Fuel filler - Final location
 

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

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

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.

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

Dave

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.

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.

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 don’t step on is the chassis. I can’t 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 won’t look right for my eyes. I’ll get there!

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

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.

I’d 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. :)

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!

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.

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
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Fuel filler rivet bracket cut and tangs raised
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Sharkfin aerial fitted
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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.
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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!

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

A few bits on the back-end fixing
 

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
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Rear arch lower bracket connection (bend galv steel riveted together and galv sprayed).
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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!
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Parcel shelf
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Fuel tube scallop and 90 deg tube
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Fuel tube installed solid
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Quicksteel epoxy - good stuff!
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Lights
 

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 won’t stay where there are pictured as they do stick out in the ugliness scale!

Cheers fella, trucking forward.....

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!
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Pre-glassing
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Glassing initial
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Fuel filler tubing and filler
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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. :)

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

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......

Fail of yesterday fading away - (slowly)
 

Hey guys, back at it today with a long day on the project.
More glassing on the back end so that is coming along, at least now can scarf the top surface and glass/fill where I need to.

Fuel filler still in work, made a bracket for it to sit on securely but it looks like it wants to sit lower when the shell is back on, so another try at that soon.

Rear boot extension glassing was finished yesterday to profile it better with the
rear of the car - Ran out of rivets during fitting but all bonded on now. Just needs a bit of tidying, more rivets and carpeting long term. the pictures show the aluminium brackets I have used to fix to the bumper (recycling at its best as this was reused material that I cut off the front bumper). Front screen top glassing finished now and the roof sits in a much better place.

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Nice recycling.

As time goes by one gets over the pain of failures - we all do it, but try not to repeat them . . . The overall cost is not significant or worrisome in the big picture.

Progress is a great motivator.

Cheers Kidge,

This week a bit slower as I am still having issues with the positioning of the fuel filler. With the size of the tube and filler and the required bend radius I am struggling to keep it off the chassis. So I have changed tack, started the strengthening and packing/fit position of the rear shell so that gives me as much room as humanely possible to play with. I am optimistic but certainly partially frustrated!

I do have made the initial prototype of the rear brake light pod that will sit on the parcel shelf and it looks good, also today gave the green light for the manufacture of the side trims. Having them formed up by a local metal company in bright stainless and then finishing off the welding/final fabrication with a good mate of mine. Things moving though and a long weekend coming up which is raining most of the time so plenty of spare hours can be spent on it.......

A quick general update, hopefully some photos at the end of the weekend as i don’t like showing “part way” mods!

I am using galv square tube and building up the back end extension support area with that and fibreglass. Nearly there. The backend needed to be approx 20mm higher so the front end looked good on the roof. Have also supported the boot extension wings with some bonded in and fibreglassed over 6mm rod. Stiffened up nicely.
As far as the fuel filler that is looking pretty good but I won’t be able to check that until the backend back on and trialled.
I have my sill trims back from production, look really good profile. My job now is to chamfer the ends, make end plates for those and weld in plus weld in the tabs/bolts to hold them on. Keeping on keeping on!

Some photos soon, promise. Cert guy has given clearance today for body structure mods that I have done. So all go to get the rear finalled and on.
Am currently working on the stainless trims, welding should go on this week. Bumpers will be wrapped with vinyl chrome week after. Style 5 alloys look good with 205/65/15 rubber on them. A bit more glassing to do on the rear end and then I can flowcoat it.
Chris and Dan sending some more stuff through this week that I needed/wanted so definitely optimistic of on the road around end of sept/early oct at this rate.... can’t come too quickly!

Lots of work going on
 

]Hi guys, been a cack load of work going on over the last few weeks and I am knackered!
The bits in work:
- Bumpers filled/sprayed and ready to vinyl wrap this week
- Exhaust resonators (ala the 275) in work but initial manufacture done - see pic (They will eventually be polished tips/redband and black painted as per the 275 original car - Maybe with ANSA badges) See capture pic for what trying to achieve.
- Exhaust hangers (again as per the capture pic - Fezza originals ordered from Germany on on their way) the other pic shows I have strengthened where the exhaust hangers will go - Where the rivets are behind the panel is T6-alclad aluminium plate bonded and riveted in so will have good structure to hang off.
- Alloys and rubber all sorted - 205/65/15 with ET20 offset - looks good possibly not to have to widen the track after all at back end.
- Glassing virtually finished on back end - trialling final fits tomorrow
- Blocked off rear light areas and "splash shields" manufactured from fglass and fitted.
- Flowcoat inside rear end started today.
- Sills nearly completed, end caps done on trims, getting retention bolts welding done on this weekend and trial fits hopefully next week.
- Door window seals fitted

Flickr for some reason not working so a few photos added as per below.

