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April 1, 2004
We should never have seen this page but never the less we are here! SVA has been applied for and we're waiting for a date to qualify for the road. Our MOT is planned to be done 2 weeks before this date allowing us some time to perform any rectification work if we fail SVA ~ not that we will! (Must remain positive!) |
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Tonight the tidying up stage is very much underway... delivery of our edge trim, nut covers and steering arm shroud had arrived and these need securing before SVA. So tonight's agenda is:
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| The steering cowl is a formed sheet of 1.2mm aluminium covered with sticky back plastic errr no it's not it's grained vinyl! This covers the large gap left by not using the cardboard sierra dash... The wire you see popping out from the securing hole is going to be used for the Speedo/Odo/Clock etc etc. |
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Same thing from the other side... what look like ripples in the dash are shadows... |
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The nut covers are courtesy of Tifosi these were also part of an SVA pack including new steering arm covers and edge trim. |
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April 4, 2004 As the SVA date approaches we are finding the tidying up jobs a little daunting... not much to do but it has to be done! The edge trim and SVA coverings from Tifosi are ready to be secured. The wing mirrors are due to be completed... so on the agenda today is:
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| The eyelets for the seatbelt within the seat are a fail point for SVA due to the seatbelt rubbing on the seat holes. So these need to be edge trimmed for protection. When finished they look like this.. |
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Quite a difficult job due to the tight internal radiuses, but the "tight & fast" did it wonderfully! Also got a very good grip to ensure it doesn't come off... once the both were finished they look smart! |
| Whilst I was edging - Ph and Dad were trying to get the wing mirror shrouds to cover the metalwork... it was hard going as all I heard was "Grrrr" and "Ooooh", always a good sign! I persevered with the edging - I finally completed the front arch's... |
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I began covering the suspension nuts with the nut cover thingies... Ph & Dad removed the washer as it had broken down... the kitchen washer that is... priorities take place!!! No more pictures of these as some have already been posted. However, we did receive a new product from Tifosi which we thought very useful... track rod end protector's. These we thought are ideal, as they are permanent and easily adjustable. Apparently, they are suitable for SVA so another bridge crossed there then.... |
| Also we covered the seatbelt anchorage bolts heads with the Nut Covers... this almost makes the whole car SVA compliant on the exterior. Next to do are the seat edges... another day! |
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April 6, 2004
Tonight's agenda is probably:
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After marking around the handbrake aperture, we could calculate the amount need to secure the gaiter. So we manufactured a piece of aluminium and a piece of plastic. These are going to be used to sandwich the gaiter. We measured out the position of the handbrake in down and up positions allowed for 25mm of width, made a template from paper. Cut out the same dimensions in the vinyl, got it all sewed up and bingo... fit like a glove! |
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| To comply to SVA we had to run edge trim around area's which can be touched with the dreaded 100mm sphere and less than 2.5mm radius. This includes the edge of the side panels around the suspension. We used "tight & fast" for this. Difficult to put into position but it was successful. |
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Also, the forward facing edges of the seats... this was difficult as the area under the front lip of the seat is double thickness. Therefore, this overstretches the "tight & fast", but it does the job! |
| Finish wiring and connecting of the cycle clock... this is now operational. The clock automatically switches on when activated via the front wheel sensor. This is also going to be used to calibrate the 'blade clocks. |
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Obviously, if we can avoid it having to be used we will. Otherwise it means more wiring to connect a light for SVA. |
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April 8, 2004
On the agenda for this evening:
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After removing the exhaust to access the brackets and clamps. The edges of the clamps were re-peaned over to reduce the flare. Then filed on a radius to further reduce the sharpness. The external edges of the exhaust were filed into a radius again to reduce sharpness. These pictures illustrate the radiusing work. |
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| Cycle clock completed, fitted with end caps and secured. |
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Completed the Handbrake Gaiter... lovely! |
