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Go Back   Madabout Kitcars Forum > Mad Build Area > Vintage and Classic Roadster Kit Car Builds

Vintage and Classic Roadster Kit Car Builds For Vintage and Classic era kit cars. Post your build reports, problems and progress here

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  #341  
Old 19th October 2018, 16:32
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Default Heating up a bit.....

Quote:
Originally Posted by Amir Manzoori View Post
I wouldn't call it kit car Peter, but a Bespoke, a one off and in your particular case an art work. Keep up the good work, you are doing brilliantly.
You can call it anything you like but it doesn't change my everlasting list of things to do!


-----------------------------------------------------------------------
This week I managed a couple of days on the car.

The first day was raining so I had to find something to do inside the garage so I thought I'd have a go at refitting the heater to the body tub. It turned out that this was a good move as it was a lot easier working standing in front of the tub (rather than leaning over from the side). The body tub is still on the trailer so at a good working height as well.
Of course, this should have been a case of re-bolting things back in the original mounting holes but, as always I had to complicate things a bit more. Because of the length of the BMW straight six space between the back of the engine and the bulkhead is at a premium so I had to mount the heater box as far back as possible. I had filled the original mounting holes before the tub was painted so had to drill new mounting holes. It was very nerve wracking working on the newly painted tub but thankfully no major disasters.

Heater by Sabrebuilder, on Flickr

Not yet finally fitted with nylocks as I had run out of sealing foam strip and I also need to figure which of the multiple outlets I am going to use. You need to be a bit of an octopus to reach both sides of the bolts so I put nutserts in the front fixing points which are almost impossible to reach.

The terminals on the original heater fan module had corroded and rusted badly.

Heater Fan by Sabrebuilder, on Flickr

Luckily I had already found a new resistor pack on ebay so it was a simple job the fit the new one.

Heater Fan by Sabrebuilder, on Flickr

And here it is fitted to the car....

Heater fan by Sabrebuilder, on Flickr

It took me sometime to open up the hole for the heater hose grommet.

The second day's weather was much better so I worked outside on the rolling chassis. I decide to tackle something that has been bugging me for sometime....

Thanks to a Royale owners magazine from June 2000, I have discovered that my original car's builder used the wrong rear springs. Here on the left are standard Sierra rear springs and on the right is the spring originally fitted.

Rear Springs by Sabrebuilder, on Flickr

The old springs may have come from the original donor Sierra but who knows now where they came from?

The standard Sierra rear spring is 306mm overall length and 14mm wire whereas the springs fitted were 283mm and 15mm wire tapering to 10mm.

Rear Springs by Sabrebuilder, on Flickr

I followed the Haynes Sierra manual's procedure to change the springs. A bit of a PITA job but much easier to do without the bodytub fitted.

Rear spring re-fitting by Sabrebuilder, on Flickr

Not exactly real progress but I am really glad I have done this now as it was a lot easier than crawling around underneath a finished car.



...peter
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  #342  
Old 24th October 2018, 20:35
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Default ARB swapping....

Today was a car building day and the weather was nice so I was off down to my yard to tackle the next job on my 'to do' list.

Initially, when the Sabre was first launched, John Barlow who designed the Sabre, advised builders to thin down the ARB to make it less stiff by grinding a flat section, But these cars failed their MOT as it was deemed to be modified suspension which is not allowed. The next best thing is to fit a 24mm bar. Longer term I may fit compression struts but not before the IVA test.

The original 28mm bar above and the new 24mm bar below.

ARB's by Sabrebuilder, on Flickr

This required new bushes which I got from Superflex.

ARB Bushes by Sabrebuilder, on Flickr

Following the Haynes Sierra manual, I swapped out the ARB.

24mm ARB fitted by Sabrebuilder, on Flickr

So another job ticked off

.......Peter
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  #343  
Old 1st November 2018, 19:24
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Default Edging closer.....

I'm now edging closer to the moment I can refit the main body tub to the chassis for what should be the final time.
This week I've completed a few more tasks on my 'to do' list.

First up, I've added one additional exhaust bracket where the centre pipe passes under the chassis cross-member just the stop the pipe dropping or rattling against the chassis.(since i took this photo I've painted the bracket)

Exhaust bracket by Sabrebuilder, on Flickr


Next up, I've re-fitted the propshaft, hopefully for the final time. It is possible to fit and remove the propshaft with the body tub in place but it was certainly easier like this. I also fitted the cables to the HP fuel pump for the same reason.

Propshaft by Sabrebuilder, on Flickr

And before bolting in the heater box, I've blocked off the fresh air vents that are not used on the Sabre. I made 'plugs' out of 9mm plywood and then fixed them in place with RTV silicone sealer.

Heater by Sabrebuilder, on Flickr

And, I made these 'plugs' from 6mm moisture resistant MDF.

Heater by Sabrebuilder, on Flickr

Now there is just a few small jobs to do before the body re-fit......

....peter
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  #344  
Old 1st November 2018, 23:24
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Looking good

Is there any kind of metal loop in the body work to protect in the event of a prop shaft failure?
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  #345  
Old 5th November 2018, 08:39
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Default Significant milestone!!

Quote:
Originally Posted by Patrick View Post
Is there any kind of metal loop in the body work to protect in the event of a prop shaft failure?
Hi Patrick,
no there isn't but I think the risk of failure is pretty low so I'm not concerned.


-----------------------------------------------------------------------------------------

This weekend I reached a significant milestone in my re-build when we re-united the main body tub with the rolling chassis. It doesn't look much but due to the quality and thickness of the GRP this is a four man lift.

Body tub fitted by Sabrebuilder, on Flickr

I can now crack on with the build inside my garage
The next milestone is to get the engine running again but there is lots to do before I get there....

Until then the car is tucked up in the dry....

Bedtime by Sabrebuilder, on Flickr


....peter

Last edited by peterux; 5th November 2018 at 08:41.. Reason: grammer
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  #346  
Old 12th November 2018, 19:56
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Default Progress steps.....

Now that the body tub is in place I can now focus on refitting all the engine ancillaries. Many of the parts have been in storage for about 4 years since I dismantled the engine donor car (Is it really four years ago, gulp!!).
Some had been cleaned and repainted already but others needed a coat of paint before installation which takes up a lot of time especially as the weather has not been ideal.

To start, I installed the oil filter housing followed by the alternator, power steering pump and the belt tensioner. A new wheel was fitted to the tensioner as these are quite cheap and good practice. And of course a new belt. The alternator was replaced by a nearly new refurbished one as the original was water damaged. I also re-installed the cam and crankshaft sensors and a new vanos oil pipe. New gaskets and seals were used throughout.

Engine ancillaries by Sabrebuilder, on Flickr

Whilst digging out the parts I also found a miscellany of cable trays and brackets that needed de-rusting and painting.

Misc. Engine parts by Sabrebuilder, on Flickr

My next job will be to try and work out how to install the engine loom whilst try to keep the engine bay looking neat and tidy....

BMW engine loom by Sabrebuilder, on Flickr

It's a great feeling to start emptying the boxes of parts although finding all the bits can be challenging at times!


....peter
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  #347  
Old 18th November 2018, 07:15
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Peter Congratulations on reaching the stage where the body shell is back on.

Good luck with getting the engine fired up again, Paul.
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  #348  
Old 19th November 2018, 19:21
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Always good when major bits go back together, nice
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