Cheers.

Hi guys, really struggling with Flickr for some reason at the mo but after half hr managed to get some photos up. Plenty of moving going on, body ready to bond, trims finishing welding this weekend (mate got tied up on other things), bumpers being wrapped and should be ready on mon or tues.
Once trims are on sills and happy then sills final fit and body bonded on.

Exhaust well under way, waiting for hangers and some welding of brackets before final painting..... Here ya go:
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hi guys.
as of yesterday we at classiccoachworks.org are building a demo of the old no 7 275 and marketing them.
thank you to Dan for giving us the opportunity

photos will be added as we go along for a full pictorial build guide.

ps kiwi.. pleeeeeease may I pop your pictures ups example when people ask how it may look. withsorry to ask! will of course credit you! lovely car by the way!

All good my end, I am hoping pictures will get a lot more “wholesome” and in short time! I am putting the hard yards into some nice touches, just hope they pay off.....cheers.

ah thank you kiwi. that's great.
we will also do a full stripdown and build thread, but on website, so do have a look in case we have quilt bits you need. although you're way ahead as we only picked up yesterday!
looking great already, can't wait to see finished...
what colour are you intending?
😊
belle.
classiccoachworks.org

Thanks Belle,

Good luck with the 275 project, certainly good to see some movement in the development/marketing of this kit for Dan.

My colour choice is dark metallic grey. A few options looking at for final colour choices, looking at BMW Mineral grey, Carpathian grey Range Rover, silverstone grigio metallic ferrari colour and a few others as well. Time to scratch the beard and decide!

I like the silver / grey on this one, who knows if its an original Ferrari colour. Similar shade to Audi Quartz Grey.

Very nice LLM. This is a touch light for what I am looking for, I am a big 007 fan so would have been very easy to have gone this route for me, as it is very similar the DB5 traditional colour, but settled on darker so the bright work touches on the car will pop a bit and eventually the same when wires fitted as well. Cheers.

ahh grigio is a favourite of mine.. that would look exceptional.im

thank you, really hoping to make Dan proud. i love all the kits and am really excited to have the opportunity to market this one on top the the Kali, Koupe Kobra..
we willcrack on with ours asap then soon as 250koupe back from paint.. prob early Sept.. it will be off to be made all shiny....

ill follow your thread if that's ok. good luck with build. you look to be doing a cracking job 😊

Quick update, but not the one I wanted.
Trims still not welded, praying for good news tomorrow otherwise another lost weekend to get the sills sorted and on.
Brackets from Germany for the exhaust have taken an age, looks like they are in NZ, but not in my hands. Net result exhaust can’t be fitted up this weekend either as they are setting the position to weld brackets on the resonators....so a few weeks before the exhaust finished now.
Wrapping the bumpers, listen very carefully I will say zis only once!
Make sure you have no overspray from any filler/spray repairs on the surface that you are wrapping.....it pulls paint off the gel coat. The guys who are wrapping thought it would be ok but not the case. So have spent the last two days rubbing all the bumpers back to gelcoat surface, polishing with 3000 grit paper and now the vinyl test wrap went well. Chrome shows nicely so let’s see how they look when done next week now!

So a few things no quite to plan, but the stream as always is flowing (eventually) in the right direction. Cheers.

ahhhh frustrating, as is always the way with builds, all the delays come when you're really wanting to crack on...
I feel your pain. hopefully more progress next week!
����

Thanks Belle, crisis half averted, the trims got the welding completed so all being well should be fitted and photos by the end of the weekend.....cracking on!

Weather terrible but work must go on.
 

Hi guys, NZ weather is atrocious at the moment, so the garage door gets opened /closed/opened quite rapidly at the moment.
Sills are needing work as the trims we manufactured look superb, but show the sills aren't flat in relation to the stainless forms so need to be profiled for that, got the filler on but with the weather sanding gonna wait until later in the week.

So got stuck into exhaust hangers, (which arrived Saturday), rear shelf carpeting and rear light assy/pod. Pod holes are for access to the OEM light nuts if needed, they will be filled with some polished ally tube for a nice finish. Also finally removed the drivers door mirror. Exhaust now booked to be fitted next weekend and bumpers will be wrapped and finished on thurs. Great to be making headway.

Flickr and my computer just don't want to mix at the moment well together so here are some photos:

Why all the rivet heads through the body by the exhaust mounts ?