| Fitted the new Tifosi track rod end covers... very neat and sweet! I can't remember where I have seen these items before. However, I know I have seen them previously but not in this application... we think for end-capping cables? Maybe you can suggest where? Please post answers in the Guestbook for rest of viewers! |
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April 12, 2004 Not that much to do anymore except make things complaint for SVA, so tonight we continued the theme
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| We were not going to fit the choke cable initially but due to us using the Sierra cowl, it made sense to use the bonnet release mechanism to operate the choke. So, away we went utilising the old bonnet release cable from the Sierra and modify it to suit our purposes. Here is the picture of it fitted on the engine end... |
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Here is it routed through the bulkhead using a grommet to prevent chafing... |
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Then up into the bonnet release mechanism. We needed to remanufacture the toggles, but this was really no problem. In total it took us about 1 hour. We left the spring return on the handle to prevent us leaving the choke on inadvertently. |
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Next up to manufacture a wooden wedge to enable the fireblade rubbers to sit down better upon the scuttle... this was duplicated on the offside to equal things out. We did notice the difference in radius from one side of the scuttle to the other, this was accounted for in the manufacture of the wedges. |
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We fitted some small yellow plastic self-adhesive buttons to make the bolts and spacers SVA compliant. |
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Its amazing where the buttons turn up. |
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We then removed the blue plastic protective trim from the tunnel... sort of completes the job wouldn't you say? |
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We started to manufacture piping for covering the top suspension nuts... lots of smoke melting and cutting. We also lined up the headlight... using Ph and St cars as a guide... amzing how different the beams are! Now all we are waiting for really is the date for the SVA. Then we can plan for the MOT date. Oh and before I forget I must order the Black Box speedo calibrator - not the yellow box as it's more expensive and not as wide correction... signing off for tonight. |
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April 14, 2004 More SVA work tonight. Looking for something original to try to bring the headlight bar to meet SVA criteria. We drew a blank after an hour or so looking around B&Q! We eventually submitted to wrapping the bar end with tight & fast, tie-wrapping it and tidying up with black tape. For the Headlight Nut we wrapped with convoluted tubing. Further work on the upper wishbone nut with more convoluted tube! We also gave the handbrake knob an extra bit of sanding to bring it into radius. We are a little concerned with the brace behind the seats on which the upper harness points are. Ours is not 2.5mm radius... but will it pass SVA? Hmmm dilemma. Very little work to do tonight... waiting for our SVA date still.... twidely fingers... |
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April 15, 2004 Contact with VOSA today, trying to gee them up a little regarding our application. Apparently the form is on it's way to Beverley... yippee! Now we wait... Began manufacture of a radius for behind the seats from the same aluminium strip as we used for the kick strips on the side panels. To complete over the weekend... well, Sunday! Wrapped the wingmirror blocks with black fuel resistant film... gives a finish much better than paint and is more resiliant. |
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April 17, 2004 Our usual visit to MK today, Ph spent most of the morning talking to Tony and a few other lads sharing information whilst Dad and I manufactured some front indicator extensions from Aluminium bar. At 100mm long they will give us more than the minimum requirement of 400mm from the outer edge of the car to the illuminated surface. Anyone requiring a drawing of this mod. let us know. As far as we know they are all the same. We received our paperwork this morning for our SVA date... May 11, 2004. Now it bites... |
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April 20, 2004 More SVA work to carry out. So on the agenda this evening:
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| Fitted with the extension bars made from aluminium to take the indicators lenses to less than 400mm from outer edge of car; the front arch. |
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fitted and straightened up, they look quite funky! We reckon we will leave them on! |
| Fitted light bulbs to replace the RED one's as; to be honest; Ph and Dad can't see very well! Also, fit surround on outer clock to bring it into SVA compliance, it now protrudes 3.2mm at the extreme. More than this constitutes a fail - apparently. |
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April 24, 2004 Take car for MOT... due to us being informed our SVA was to be rescheduled forward (due to a cancellation) to April 28, 2004! Marvellous... My first drive of the car - fully insured and legal... jees...wHaT a BuZz |
| So there is was waiting for it's MOT... |
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Tested Lights etc... ok! Brakes to test...
