Finished Paint and Final Assembly

Since the last post a lot of work has been done, women’s health although it is not always really obvious from looking.  I’ve spent a lot of time on the engine with the builder on the phone, visit this site doing a net meeting and having the computer hooked to the EFI system.  We spent most of the time working on eliminating a stalling problem and trying to get the engine to start better and run smoothly when cold.  The stalling problem appears to be resolved, but the engine still starts poorly.  It was oscillating at cold starts – nearly stalling and then revving back up multiple times before leveling out at idle.  Now it just starts poorly – if at all – unless I give it gas.  That will have to continue to be a focus area.

Other things we did were to run the go-kart on road with the engine at high RPM – 3500-5500 – to monitor and set up the Air/Fuel ratios.  Julie and I did this, Julie in the passenger seat holding and reading the EFI info on the laptop.  I was driving and trying to hold my hat on.  We ran at 70-80 mph – probably not really safe considering the state of the build.  But, the good thing is the car handled and drove well, so it was worth it – mostly.  Julie said she feared for her life – I thought it was fun! Continue reading

Body Paint, Carpet, Cockpit, Ground strap, hood, Mirrors, Radiator, Roll Bars, Seat Belts, Seats, Speakers, Steering Wheel, Stripes, Trunk, Uncategorized, weatherstrip, Wheels, windshield, wiper

Body Paint, Wet Sanding, Stereo, Masking for Stripes

On May 19th I got the car over to Dave Dante.  He wanted to do the initial body work with the body still on the chassis to make sue he got panel-panel edges and contours correct.  I did a bit more work on the hood scoop opening and all panel edges, cost but mostly, advice it was Dave’s show.  He re-filled and sanded and got things smooth.  Two weeks later we removed the body so he could start spraying hi-build fillers and primers.  I took the chassis home.

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While Dave kept working on the body, recuperation I did more to start tying up the final steps on the chassis.  I cut and soldered smaller gauge wires on the stereo speaker wires, although I may end up removing those.

I spent many hours just cleaning the entire chassis and parts.  It was covered with dust from Dave’s work, a necessary but “dirty” evil.  I re-worked the brake cylinder access cover panel in the driver footbox to simplify removal with the body on.  I also determined where I thought the interference was for the windshield support arm and cut the opening larger on the driver side.

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DSC03986Next I did some cleaning and polishing of aluminum panels that will be installed with the final build.  Now they are ready to go.

Now I started some work in the cockpit.  I trimmed some insulation off the rear cockpit wall to help with the tight fit.  I also then measured and cut all the pieces of insulation needed to cover the cockpit.  I only glued some in place.  I need to finalize the tunnel cover aluminum fit and fastening before the rest are put in permanently.  I drilled access holes in the tunnel cover for sear heater and control wiring and installed grommets.

DSC03990I needed to actually do some driving of the car, so I put in the driver seat belts seat and roll bar.  I re-attached the side pipes and then took the chassis over to the local high school parking lot and just drove it around. I barely got past third gear and probably not above 40-45 mph, but I did a lot of hard turning and reasonably strong braking and acceleration.  It all worked very well.  I did notice one rattle, which I eventually traced to the side pipe bracket under the passenger door opening.  I will deal with that at final build.  Overall I was very happy with how everything worked.

The next day I contacted Performance Products, the EFI manufacturer, to see if I could get some help with the problems getting the car started.  We discussed the details and they had me make some adjustments to the Cold Cranking table, as well as a couple other things.  After this was done I turned the engine over and it immediately started and idled beautifully.  Hopefully, problem solved!

A couple days later I took it to a service center and had the wheels aligned.  This also came out well.

In between I completed the cutting and installation of the trunk carpeting.  This looks great.  I also took a piece of carpeting to a carpet dealer and had the edge bound.  This piece will cover the are of the battery box to hide the access cut-outs.  I also later had this piece of carpet embroidered.

20130620_145919DSC04015I put in the passenger roll bars again, and then properly drilled the upper bolt holes.  With two bolts up top now I have a unique look !?!?

Next I began to look into putting on the tunnel cover.  While doing this I noticed some greasy residue on the transmission support A-frame.  I put the car on jack stands and checked underneath and it appears that transmission fluid is leaking out of the speedometer unit.  I checked it and the O-ring looks good and the unit is fastened tight.  I will have the investigate this further.

I decided to raise the steering whelk a it.  I noticed with the adjustments to make the seat higher to fit over the body the steering wheel seemed a bit low.  So I unfastened the pillow block and added some washers to bring it up a bit.

