Fuel tube installed solid
https://live.staticflickr.com/65535/...2ace5e34_z.jpgIMG_20190519_142251

Quicksteel epoxy - good stuff!
https://live.staticflickr.com/65535/...dbfabb67_z.jpgIMG_20190519_142217

Egdik 23rd May 2019 16:24

Lights
 
Always a pleasure to see your progress. You seem to take nice pictures inside the garage . . .

If your bumpers are the same shape as mine, you might consider trimming the base of the number plate light - could use only one - and mounting it very close to the top edge of the bumper. A single 10w bulb is enough - or use an led.

Do the regs force you to mount the fog and reversing lights so far 'out the back' ? Brackets off the bumper perhaps, or could you hang them off the bodywork behind the bumper ? They are not things of beauty.

All the best for a drive before too long - late 'winter' in your tropical zone !

Welshkiwi 24th May 2019 04:19

Quote:

Originally Posted by Egdik (Post 100542)
Always a pleasure to see your progress. You seem to take nice pictures inside the garage . . .

If your bumpers are the same shape as mine, you might consider trimming the base of the number plate light - could use only one - and mounting it very close to the top edge of the bumper. A single 10w bulb is enough - or use an led.

Do the regs force you to mount the fog and reversing lights so far 'out the back' ? Brackets off the bumper perhaps, or could you hang them off the bodywork behind the bumper ? They are not things of beauty.

All the best for a drive before too long - late 'winter' in your tropical zone !

Hi Kidge, thanks so much for the kind words!
Good tips with the number plate light for trimming will look at that. The nz rear plate is a long thin one just like the uk front so I think will probably stay with the two lights, it balances it better and with the original being a long thin light just visually balances a bit as well.

The fog and reverse are only in as a mock-up at the moment, final orientation will be further in likely to be on brackets to square the rear face off. They wont stay where there are pictured as they do stick out in the ugliness scale!

Cheers fella, trucking forward.....

Welshkiwi 25th May 2019 05:19

Bleeping mother bleep, bleep, bleeper!
 
Well I promised to post all progress or fails, it is the turn of the fails and this is going to be cathartic for me to tell the world I am a dope and I pray that this is the last of the backwards steps!

Let me cast you back to when I bought the car, very good condition, awesome sellers that took the car for some chip repairs in the windscreen on their insurance and came back with a new screen - So who was a happy boy knowing he had a donor with a brand new screen being covered by bonded roof panels/surrounds etc? Of course me.

Step forward to today and I now need a windscreen replacement in the next two weeks. Pretty innocuous but expensive all the same. Left a roll of aluminium tape on the bottom of the screen after using it and then decided whilst tidying up for the day to lower the bonnet because it was in the way. Net result a crunch that I thought was the bonnet cracking and no it was the screen - See below for picture.

Now deep breaths, my healing is done......(After $500 plus for a new screen):eusa_doh:

The good bits of the day have been starting the glassing of the filler holes etc, progressing with the fuel pipe and bonding the half of the roof support that I re-positioned back in.....Lots of dust and fumes........

Show us your crack!
https://live.staticflickr.com/65535/...1e3603f2_z.jpgIMG_20190525_153358

Pre-glassing
https://live.staticflickr.com/65535/...064a4d07_z.jpgIMG_20190525_103825

Glassing initial
https://live.staticflickr.com/65535/...07cdcdab_z.jpgIMG_20190525_132522

Fuel filler tubing and filler
https://live.staticflickr.com/65535/...55ecbc5a_z.jpgIMG_20190525_142947

Paul L 25th May 2019 08:49

Sorry to hear about the windscreen. :icon_sad:

I know there was a deep rooted horror as I watched my own car fall off the axle stands in slow motion.

Which was a combination of the damage I knew I was about to cause and the fact I needed to ensure I wasn't trapped under it! :eek:

Stressing the positive, at least fibreglassing the old filler cap hole is progress. :cool:

Good luck, Paul. :)

Barber 25th May 2019 10:09

Quote:

Originally Posted by Welshkiwi (Post 100558)
Show us your crack!

:icon_biggrin: I guess I will never get to grow up now.

Welshkiwi 25th May 2019 10:27

Thanks Paul L and Barber,

I have slowly regained my sense of humour and pragmatic sense during the day. Be back on it tomorrow, windscreen repair booked for Jun 13th so a bit of time focussing on the back now with the delay in being able to bond the back on.

Be back at it tomorrow, more dust, more fumes and at least now I don’t have to protect the front screen anymore whilst working around it! Cheers guys......


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