EASY! |
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So... passed the MOT easily. He also commented on how very well put together our car was, which is nice! If anything, the bike clocks were reading a bit too fast now... 50mph when doing 35~36mph. Speedohealer to fit tomorrow will cure this! Absolutely glorious day for it thought - 21 degree sunny day - fantastic! |
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April 25, 2004 Today (again hot and sunny) agenda:
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| Fit exhaust surround as we noticed the fibreglass going orange with the heat from the manifold! |
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So here we go again... to test the speedo accuracy! BANG ON within 1%! Aren't electronics just brilliant! |
| SORTED... now to prepare for the SVA proper! |
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| We have discovered a slight problem - NOT TO DRIVE IT - also when you get above 90mph the front goes a little light! Ah-hem allegedly! |
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April 26, 2004
Make last minute adjustments for SVA as we're going tomorrow. Reading the weather forecast was a bit depressing as it says "Rain all day!" such fun... |
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April 27, 2004
Well - today is the day for SVA. It's cold and raining outside and I've got the unenviable task of driving an open topped car in the pouring down rain! Yippee!! Driving the M18, M62 towards Beverley was going to be such joy! To be honest it wasn't too bad... sure I got DAMP but not Wet! I was wearing my crash-helmet which was thankful as the rain spray from the lorries could have made me turn around and go home! So 50 miles later averaging about 60mph, the engine and everything were faultless. Driving near to Hull the weather improved and dried up the roads... our appointment was for 1300 but we arrived at 1200 for some packed sarni's and stuff.
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| Here we are waiting for our SVA Test at the Beverley Test Centre... |
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| Our first job was to toe in the wheels... whilst testing the centering, the SVA bloke flagged me in! Oh Jesus - this was it! Off he went... the other two were still munching! |
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Anyway - I tried to take pictures to help you lads, but got booed off by the man as he stated it was government testing ground and NO PICTURES could be taken. Everything proceeded excellently, flew through emissions, until we came to self centering, as we thought the wheels had no intention of centering. So he went of for a coffee... during which time we toe'd OUT... this definitely centered but going in a straight line was a problem! (This was to be returned for the journey home! |
| Onto the emissions - as it was an early 1995 engine, we didn't have to meet some of the more critical emissions as on later 1995 emissions regulations. So, here we passed easily! |
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As the chassis was built by MK it may have been easy, but he didn't question anything. He worked out the centre of gravity for loading on the brakes. Then used the Rolling Road to calculate the brake effectiveness and front/rear proportions. Basically this was to check if the rears would lock up before the front's. Which they wouldn't... so this easily passed! Even thought the rears hadn't bedded in yet! |
| Next up noise... oh dear 104Db first time - way over! tilted up exhaust after calling MK for advice. Dropped to 102Db... not enough. Initial FAIL! Went to park up all dejected - then a kind man came over and advised us to put some extra wadding up the exhaust... Hmmm - Popped over the road to Focus and bought some wire wool - stuffed it up exhaust and asked for one more chance on the noise meter. After a few wire wool rat blow out's... at 7,875rpm it eventually scraped through at 98Db... this will be one to watch for the future! |
| Then he gave us this... pretty cool! |
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April 28, 2004
Armed with our MAC (VOSA) Certificate - off we went to the local ('ish) DVLA Centre in Sheffield. Armed with files of receipts and documentation to verify all our build details. We qualified for an age related plate - in our eyes at least! |
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April 30, 2004
The registration documents and road tax arrived in the post this morning. We had achieved our goal of obtaining an age-related plate; F121 HWJ. We had the number plates made up and purchased an aluminium tax disc holder, so tonight's job was to fix these to the indy. |
| We manufactured some aluminium brackets for the front plate and fastened the rear plate using self-adhesive pads. Fixing of the tax disc will have to wait until we obtain some suitable sized bolts. The car is now 100% road legal. |
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One last word...
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Overall, the build of the Indy has taken slightly longer than we initially anticipated. We had set ourselves a target date of Easter 2004 for completion and have over-run by some three weeks. The build itself has gone very smoothly from start to finish and although there have been some heated discussions and minor rifts along the way, it has been an immensely enjoyable and rewarding project - one that we would like to experience again. We have discussed building another one but we'll have to wait and see..... With the knowledge and skills acquired during this build, it would almost be a shame not to build another and hone those skills even further and besides, I'm sure that a second build could be undertaken in a fraction of the time and maybe to a slightly higher standard than the first. To actually drive something that you have built with your own hands makes you feel extremely proud and satisfied. There is a wealth of knowledge out there and I'm sure that - armed with this - most people could build one of these cars if they have the desire, the patience and the tenacity. Driving the car is pure exhilaration and truly gives you an adrenalin rush. You forget the petty unimportant things in life and for a short time you are in your own world. None of this would have been possible without two major influences: So our thanks go to; From the webmaster: |
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