Then I removed the seat and began fitting the tunnel cover.  I checked the shifter fit and had to enlarge the opening in that and the shifter fill plate to accommodate the shifter position and movement.  I riveted the fill plate on the tunnel and drilled and riveted the tunnel in place.  I also riveted the dash extension in place and fastened the support bracket to the firewall.  I then put in the final pieces of insulation and began on the cockpit carpeting.

DSC04002DSC04003I followed the manual directions for installing the carpet.  Some of the pieces fit perfectly, but most required trimming.  Obviously, there was a need to trim where I made modifications, specifically the dash extension and the driver footbox punch-out areas. There was also trimming for e-brake, shifter and other areas.  I tried to be very cautiousDSC04012 when cutting so have spent many hours getting the pieces to fit.

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I still have a bit to do with the carpet, and the body is almost finished and ready for the stripe color to be painted.  I will post on that later.  For more pictures, see the Gallery.
After returning from our extended vacation, link I needed to take the next steps on the body.  I had Dave come by and give me a lesson on wet sanding.  It was somewhat painful to have to do this.  The paint looked awesome – the silver color was even nicer looking than I expected – so sanding it seemed wrong.  But, click it is necessary to get ready for painting the stripes.  Dave cautioned me about sanding around sharp curves and edges of the body and panels.  He recommended putting tape around the edges while doing the flat surface parts, then removing the tape and lightly sanding those areas.  I did this for most of the sanding, but eventually was able to sand without taping and just being cautious.  I continued on this over the course of the next 10 days or so until all surfaces were completed.  Very few flaws were seen anywhere on the body – Dave has done a great job so far.

DSC04033DSC04031 DSC04032 Continue reading

Body Paint, bulb seal, Cockpit, Dash, E-brake boot, hood, sanding, scoop, Seat Belts, Seat heaters, Seats, Shifter boot, Speakers, Stereo, Stripes, Trunk, windshield

More Bodywork, Carpet and More

After a vacation break, no rx I got back to work.  I started with the hood scoop.  I cut off the bulk of the excess on the flange, prostate then used the sander and hand sanding to get the flange to the correct size.

DSC03880After a few more times sanding, remedy I got it to where I wanted.  Then I drilled pilot holes for the screws I will use to fasten it to the hood. Continue reading

Carpet, Cockpit, Dash, door, EFI, filler, Footbox, Insulation, Roll Bars, Seats, Steering Wheel

Body, Stripes Test and More

After a vacation break, generic ailment I got back to work.  I started with the hood scoop.  I cut off the bulk of the excess on the flange, asthma then used the sander and hand sanding to get the flange to the correct size.

DSC03880After a few more times sanding, order I got it to where I wanted.  Then I drilled pilot holes for the screws I will use to fasten it to the hood. Continue reading

door, filler, Footbox, hood, J pipes, Radiator, sanding, scoop, Side Exhaust, Stripes, Trunk, windshield, wiper

Fitting Body Panels and More

My next step was to begin on the body.  I had no knowledge or skill in this, shop
so had a friend, Dave Dante, come and teach me the basics.  With his help I knew enough to get started.  There were several open times during this work when I was able to also complete a few other tasks.  This includes cleaning and waxing much of the visible sheet metal in the engine compartment, putting bulb seal and weatherstripping on some of the chassis and panels, trimming some excess panel edges, removing unneeded electrical wiring and investigating attaching heater and defroster hoses.

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The other major activity was to drill holes for the windshield wiper mounts. Fortunately, I investigated this prior to beginning the work.  I found out that I had outdated instructions for the installation.  The new instructions required moving the position of the drilling guide tool.  I put this in the correct position for the Mark IV, and drilled the wiper mechanism mount holes on each side.

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Prior to doing any of the body work, I first wanted to clean the outer surface of the body and door, trunk lid and hood panels to get rid of remnant mold release chemicals.  I went over it with a degreaser and with comet cleanser.  Continue reading

door, filler, Heater vents, heater-defroster, hood, sanding, scoop, Seats, Trunk

Begin Body Work

Now that all the electrical is done (except for the horns), ask
I can start work on completing the sheet metal, mind
and then move on to body work.  First, medicine
I had a few other items to do as well.  I decided to drain and replace the transmission fluid.  I realized once all the sheet metal was in on the tunnel, getting to the fill plug would be very difficult, so I just did it now to get the GM synchromesh fluid in.  I had driven it enough that it had a bit of time breaking it in and I wanted the recommended long term fluid in.  Next, I trimmed the excess belt material from the shoulder harness straps, and then removed the shoulder and seat belts from the car.

Next came removing the seats.  I did the passenger side first.  I also cut some length off the mounting bolts for a better fit.  Then I repeated the process for the driver side.  The floor support brackets were left in the car.

