Marlin Roadster (Re)Build

[MartinClan]

I have been pondering the problem of my propshaft for some time now. For some reason the little screwed cap that holds the oil seal on the splined joint is way to big and hence impossible to screw up. I can only think that it has come loose at some point and years of rattling arround on the propshaft joint has stretched it. Its at least 3mm too big in diameter.
propshaft_problem by Robin Martin, on Flickr
Anyway I was doing some routine maintenance on the Pembleton. The driveshafts (2cv) have 3 joints the centre one of which is a sliding spline like on a propshaft. They are all protected by rubber gaitors. So I got out the callipers and, would you believe it, the size of the shafts making up the splined joint is almost the same as that on the Marlin propshaft. Getting excited now... So I ordered a gaitor from ECAS, the main source for 2CV spares and it fits perfectly!
propshaft_solution by Robin Martin, on Flickr
Not very often you get a piece of luck like that.

[peterux]

A brilliant bit of lateral thinking and repurposing!

[MartinClan]

I thought it was about time to do a reality check and make sure the gearbox actually fitted in my new transmission tunnel. I had to take the hacksaw to one of the unused lugs on the gearbox casing but now it fits with about 1/2" clearance on either side which hope is enough for any movement. And the propshaft fits as well, always a bonus....
gearbox_fit1 by Robin Martin, on Flickr
propshaft_check1 by Robin Martin, on Flickr
From the front it looks like I may have to adjust the position of the fuel line but I'll wait untill the gearbox is finally fitted before I do that.
gearbox_fit2 by Robin Martin, on Flickr
And I have taken the advice of various sages and fixed the tunnel top using M5 screws and rivet nuts. I have put the ignition switch on the top of the tunnel, the idea being all of the wiring is then almost impossible to get at for any would be joy rider. The switch itself is an industrial tamper proof item. NOS from ebay for a bargain tenner.
transmission_tunnel by Robin Martin, on Flickr
And yes the gearbox is almost new! It looks like it had been recently fitted before I bought the car from the previous owner and builder.

[MartinClan]

I have just about completed the wiring loom now. All I need is the engine and a few lights to connect up!
I have confined a lot of the spaggetti to the dashboard.
dashboard5 by Robin Martin, on Flickr
The little button (temporarily) mounted on the steering wheel is actually a wireless horn button. The receiver is amongst the stuff on the rear of the dashboard. The plan is to bodge it around so that it sits behind the steering wheel central horn push.
dashboard4 by Robin Martin, on Flickr
And a few more pictures of the rest of the wiring waiting to be connected up. All i need is the engine now!
loom2 by Robin Martin, on Flickr
I have managed to keep the high current (starter motor) wiring nice and short. Not sure what route I am going to use yet to reach the rear of the car but it is all contained within one cable.
loom3 by Robin Martin, on Flickr

[peterux]

Great progress, Robin.
Love the dashboard, looks really period and unique.

cheers, Peter