DSC03650Next I moved on to the cockpit sheet metal and siliconed and riveted in the passenger cockpit floor and the lower door walls on both sides.

DSC03654 Continue reading

Aluminum Panels, bulb seal, door, filler, hood, Rage Gold, sanding, scoop, seam, Trunk, weatherstrip, wiper

Completing Sheet Metal and Other Tasks

Since the last post a lot of work has been done, women’s health although it is not always really obvious from looking.  I’ve spent a lot of time on the engine with the builder on the phone, visit this site doing a net meeting and having the computer hooked to the EFI system.  We spent most of the time working on eliminating a stalling problem and trying to get the engine to start better and run smoothly when cold.  The stalling problem appears to be resolved, but the engine still starts poorly.  It was oscillating at cold starts – nearly stalling and then revving back up multiple times before leveling out at idle.  Now it just starts poorly – if at all – unless I give it gas.  That will have to continue to be a focus area.

Other things we did were to run the go-kart on road with the engine at high RPM – 3500-5500 – to monitor and set up the Air/Fuel ratios.  Julie and I did this, Julie in the passenger seat holding and reading the EFI info on the laptop.  I was driving and trying to hold my hat on.  We ran at 70-80 mph – probably not really safe considering the state of the build.  But, the good thing is the car handled and drove well, so it was worth it – mostly.  Julie said she feared for her life – I thought it was fun! Continue reading

Aluminum Panels, Battery, Battery Box, Cable, Cockpit, Footbox, Fuel tank, Insulation, remote battery terminal, Roll Bars, seat tracks, Seats, Speakers, Trunk

Engine Tuning and Finish Electrical

On Saturday July 28 at about 4:45 pm – success with the first engine start!!

Video  of First Start

A big milestone was passed when we turned the engine over for the first time.  It was awesome.  Many final things were done to get to this point.  I had to get the side exhausts mounted.  I did the passenger side first, ampoule since access was easy without the cockpit sheet metal.  There is a side support bracket that mounts on the chassis under the floor, so I could work on this from above.

I attached the bracket to the exhaust, then attached the exhaust and gasket to the J pipe.  I had Julie holding the pipe in place, then marked and drilled where I needed to mount the side support.  Once this was loosely attached I positioned the pipe where I wanted then secure the J pipe firmly to the header then tightened the side support. Continue reading

Battery disconnect, Diode, EFI, Engine, Fuel tank, Gauges, Headers, Indicator lights, Seat heaters, Speakers, Stereo, Switches, Trun signals, Uncategorized, Weatherpack, Wiring harness

First Engine Start

On Saturday July 28 at about 4:45 pm – success with the first engine start!!

Video  of First Start

A big milestone was passed when we turned the engine over for the first time.  It was awesome.  Many final things were done to get to this point.  I had to get the side exhausts mounted.  I did the passenger side first, malady since access was easy without the cockpit sheet metal.  There is a side support bracket that mounts on the chassis under the floor, more about so I could work on this from above.

I attached the bracket to the exhaust, then attached the exhaust and gasket to the J pipe.  I had Julie holding the pipe in place, then marked and drilled where I needed to mount the side support.  Once this was loosely attached I positioned the pipe where I wanted then secure the J pipe firmly to the header then tightened the side support. Continue reading

Air cleaner, Alignment, Engine, Front end, Fuel Filter, Fuel tank, Gauges, J pipes, O2 Sensor, Radiator, Ride height, Roll Bars, Side Exhaust, Steering Wheel

Seat Installation

Installing the seats and adjustment tracks turned out to be a much more difficult process than I had expected.  I knew it would be difficult since I had the high back racing seats and the seat track for the driver side.  I looked at the seat track instructions and figured those would help, more about more about even if I did not have the standard roadster seat.  Boy, I was wrong.  Nothing seemed to match up.. I called FFR and was told that the directions were still correct even though 11 years old, and that seat mounting was really owners choice and every car is a bit different.

So, I spent a lot of time looking at forums, posted a thread, and emailed with a couple people.  Ultimately I decided how I would proceed.  I would need to mount brackets made from angle iron to the sides of the seat, mount the sliders on the bottom of the angle iron brackets, and then fasten the sliders to the cockpit floor.  At my wife’s request I also decided to make the passenger seat adjustable, which turned out to be a good idea as it would keep the seats at the same height.  As I looked more at positioning the seats and where they would fasten to the floor I also noticed many of the fastening locations would not be into the chassis, they would only be through the cockpit floor sheet metal.  This would not be secure and safe, so I decided to add a support cross direction on the floor in the front and back mounting locations.  This could be attached to the chassis pieces and then the seat would attach through it, providing adequate strength.  Continue reading

Cockpit, seat tracks, Seats, Sliders